WO2018039472A1

WO2018039472A1 - Air distribution device for a ventilation system of a vehicle seat

Info

Publication number: WO2018039472A1
Application number: PCT/US2017/048448
Authority: WO
Inventors: John Danielson; Benjamin Craig; Steven ZIOLKOWSKI
Original assignee: Kongsberg Automotive, Inc.
Priority date: 2016-08-24
Filing date: 2017-08-24
Publication date: 2018-03-01
Also published as: DE112017004243T5; CN109689428A; CN109689428B

Abstract

One embodiment includes a vehicle seat for a passenger cabin of a vehicle. The vehicle seat can include an air distribution device having a bottom layer formed of air impermeable material, with the bottom layer having a bottom peripheral edge and defining a single hole spaced from the bottom peripheral edge in fluid communication with the fan. The air distribution device can further include a top layer having a top peripheral edge, with the bottom and top layers attached to one another along the bottom and top peripheral edges to define an interior chamber. The air distribution device can further include a spacer layer formed of air permeable material and disposed within the interior chamber between the bottom and top layers. The air distribution device can further include at least one non-adhesive mechanical fastener sealingly attaching the bottom peripheral edge of the bottom layer and the top peripheral edge of the top layer to one another.

Description

AIR DISTRIBUTION DEVICE FOR

A VENTILATION SYSTEM OF A VEHICLE SEAT

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 62/378,902 filed August 24, 2016, herein incorporated in its entirety.

BACKGROUND OF THE DISCLOSURE

[0002] It is known to provide ventilation systems having a spacer mesh device and a fan for flowing air through the spacer mesh device to provide ventilation for the vehicle seat. The spacer mesh device can comprise a bottom layer, a top layer, and an adhesive coupling corresponding edges of the bottom and top layers to one another to enclose an interior chamber between the bottom and top layers. The spacer mesh device can include a spacer mesh disposed within the interior chamber between the bottom and top layers. The bottom layer typically defines a hole fluidly communicating with the fan, and the top layer typically comprises a plurality of openings arranged in corresponding positions to flow air to or from various portions of the vehicle seat. Installation of the ventilation systems in vehicle seats can require alignment of the openings of the top layer with portions of the vehicle seat configured to flow air. Misalignment of the openings with portions of the vehicle seat configured to flow air can decrease the efficiency of the ventilation systems. As such, it is desirable to provide an air distribution unit that can increase the efficiency of ventilation systems in vehicle seats. SUMMARY OF THE DISCLOSURE

[0003] One example of the invention provides a vehicle seat for a passenger cabin of a vehicle. The vehicle seat can include a seat bottom having a cover layer formed of air permeable material. The seat bottom can further include a seat cushion having an A side facing toward the cover layer and a B side facing away from the cover layer. The vehicle seat can further include a seatback pivotally coupled to the seat bottom. The vehicle seat can further include a ventilation system integrated within the seat bottom. The ventilation system can include a fan and an air distribution device fluidly coupled to the fan. The air distribution device can include a bottom layer formed of air impermeable material, with the bottom layer having a bottom peripheral edge and defining a single hole spaced from the bottom peripheral edge in fluid communication with the fan. The air distribution device can further include a top layer having a top peripheral edge, with the bottom and top layers attached to one another along the respective bottom and top peripheral edges to define an interior chamber. The air distribution device can further include a spacer layer disposed within the interior chamber between the bottom and top layers, and at least one non-adhesive mechanical fastener may sealingly attach the bottom peripheral edge of the bottom layer and the top peripheral edge of the top layer to one another.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.

[0005] Figure 1 is a perspective view of a first embodiment of a vehicle seat assembly having a seat bottom, a seat back coupled to the seat bottom, and a ventilation system coupled to the seat bottom.

[0006] Figure 2A is an upper perspective exploded view of the ventilation system of Figure 1, illustrating the ventilation system comprising an air distribution device.

[0007] Figure 2B is a lower perspective exploded view of the ventilation system of Figure 2A.

[0008] Figure 3 is a bottom view of the air distribution device of Figure 2 A.

[0009] Figure 4A is an enlarged cross-sectional view of one portion of the air distribution device of Figure 5, illustrating the air distribution device including a bottom peripheral edge of a bottom layer and a top peripheral edge of a top layer unfolded radially outward and attached to one another by stitching.

[0010] Figure 4B is an enlarged cross-sectional view of another embodiment of an air distribution device having s bottom peripheral edge of a bottom layer and a top peripheral edge of a top layer attached to one another by staples.

[0011] Figure 4C is an enlarged cross-sectional view of yet another embodiment of an air distribution device having s bottom peripheral edge of a bottom layer and a top peripheral edge of a top layer attached to one another by hook and loop fasteners [0012] Figure 4D is an enlarged cross-sectional view of another embodiment of an air distribution device having s bottom peripheral edge of a bottom layer and a top peripheral edge of a top layer folded radially inward and attached to one another by stitching.

