CN116945990A

CN116945990A - Ventilated seat and method of manufacture

Info

Publication number: CN116945990A
Application number: CN202310173837.5A
Authority: CN
Inventors: 马克·帕尔默; 里福德·格雷厄姆·科克斯
Original assignee: Lear Corp
Current assignee: Lear Corp
Priority date: 2022-02-28
Filing date: 2023-02-28
Publication date: 2023-10-27

Abstract

The application relates to a ventilated seat and a method of manufacture. A ventilated seat comprising: a cushion pad having a plurality of air distribution holes therethrough and a hook and loop fastener attached to the cushion pad; a seat bottom including a main bottom cushion; a seat back operatively engaging the seat bottom and including a main back cushion; wherein one of the primary bottom cushion and the primary back cushion comprises a closed cell foam and includes a recess shaped to receive and orient the cushion therein, a ventilation channel for directing air flow from the climate control system to the recess, and a hook and loop fastener molded into the closed cell foam in the recess; and wherein the cushion is secured in the recess by hook and loop fasteners of the cushion operatively engaging the hook and loop fasteners in the recess.

Description

Ventilated seat and method of manufacture

Background

The present application relates to an improved structure for a ventilated seat.

Ventilated seats are known that provide heating, cooling, or both heating and cooling to a seat occupant. Such heating and cooling may be provided via an air flow through the seat itself. Some have provided airflow through the seat cushion by employing an open cell foam material that allows the airflow to be directed through the open cell foam cells. However, open cell foam has drawbacks with respect to the comfort of the seat occupant.

It is desirable to effectively provide heating and cooling to various portions of a seat occupant and to have a desired airflow to increase occupant comfort.

Summary of The Invention

According to a first aspect, the present application provides a ventilated seat comprising a cushion formed of closed cell foam in the shape of a flat panel and comprising a plurality of air distribution apertures extending from a first side to a second side of the flat panel. A hook and loop fastener is attached to the first side of the panel. The seat bottom includes a primary bottom cushion and the seat back operatively engages the seat bottom and includes a primary back cushion. At least one of the primary bottom cushion and the primary back cushion comprises a closed cell foam having a recess in a portion of the surface shaped to receive and orient the cushion therein. The ventilation channel is configured to direct an airflow from the climate control system to the recess. The hook and loop fasteners are molded into the closed cell foam in the recess. The cushion is secured in the recess by hook and loop fasteners of the cushion operatively engaging the hook and loop fasteners in the recess and is configured to create an air distribution interface for airflow from the ventilation channel through the plurality of air distribution holes.

According to a second aspect, the present application provides a method of manufacturing a ventilated seat, the method comprising the steps of: molding a primary backing using closed cell foam while molding a recess into the primary backing and molding a hook and loop fastener into the recess; creating a vent passage through the primary backing, the vent passage having an end within the recess; forming a seat cushion as a flat plate using a closed cell foam, the flat plate sized and shaped to be received in the recess; securing a hook and loop fastener to a first side of the panel; die cutting a plurality of holes through the seat cushion from a first side to a second side configured to face a seat occupant; and securing the seat cushion in the recess by operably engaging a hook and loop fastener of the seat cushion to a hook and loop fastener of the seat cushion.

According to a third aspect, the present application provides a desired airflow profile to a seat occupant. Ease of assembly is provided by self-positioning (self-locating) the cushion in a corresponding recess in the primary cushion and aligning the shackle strips to quickly secure the cushion to the corresponding primary cushion. The primary cushion has fewer channels through the closed cell foam, while the relatively thin cushion has more holes to distribute the airflow at the desired locations. The manufacturing costs are generally lower relative to a one-piece primary pad having a large number of holes therethrough. The air distribution holes in the cushion pad may be die cut. The primary cushion is of closed cell foam and the cushion is more comfortable and liquid resistant to the seat occupant. The cushion, being separate from the main cushion, may allow for easier design changes to control the airflow to the seat occupant.

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

Brief Description of Drawings

FIG. 1 is a schematic perspective view of a portion of a seat for use with a seat climate control system.

FIG. 2 is another schematic perspective view of a portion of a seat for use with a seat climate control system.

Fig. 3 is a schematic plan view of a portion of a primary pad.

Fig. 4 is a schematic plan view of an air distribution pad.

Fig. 5 is another schematic plan view of an air distribution pad.

