CN113352969A

CN113352969A - Ventilated seat with integrated air passage

Info

Publication number: CN113352969A
Application number: CN202010143843.2A
Authority: CN
Inventors: 史蒂文·C·罗杰斯; 小约瑟·埃布拉多; 凯尔·史密斯
Original assignee: Lear Corp
Current assignee: Lear Corp
Priority date: 2020-03-04
Filing date: 2020-03-04
Publication date: 2021-09-07

Abstract

The invention relates to a ventilated seat with an integral air passage. The ventilated seat includes a seat cushion having an air passage extending from a seat cushion B side. The ventilated seat also includes a spacer that defines one or more air passages. The air passage is connected to the air passage and one or more air distribution holes on the seat cushion a side. The ventilated seat further comprises a cover layer between the spacer and the side of the seat cushion a. The cover layer is made of a foam material and the spacer is made of a different material, and the cover layer and the spacer are of foam with an integral air passage.

Description

Ventilated seat with integrated air passage

Background

The invention relates to a ventilated seat. More particularly, the present invention relates to a foam seat (foam seat) having an integrally formed air flow channel.

Some conventional vehicle seats include climate control features to provide occupant comfort. Typical ventilated vehicle seats use a blower to move air past the occupant. The moving air may enhance evaporation and help cool the occupant. Heating or cooling elements may be included to provide conditioned air to further increase occupant comfort.

The blower on the ventilated seat may operate as a pushing device or a suction device. As the blower pushes air, it draws in air from the environment, typically from beneath or behind the ventilated seat. The blower then pushes air through an air passage (which passes through the ventilated seat) to the a surface of the seat on which the occupant sits. Air flows out through the a surface and past the occupant. When the blower draws air, it draws air through the occupant through the A surface. The air is then drawn through the air passage and exhausted to the environment, typically beneath or behind the ventilated seat.

Ventilated seats typically include an air distribution system located on the a surface. The air distribution system allows air to move over an enlarged area on the a-surface. This can prevent the occupant from being subjected to a concentrated flow of air flow over a part of the occupant's body. Further, by allowing airflow to flow through the enlarged area, the occupant is less likely to completely block the airflow when the occupant is seated on the a surface.

Ventilated seats typically include molded seat foam that supports the occupant. A typical air distribution system includes an insert that is placed into a cavity defined by the seat foam. Because the air distribution system is located on the a-surface of the ventilated seat, the air distribution system will support a portion of the occupant's weight. The inserts typically include a spacer material that maintains an even air path while supporting the weight of the occupant. The blower can then move air through the a surface, through the air path around the spacer material, and through the air passages, even when the ventilated seat is occupied.

The foam of ventilated seats is typically a closed cell foam, which can comfortably support a seated occupant. Because the insert is made of a material other than foam, the occupant of the ventilated seat may detect its presence. It is desirable to have an alternative air distribution system for ventilated seats.

Summary of The Invention

The invention relates to a ventilated seat. The ventilated seat includes a seat cushion (cushinon) having an air passage extending from a seat cushion B side. The ventilated seat also includes spacers (spacers) that define one or more air passages. The air passage is connected to the air passage and one or more air distribution holes on the seat cushion a side. The ventilated seat further comprises a cover layer between the spacer and the side of the seat cushion a. The cover layer is made of a foam material and the spacer is made of a different material. The cover layer and the spacer are of foam with integral air passages.

The invention also relates to a method for manufacturing the ventilated seat. The method includes positioning a spacer in the mold to form a foam space adjacent the spacer. The spacer defines one or more air passages. The method also includes filling the foam space with a foam material to produce a foam having an integral air passageway.

Various aspects of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.

Drawings

Fig. 1 is a perspective view of a ventilated seat.

Fig. 2 is an enlarged cross-sectional view of a seat cushion of the ventilated seat.

Figure 3 is a top view of an insert for a seat cushion.

Fig. 4 is a bottom view of the insert.

FIG. 5 is a cross-sectional view of a portion of the ventilated seat taken along line 5-5 of FIG. 1.

Fig. 6 is a cross-sectional view of two spacers of an insert positioned in a tray.

FIG. 7 is a view similar to FIG. 6 showing the tray in place in the foam tool.

FIG. 8 is a view similar to FIG. 7 showing foam added to the tool.

FIG. 9 is a view similar to FIG. 8 showing the complete foam with integral air passages.

FIG. 10 is a cross-sectional view of an alternative foam with integral air passages.

Description of The Preferred Embodiment

Referring now to the drawings, there is shown in FIG. 1 a perspective view of a ventilated seat, indicated generally at 10. The illustrated ventilated seat 10 is a vehicle seat suitable for use in a vehicle such as a passenger car. However, the ventilated seat 10 may be any desired type of seat.

The ventilated seat 10 may include a seat cushion 12 and/or a seat back 14. The seat cushion 12 includes a cushion trim 16 and the seat back 14 includes a back trim 18. The seat cushion trim 16 and the back trim 18 are shown to be made of cloth fabric and leather, but the seat cushion trim 16 and the back trim 18 may be made of any desired material.