[0013] Figure 5 A is a top view of the air distribution device of Figure 2A, illustrating the air distribution device having a top layer formed of air permeable material.

[0014] Figure 5B is an enlarged view of the air permeable material of the air distribution device of Figure 2A, illustrating the air permeable material formed of a woven fabric having fibers spaced from one another to define passages such that air flows through the top layer through only the passages of the woven fabric.

[0015] Figure 5C is an enlarged view of another embodiment of air permeable material of an air distribution device, illustrating the air permeable material formed of a nonwoven fabric having fibers spaced from one another to define passages such that air flows through the top layer through only the passages of the nonwoven fabric.

[0016] Figure 5D is an enlarged view of still another embodiment of air permeable material of an air distribution device, illustrating the air permeable material formed of a homogeneous material having a porous structure to define passages such that air flows through the top layer through only the passages of the homogeneous material.

[0017] Figure 6 is a bottom view of another embodiment of an air distribution device.

[0018] Figure 7 is an enlarged cross-sectional view of one portion of the air distribution device of Figure 8.

[0019] Figure 8 is a top view of the air distribution device of Figure 6. DETAILED DESCRIPTION OF THE INVENTION

[0020] The embodiments below are described with reference to the drawings. The relationship and functioning of the various elements of the embodiments are better understood by the following detailed description. However, the embodiments as described below are by way of example only, and the invention is not limited to the embodiments illustrated in the drawings. It should also be understood that the drawings are not drawn to scale and, in certain instances, details which are not necessary for an understanding of the embodiments have been omitted.

[0021] As generally shown in Figure 1, one embodiment of the invention relates to a ventilation system 100 for a vehicle seat 102 in a passenger cabin of a vehicle. The vehicle seat 102 includes seat bottom 104 and a seatback 106 pivotally coupled to one another. In this example, the ventilation system 100 is integrated within the seat bottom 104 of the vehicle seat 102. However, it is contemplated that the ventilation system can be integrated within the seatback 106 or any other portion of the vehicle seat.

[0022] Referring to Figures 2A and 2B, the ventilation system 100 comprises an air mover or fan 108, an air distribution device 110 fluidly coupled to the fan 108, and an A surface or a cover layer 112 (Figure 1) of the vehicle seat 102, which is formed of air permeable material fluidly coupled to the air distribution device 110. The seat bottom 104 includes a seat cushion 114 having an A side 116 (Figure 2 A) facing toward the cover layer 112 and a B side 1 18 (Figure 2B) facing away from the cover layer 112. The seat bottom 104 further includes one or more foam padding elements 120 positioned adjacent to the A side 116 of the seat cushion 114, with the air distribution device 110 positioned adjacent to the B side 1 18 of the seat cushion 114. However, it is contemplated that the air distribution device can be positioned adjacent to the A side 116. In this example, the vehicle seat 102 can further include an air permeable heating mat 119 including one or more heating elements (not shown) and positioned between the foam padding elements 120 and the cover layer 112. Other examples of the vehicle seat may not include the heating mat.

[0023] The ventilation system 100 is configured to pull air surrounding the vehicle occupant, who is positioned on the cover layer 112, such that ambient air within the passenger cabin replenishes the air surrounding the vehicle occupant. More specifically, the ventilation system 100 is configured to draw air surrounding the vehicle occupant sequentially through the cover layer 112, the heating mat 119, the foam padding elements 120, the seat cushion 114, the top layer 128 of the air distribution device 110, the spacer layer 140 of the air distribution device 110, the bottom layer 122 of the air distribution device 110, and the fan 108.

[0024] In another example, the ventilation system 100 can push air toward the vehicle occupant positioned on the cover layer 112. In particular, the fan 108 can produce a flow of air, which is directed through the bottom layer 122 of the air distribution device 110, the spacer layer 140 of the air distribution device 110, the top layer 128 of the air distribution device 110, the seat cushion 114, the foam padding elements 120, the heating mat 119, and the cover layer 112 and toward the vehicle occupant. Other examples of the ventilation system 100 can be configured to selectively push air toward the vehicle occupant and pull air from the vehicle occupant in one or more zones of the seat bottom 104 and/or the seatback 106.

[0025] Referring to Figures 3 and 4A, a first embodiment of an air distribution device 110 includes a bottom layer 122 formed of air impermeable material having a bottom peripheral edge 126 and defining a single hole 124 spaced from the bottom peripheral edge 126. The single hole 124 is in fluid communication with the fan 108 by, for example, a bellows or foam ring (both not shown). [0026] As best shown in Figure 4A, the air distribution device 110 includes a top layer 128 formed of air permeable material and having a top peripheral edge 130 sealingly coupled to the bottom peripheral edge 126 of the bottom layer 122 to define an interior chamber 132. In particular, the air distribution device 110 includes one or more non-adhesive mechanical fasteners 133 for attaching the bottom and top peripheral edges 126, 130 to one another. Examples of these mechanical fasteners can include stitching 133 (Figure 4 A), staples 135 (Figure 4B), hook-and- loop fasteners 137 (Figure 4C), other suitable mechanical fasteners, or any combination thereof. Furthermore, in this embodiment, the bottom and top peripheral edges 126, 130 are unfolded and extend radially outward. However, it is contemplated that one or both of the bottom and top peripheral edges 126, 130 may be folded radially inward (Figure 4D). Non-limiting benefits of inwardly folded edges can include providing a more compact device and facilitating installation of the air distribution device 110 in a vehicle seat.