Description of The Preferred Embodiment

Referring now to the examples shown in the drawings, FIGS. 1-5 illustrate portions of a ventilated (climate controlled) seat 20. For example, the seat 20 may be used in a vehicle with a ventilation system (climate control) provided for cooling/heating a vehicle occupant seated in the seat 20. A heating, ventilation, and air conditioning (HVAC) system 21 cooperatively engages the seat 20 to provide a flow of ventilation air. The ventilated (climate controlled) seat 20 may be used in applications other than vehicles.

The seat 20 includes a seat bottom 22 mounted on a seat frame 24, which seat frame 24 may be mounted to a vehicle structure 26, for example. The seat 20 also includes a seat back 28, the seat back 28 operably engaging the seat bottom 22 to define a surface for supporting a seat occupant. The seat 20 may also include optional features such as a headrest mount 30 and armrests 32.

The seat bottom 22 includes a main bottom cushion 34 made of a closed cell foam material, such as a closed cell polyurethane foam. The main bottom cushion 34 is formed in a shape including a rear portion 36, a front portion 38, and a side bolster 40, the rear portion 36 may be configured to support the buttocks of a seat occupant, the front portion 38 may be configured to support a portion of the underside of the thighs of the occupant, and the side bolster 40 may be configured to laterally support the seat occupant. As used herein, the terms "rear" and "front" relate to the general orientation of the seat 20 when used in a vehicle. The main bottom pad 34 is also formed to include a rear recess 42 (best seen in fig. 3) and a front recess 44 (best seen in fig. 3), the rear recess 42 being formed in the top surface of the rear portion 36 and the front recess 44 being formed into the top surface of the front portion 38. The shackle strip 46 is molded into the foam in the rear recess 42 (as shown in fig. 3). In the illustrated embodiment, four shackle strips 46 are shown, but other numbers of such shackle strips 46 may be employed. The shackle strip 48 is molded into the foam in the front recess 44 (also shown in fig. 3). In the illustrated embodiment, two shackle strips 48 are shown, but other numbers of such shackle strips 48 may be employed. The molded-in strips 46 and 48 are only half of a hook and loop fastener (each strip may be one of a hook or loop). The respective halves of the hook and loop fastener will be discussed below.

Because the main bottom pad 34 is made of closed cell foam, a ventilation channel is formed through the pad 34 to allow ventilation air to flow from the HVAC system through the pad 34. The main bottom pad 34 includes a set of rear ventilation channels 50 (shown in fig. 3), the set of rear ventilation channels 50 directing airflow to the rear recess 42. In the illustrated embodiment, eleven rear vent passages 50 are shown, but other numbers of such rear vent passages 50 may be employed. The main bottom pad 34 also includes a set of front vent passages 52 (shown in fig. 3), the set of front vent passages 52 directing airflow to the front recess 44. In the illustrated embodiment, four front vent channels are shown, but other numbers of such vent channels 52 may be employed. The vent passages 50, 52 may be formed in the main bottom pad 34 by drilling through or molding into the closed cell foam. As used herein, the term "ventilation channel" refers to a channel created specifically to allow air flow through closed cell foam, and not to the ability of air to generally flow through open cell foam.

The seat back 28 also includes a main back cushion 54 made of a closed cell foam material, such as a closed cell polyurethane foam. The main back cushion 54 is formed in a shape including a lower portion 56, an upper portion 58, and a side bolster 60, the lower portion 56 may be configured to support a lower back of a seat occupant, the upper portion 58 may be configured to support an upper back of the occupant, and the side bolster 60 may be configured to laterally support the back of the seat occupant. As used herein, the terms "lower" and "upper" refer to the general orientation of the seat 20 when used in a vehicle (with the seat back 28 in an upright position).

The main back pad 54 is also formed to include a lower recess 62 and an upper recess 64, the lower recess 62 being formed in the front surface of the lower portion 56 and the upper recess 64 being formed in the front surface of the upper portion 58. A shackle strip is molded into the foam in the lower recess 62, which is similar to the shackle strip for the seat bottom shown in fig. 3, and a shackle strip is molded into the foam in the upper recess 64, which is similar to the shackle strip for the seat bottom shown in fig. 3. The in-molded strips are also only half of a hook and loop fastener (each strip may be one of a hook or loop). The respective halves of the hook and loop fastener will be discussed below. Because the main back pad 54 is made of closed cell foam, ventilation channels are formed through the pad 54 to allow ventilation air to flow from the HVAC system through the pad 54. The main back cushion 54 includes a set of lower ventilation channels similar to the ventilation channels for the seat bottom shown in fig. 3 and directing airflow to the lower recess 62, and a set of upper ventilation channels similar to the ventilation channels for the seat bottom shown in fig. 3 and directing airflow to the upper recess 64.