Referring to fig. 2, an enlarged cross-sectional view of the seat cushion 12 is shown. The seat cushion trim 16 is not shown in fig. 2 so that the lower portion of the ventilated seat can be seen. The ventilated seat 10 includes cushion foam 20. The cushion foam 20 is shown as a molded closed cell foam, but may be made of any desired material and by any desired process. The cushion foam 20 provides comfort and support to an occupant (not shown) of the ventilated seat 10. The cushion foam 20 includes a cushion a side 22 and an opposing cushion B side 24, the cushion a side 22 being the side of the cushion foam 20 that generally faces the occupant. The cushion foam 20 is supported by a cushion frame (not shown) as is known in the art.

The seat cushion 12 includes a cavity 26 on the cushion a side 22. The cavity 26 is a recessed area defined in the cushion a side 22 of the cushion foam 20. The cavity 26 is shown as being formed during the molding of the cushion foam 20 by excluding foam from the area of the cavity 26. However, the cavity 26 may be formed by any desired method. One or more air passages 28 extend from the cavity 26 to the B side 24 of the seat cushion. The air passage 28 is an opening defined through the cushion foam 20. The cushion foam 20 is shown to include two air channels 28, although only one is visible in fig. 2. The cushion foam 20 may have any desired number of air channels 28.

The ventilated seat 10 includes an optional B-side air distributor 30 on the B-side 24 of the seat cushion. A blower 32 is attached to the B-side air distributor 30. The blower 32 is adapted to draw air from the environment and push the air into the B-side air distributor 30. Air then flows from the B-side air distributor 30 to the cavity 26 through the air passages 28. If desired, blower 32 may be adapted to operate in a suction mode. In this case, the blower 32 will draw air from the environment of the a-side 22 of the seat cushion through the air passage 28 and the B-side air distributor 30 to the blower 32.

The ventilated seat 10 includes an insert 34, the insert 34 being located in the cavity 26. The insert 34 includes a plurality of air passages 36, each air passage 36 communicating with the air channel 28 and extending through a venting area 38 of the ventilated seat 10. The air passage 36 is shown extending substantially parallel to the seat cushion a-side 22, but may have any desired orientation. The insert 34 also includes a cover 40, the cover 40 being located between the air passageway 36 and the cushion trim 16. The illustrated cover layer 40 is molded from foam and will be described in more detail below. A plurality of air distribution holes 42 extend from the air passage 36 through the cover 40 and allow air to flow from the air passage 36 to the cushion garnish 16. The cushion trim 16 includes perforations (not shown) in the vented area 38 that allow air from the distribution holes 42 to pass through the cushion trim 16. Although the venting area 38 is shown at one end of the seat cushion 12, the venting area 38 may be located at any desired location. In the illustrated embodiment, each air passage 36 communicates with one air distribution hole 42. However, the air passage 36 may communicate with any desired number of air distribution holes 42. For example, each air passage 36 may communicate with a plurality of air distribution apertures 42 of different sizes to increase the size of the ventilation zone 38.

Referring to fig. 3, a top view of the insert 34 is shown, and referring to fig. 4, a bottom view of the insert 34 is shown. The insert 34 includes one or more spacers 44 attached to the cover layer 40. The illustrated insert 34 includes two spacers 44, but may include any desired number of spacers 44. The spacers 44 are shown as being made of felt fabric, but may be made of any desired material. The spacers 44 are shown to have a substantially rectangular shape, but may have any desired shape. Each spacer 44 includes a plurality of sidewalls 46 defining the air passages 36 between the plurality of sidewalls 46. The side walls 46 extend between two end walls 48 of the spacer, the two end walls 48 being located at opposite ends of each spacer 44. In each of the illustrated spacers 44, the air passages 36 extend linearly between two end walls 48. However, the spacer 44 may have any desired configuration, and the air passage 36 may have any desired shape, length, and orientation.

The insert 34 includes a plurality of openings 50 that cooperate with corresponding projections 52 (shown in figure 2) on the cushion foam 20 to properly position the insert 34 on the cushion foam 20 during assembly of the ventilated seat 10. However, the ventilated seat 10 may include any desired positioning aid. The illustrated opening 50 is defined in the cover layer 40, but may be positioned in any desired portion of the insert 34.

When the ventilated seat 10 is assembled, the insert 34 is positioned in the cavity 26 and the cushion trim 16 is positioned around the cushion foam 20 and the insert 34 to hold the insert 34 in place relative to the cushion foam 20. However, the insert 34 may be held in place using any desired mechanism. The cover layer 40 is shown to be made of the same foam as the cushion foam 20. Thus, the ventilated seat 10 provides a consistent feel to the occupant. However, the cover layer 40 may be made of any desired material. Although the insert 34 is shown positioned in the cavity 26, the insert 34 may be any desired size and may, for example, cover the entire seat cushion a side 22, if desired.