The illustrated example also includes a rear seat cushion 66, the rear seat cushion 66 being sized and shaped to fit into the rear recess 42 and substantially fill the rear recess 42 such that a top surface of the rear seat cushion 66 is substantially flush with a top surface of the rear portion 36 of the main bottom cushion 34. The rear seat cushion 66 is substantially shaped as a flexible flat plate. This creates a flush surface upon which the seat bottom cover 68 can be assembled. The seat bottom covering 68 may be made of, for example, cloth, fabric, leather with perforations, or other common materials used to decorate seats. The rear seat cushion 66 may be formed of a closed cell foam (e.g., closed cell polyurethane). The rear seat cushion 66 includes a matrix of air distribution holes 70 extending through the rear seat cushion 66 from a first side to a second side and configured to distribute air flow from the rear ventilation channel 50 to a desired location for air flow onto a seat occupant, thus forming an air distribution interface substantially between the main bottom cushion 34 and the rear seat cushion 66. The thin rear seat cushion 66 (relative to the thick main bottom cushion 34) allows more holes to be quickly and economically formed during manufacture to achieve a desired airflow relative to the seat occupant. In addition, the air flow to the seat occupant can be changed by changing only the size and spacing of the air distribution holes 70 without changing the design of the main bottom cushion 34. The air distribution holes 70 may be formed in the rear seat cushion 66 by, for example, die cutting (stamping) the holes 70 through the rear seat cushion 66. Fewer rear vent channels 50 through the relatively thicker main bottom pad 34 may be formed, for example, by drilling or molding the channels 50 through the main bottom pad 34. The rear seat cushion 66 has a shackle strip 72 (shown in fig. 4) attached to the underside surface, wherein the number and location of the shackle strips 72 are configured to mate with the corresponding shackle strips 46 of the main bottom pad 34. That is, if the particular shackle strip 46 of the main bottom cushion 34 is a set of hooks, then the corresponding shackle strip 72 on the rear seat cushion 66 is a set of loops positioned to mate with the set of hooks.

The illustrated example also includes a front seat cushion 76, the front seat cushion 76 being sized and shaped to fit into the front recess 44 and substantially fill the front recess 44 such that a top surface of the front seat cushion 76 is substantially flush with a top surface of the front portion 38 of the main bottom cushion 34. The front seat cushion 76 is substantially in the shape of a flexible flat plate. This creates a flush surface upon which the seat bottom cover 68 can be assembled. The front seat cushion 76 may be formed of a closed cell foam (e.g., closed cell polyurethane). The front seat cushion 76 includes a matrix of air distribution holes 80 extending through the front seat cushion 76 from a first side to a second side and configured to distribute air flow from the front vent channel 52 to a desired location for air flow onto a seat occupant, thus forming an air distribution interface substantially between the main bottom cushion 34 and the front seat cushion 76. The thin front seat cushion 76 (relative to the thicker main bottom cushion 34) allows for more holes to be quickly and economically formed to achieve a desired airflow relative to the seat occupant. In addition, the air flow to the seat occupant can be changed by changing only the size and spacing of the air distribution holes 80 without changing the design of the main bottom cushion 34. The air distribution holes 80 may be formed in the front seat cushion 76 by, for example, die cutting (stamping) the holes 80 through the front seat cushion 76. Fewer front vent channels 52 through the relatively thicker main bottom pad 34 may be formed, for example, by drilling or molding the channels 52 through the main bottom pad 34. The front seat cushion 76 has hook and loop strips 82 (shown in fig. 5) attached to the underside surface, wherein the number and location of the hook and loop strips 82 are configured to mate with the corresponding hook and loop strips 48 of the main bottom cushion 34. That is, if a particular shackle strip 48 of the main seat cushion 34 is a set of hooks, then the corresponding shackle strip 82 on the front seat cushion 76 is a set of loops positioned to mate with the set of hooks.

The illustrated example also includes a lower seat cushion 86, the lower seat cushion 86 being sized and shaped to fit into the lower recess 62 and substantially fill the lower recess 62 such that a front surface of the lower seat cushion 86 is substantially flush with a front surface of the lower portion 56 of the main back cushion 54. The shape of the lower seat cushion 86 is essentially a flexible flat plate. This creates a flush surface upon which the seat back cover 88 can be assembled. The seat back cover 88 may be made of, for example, cloth, fabric, leather with perforations, or other common materials used to decorate seats. The lower seat cushion 86 may be formed of a closed cell foam (e.g., closed cell polyurethane). The lower seat cushion 86 includes a matrix of air distribution holes 90 extending through the lower seat cushion 86 from a first side to a second side and configured to distribute air flow from a lower ventilation channel (similar to the ventilation channels 50, 52 shown in fig. 3) to a desired location for air flow to a seat occupant, thus forming an air distribution interface substantially between the main back cushion 54 and the lower seat cushion 86. The thin lower seat cushion 86 (relative to the thicker main back cushion 54) allows for more holes to be quickly and economically formed to achieve a desired airflow relative to the seat occupant. In addition, the air flow to the seat occupant can be changed only by changing the size and spacing of the air distribution holes 90 without changing the design of the main back cushion 54. The air distribution apertures 90 may be formed in the lower seat cushion 86 by, for example, die cutting (stamping) the apertures 90 through the lower seat cushion 86. Fewer lower ventilation channels through the relatively thicker main back pad 54 may be formed, for example, by drilling or molding channels through the main back pad 54. The lower seat cushion 86 has a shackle strip (similar to the shackle strips 72, 82 shown in fig. 4 and 5) attached to the rear surface that is positioned and configured to mate with a corresponding shackle strip of the main back pad 54. That is, if a particular shackle strip of the main back pad 54 is a set of hooks, then the corresponding shackle strip on the lower seat cushion 86 is a set of loops positioned to mate with the set of hooks.

The illustrated example also includes an upper seat cushion 92, the upper seat cushion 92 being sized and shaped to fit into the upper recess 64 and substantially fill the upper recess 64 such that a front surface of the upper seat cushion 92 is substantially flush with a front surface of the upper portion 58 of the main back cushion 54. The upper seat cushion 92 is substantially in the shape of a flexible flat panel. This creates a flush surface upon which the seat back cover 88 can be assembled. The upper seat cushion 92 may be formed of a closed cell foam (e.g., closed cell polyurethane). The upper seat cushion 92 includes a matrix of air distribution holes 94 extending through the upper seat cushion 92 from a first side to a second side and configured to distribute air flow from an upper vent channel (similar to the vent channels 50, 52 shown in fig. 3) to a desired location for air flow onto a seat occupant, thus forming an air distribution interface substantially between the main back cushion 54 and the upper seat cushion 92. The thin upper seat cushion 92 (relative to the thicker main back cushion 54) allows for more holes to be quickly and economically formed to achieve a desired airflow relative to the seat occupant. Further, the air flow to the seat occupant may be changed by changing only the size and spacing of the air distribution holes 94 without changing the design of the main back cushion 54. The air distribution holes 94 may be formed in the upper seat cushion 92 by, for example, die cutting (stamping) the holes 94 through the upper seat cushion 92. Fewer upper ventilation channels through the relatively thicker main back pad 54 may be formed, for example, by drilling or molding channels through the main back pad 54. The upper seat cushion 92 has a shackle strip (similar to the shackle strips 72, 82 shown in fig. 4 and 5) attached to the rear side surface that is positioned and configured to mate with a corresponding shackle strip of the main back pad 54. That is, if a particular shackle strip of the main back pad 54 is a set of hooks, then the corresponding shackle strip on the upper seat cushion 92 is a set of loops positioned to mate with the set of hooks.

An example of assembling the cushion pad to the corresponding main cushion will now be discussed with reference to fig. 1 to 5. Because the main bottom pad 34 is formed with recesses 42, 44 and shackle strips 46, 48, alignment and assembly of the cushions 66, 76 with the main bottom pad 34 is quick, easy, and accurately positions the cushions 66, 76. The rear seat cushion 66 is aligned with the rear recess 42 and with the shackle strip 72 facing the rear recess 42. The rear seat cushion 66 moves into contact with the rear recess 42 at which point the shackle strips 46 engage their respective shackle strips 72. The rear seat cushion 66 is now secured to the main bottom cushion 34 in the correct position and orientation. The seat bottom cover 68 is assembled to the main bottom cushion 34. The front seat cushion 76, the lower seat cushion 86, and the upper seat cushion 92 are assembled to the respective seat components in a similar manner. The seat back cover 88 may be assembled to the main back cushion 54. Thus, a seat 20 is created that is comfortable for a seat occupant to sit on while also providing ventilation to the seat occupant in a desired location.