Referring to fig. 5, a cross-sectional view taken along line 5-5 of fig. 1 is shown illustrating a portion of the seat cushion 12. As previously described, the spacer 44 defines the air passage 36. When a passenger sits on the ventilated seat 10, their weight is distributed by the cover 40 to the spacers 44. The spacer 44 supports the weight of the occupant to prevent the air passage 36 from being closed. The air passage 36 defines a height 54 that is measured generally perpendicular to the seat cushion a side 22. The spacer 44 is made of a material that compresses less than the cushion foam 20 when bearing the weight of the occupant. The result of this is that while an occupant is seated in the ventilated seat 10, the air passage 36 will remain open under normal load, although the height 54 of some of the air passage 36 may be reduced.

To form the insert 34, the cover layer 40 is molded onto the spacer 44. Referring to fig. 6, a cross-sectional view of the spacer 44 positioned in the tray 56 is shown. The cross-sectional view is taken perpendicular to the air passage 36. The illustrated tray 56 is made of plastic, but may be made of any desired material. Referring to fig. 7, the spacer 44 and tray 56 are placed in a mold 58, which forms a foam space 60 adjacent the spacer 44. As shown in fig. 8, foam material 62 is injected into foam space 60 to form cover layer 40 over spacers 44. In the illustrated embodiment, the foam material 62 is not included in the air passage 36 during molding of the insert 34. However, the air passages 36 may be formed by any desired method. Referring to FIG. 9, when the foam material 62 cures, a foam, generally indicated at 64, is created having integral air passages. In the illustrated embodiment, the foam 64 with integral air passages is the insert 34.

As previously described, the insert 34 is placed over the cushion foam 20 such that the ventilated seat 10 includes foam 64 with an integral air passageway. The air passage 36 distributes the air flow across the seat cushion a side 22. In the illustrated embodiment, the foam 64 with integral air passages is the insert 34. However, the spacer 44 may be located within the cushion foam 20 such that the foam 64 with integral air passages is the cushion foam 20. In this case, the ventilated seat 10 would not include the insert 34. For example, multiple-shot molding processes may be used to apply foam to opposite sides of the spacer 44 to embed the spacer 44 within the cushion foam 20.

Referring to fig. 10, a cross-sectional view of an alternative foam with integral air passages is shown, generally indicated at 164. The alternative foam with integral air passages 164 includes two spacers 144 defining a plurality of air passages 136. Each spacer 144 is similar to the spacer 44 previously described and will not be separately described. Moreover, each air passage 136 is similar to the previously described air passage 36 and will not be separately described. An alternative foam 164 having an integral air passageway is the cushion foam 120, which may be used on the ventilated seat 10, if desired, in place of the cushion foam 20 and insert 34.

The insert 34 has been described as being part of the seat cushion 12. It should be understood that the seat back 14 may also or alternatively include the air passage 36. If desired, the seat back 14 may include an insert 34 or other type of integral air passage 36.

The principles and modes of operation of the present invention have been explained and illustrated in its preferred embodiments. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.

Claims

1. A ventilated seat, comprising:

a seat cushion having an air passage extending from a seat cushion B side;

a spacer that defines one or more air passages connected to the air passage and one or more air distribution holes on a seat cushion a side; and

a cover layer located between the spacer and the seat cushion a side, wherein the cover layer is made of a foam material, the spacer is made of a different material, and the cover layer and the spacer are foam having an integral air passage.

2. The ventilated seat of claim 1 further comprising a blower in fluid communication with the air channel.

3. The ventilated seat according to claim 1, wherein the cover layer and the spacer are inserts positioned on the cushion a side.

4. A ventilated seat according to claim 3, wherein the insert comprises one or more openings, the cushion comprises one or more projections, and each projection is positioned in one of the openings.

5. A ventilated seat according to claim 3 in which the cushion is made from the foam material.

6. A ventilated seat according to claim 3, wherein the air passage extends substantially parallel to the seat cushion a side between the air passage and the air distribution hole.

7. The ventilated seat of claim 1 wherein the cover and the spacer are inserts positioned in cavities on the a side of the seat cushion.

8. The ventilated seat of claim 7 wherein the insert comprises one or more openings, the seat cushion comprises one or more protrusions, and each protrusion is positioned in one of the openings.

9. A ventilated seat according to claim 7 in which the cushion is made from the foam material.

10. A ventilated seat according to claim 7, wherein the air passage extends substantially parallel to the seat cushion A side between the air passage and the air distribution hole.

11. A ventilated seat according to claim 1 in which the cushion is made from the foam material.

12. A ventilated seat according to claim 1 in which the seat cushion is made of the foam material and the cover layer, the seat cushion and the spacer are foam with integral air passages.

13. A ventilated seat according to claim 12, wherein the air passage extends substantially parallel to the seat cushion a side between the air passage and the air distribution hole.

14. A method of manufacturing a ventilated seat, the method comprising the steps of:

positioning a spacer in a mold to form a foam space adjacent the spacer, wherein the spacer defines one or more air passages; and

the foam space is filled with a foam material to produce a foam having an integral air passageway.

15. A method of manufacturing a ventilated seat according to claim 14, comprising the further step of: a blower is attached to an air channel in communication with the air passageway.

16. A method of manufacturing a ventilated seat according to claim 14, comprising the further step of: a foam having an integral air passage is attached to a seat cushion having an air channel extending from the side of the seat cushion B.