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

Claims

1. A ventilated seat comprising:

a cushion formed of closed cell foam in a flat plate shape and including a plurality of air distribution holes extending from a first side to a second side and having a hook and loop fastener attached to the first side;

a seat bottom including a main bottom cushion; and

a seat back operatively engaging the seat bottom and including a main back cushion, wherein

At least one of the primary bottom cushion and the primary back cushion is formed of a closed cell foam and includes a recess in a portion of a surface shaped to receive and orient the cushion in the recess, a ventilation channel configured to direct airflow from a climate control system to the recess, and a hook and loop fastener molded into the closed cell foam in the recess; and

the cushion is secured in the recess by the hook and loop fasteners of the cushion operatively engaging the hook and loop fasteners in the recess and is configured to create an air distribution interface for airflow from the ventilation channel through the plurality of air distribution holes.

2. The ventilated seat of claim 1 further comprising a second cushion formed of closed cell foam in a second panel shape and including a second plurality of air distribution holes extending from a first side of the second panel to a second side of the second panel and having a hook and loop fastener attached to one of the first side and the second side of the second cushion, wherein:

the at least one of the primary bottom pad and the primary back pad is the primary bottom pad, wherein the primary bottom pad further comprises a second recess in a portion of the surface spaced from the recess, a second vent channel configured to direct an air flow from the climate control system to the second recess, and a hook and loop fastener molded into the closed cell foam in the second recess, the second recess being shaped to receive and orient the second cushion in the second recess; and

the second cushion is secured in the second recess by the hook and loop fasteners of the second cushion operably engaging the hook and loop fasteners in the second recess.

3. The ventilated seat of claim 2 wherein the second ventilation channel is a plurality of second ventilation channels and the number of air distribution holes in the second plurality of air distribution holes is greater than the number of ventilation channels in the second plurality of ventilation channels.

4. A ventilated seat according to claim 3 wherein the ventilation channel is a plurality of ventilation channels and the number of air distribution holes in the plurality of air distribution holes is greater than the number of ventilation channels in the plurality of ventilation channels.

5. The ventilated seat of claim 1 wherein the ventilation channel is a plurality of ventilation channels and the number of air distribution holes in the plurality of air distribution holes is greater than the number of ventilation channels in the plurality of ventilation channels.

6. The ventilated seat according to claim 1 further comprising a seat cover extending over the cushion pad and the at least one of the primary bottom cushion and the primary back cushion secured to the cushion pad.

7. The ventilated seat of claim 1 wherein the hook and loop fasteners of the cushion are a plurality of hook and loop fasteners attached to the first side, the hook and loop fasteners of the at least one of the primary bottom cushion and the primary back cushion are a plurality of hook and loop fasteners molded into the closed cell foam of the recess, and positioned such that each hook and loop fastener mates with a respective hook and loop fastener of the plurality of hook and loop fasteners attached to the cushion when the cushion is properly oriented in the recess.

8. The ventilated seat of claim 1 wherein the ventilated seat is a vehicle seat and further comprising a seat frame secured to the seat bottom and configured to be mounted to a vehicle structure.

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

molding a primary pad using closed cell foam while molding a recess into the primary pad and molding a hook and loop fastener into the recess;

creating a vent passage through the primary pad, the vent passage having an end within the recess;

forming a seat cushion as a flat plate using a closed cell foam, the flat plate sized and shaped to be received in the recess;

securing a hook and loop fastener to a first side of the panel;

die cutting a plurality of holes through the seat cushion from the first side to a second side, the second side configured to face a seat occupant; and

the seat cushion is secured in the recess by operably engaging the hook and loop fastener of the seat cushion to the hook and loop fastener of a seat cushion.

10. The method of claim 9, wherein the step of creating the vent channel comprises molding the vent channel into the primary backing.

11. The method of claim 9, wherein creating the vent channel comprises drilling the vent channel after molding the primary liner.

12. The method of claim 9, further comprising the step of installing a seat cover over both the main cushion and the seat cushion.

13. The method of claim 9, wherein the step of molding the primary backing further comprises molding a second recess into the primary backing and molding a second hook and loop fastener into the second recess.

14. The method of claim 13, further comprising the step of: forming a second seat cushion using closed cell foam into a second flat plate sized and shaped to be received in the second recess; securing a third hook and loop fastener to the first side of the second panel; die cutting a second plurality of apertures through the second seat cushion from the first side to a second side configured to face a seat occupant; and securing the second seat cushion in the second recess by operably engaging the third hook and loop fastener of the second seat cushion to the second hook and loop fastener of the seat cushion.