[0027] Referring to Figures 5A and 5B, the top layer 128 is formed of a sheet of an air permeable fabric 151 (Figure 5B) comprising a plurality of fibers 153 spaced apart from one another to define a plurality of passages 155 through the fabric capable of flowing air through only the passages in the fabric 151. The air permeable fabric 151 may be a homogeneous woven fabric with the fibers 153 woven together to define the passages 155 between the fibers 153. Put another way, the top layer 128 does not include any holes, openings, or apertures cut, punched, or otherwise formed in the top layer during a process separate from the process for forming the air permeable fabric. The top layer 128 can have a footprint or surface area configured to direct air toward portions of the cover layer 112 corresponding in size with the footprint or surface area of the top layer 128. One non-limiting benefit of the top layer 128 not being formed of air impermeable material with multiple holes cut or punched in the air impermeable material is an improvement to the seat manufacturing process by eliminating the need to align the holes of the top layer with corresponding holes of the seat cushion 114.

[0028] Referring to Figure 5C, another embodiment of a top layer 228 may be formed of a nonwoven air permeable fabric 251 including short staple fibers 253a and continuous long fibers 253b, bonded together by chemical, mechanical, heat, or solvent treatment. One example of a nonwoven fiber is felt, which is neither woven nor knitted. The nonwoven fabric may include a heterogeneous or random arrangement of fibers 253a, 253b bonded together and spaced apart from one another to define a plurality of passages 255 between the fibers 253a, 253b such that the top layer 228 is capable of flowing air through only the passages 255 in the fabric 251.

[0029] Referring to Figure 5D, still another embodiment of a top layer 328 may be a sheet of homogeneous material 351 having a porous structure 353 forming a plurality of passages 355 through the top layer 328 capable of flowing air through only the passages 355 in the top layer 328. As one example, the homogenous material may be formed of an open-cell porous foam. Other embodiments of suitable air permeable top layers are contemplated.

[0030] Referring to Figures 4A and 5 A, the air distribution device 110 can further include one or more barriers 134 formed of air impermeable material coupled to one or more portions of the top layer 128 for selectively directing air through other portions of the top layer 128. In this example, the top layer 128 can comprise a central portion 138 disposed radially inward of the top peripheral edge 130, and the barriers 134 can be one or more strips of adhesive tape adhered to the top layer 128 and extending along or parallel with the top peripheral edge 130 of the top layer 128. In this way, the barriers 134 can direct air through the central portion 138 of the top layer 128 spaced radially inward from the peripheral edge 126 of the top layer 128. Other embodiments of the barrier can be one or more strips, sheets, or films of air impermeable material coupled to any portion of the top layer 128 to block the flow of air through the corresponding portions of the top layer 128 and thus direct air through other portions of the cover layer 112. Of course, it is contemplated that the air distribution device may not include any barriers coupled to the top layer.

[0031] The air distribution device 110 further includes a spacer layer 140 disposed within the interior chamber 132 between the top and bottom layers 128, 122. The spacer layer 140 formed of air permeable material and configured to space apart the top and bottom layers 128, 122 from one another and prevent the interior chamber 132 from collapsing when, for example, a vehicle occupant is positioned on the vehicle seat. In this example, the spacer layer 140 is a spacer mesh. Other examples of the spacer layer 140 can be a porous material, a reticulated foam, or any suitable air permeable support.

[0032] Referring to Figures 6 through 8, a second embodiment of an air distribution device 210 is similar to the air distribution device 110 of Figure 3, 4A, and 5A, and includes similar components identified by the same numbers increased by 100. This second embodiment of the air distribution device 210 (Figures 6 through 8) includes a top layer 228, which is formed of air impermeable material and is distinct from the top layer 228 of Figure 5C formed of air permeable material 251. The air distribution device 210 includes a bottom layer 222 formed of air impermeable material. The bottom layer has a bottom peripheral edge 226 and defines a single hole 224 spaced from the bottom peripheral edge 226. The single hole 224 is in fluid communication with the fan 108.

[0033] Referring to Figures 7 and 8, while the air distribution device 110 of Figures 4A and 5 A further includes the top layer 128 formed of air permeable material without any holes cut or otherwise formed therein, the air distribution device 210 includes a top layer 228 formed of air impermeable material with a single opening 242 formed therein. The air impermeable top layer 228 is configured to direct air through only the single opening 242 toward a corresponding portion of the cover layer 212. In this example, the top layer 228 includes a rim 244, which is spaced radially inward from the top peripheral edge 230 by any suitable constant or variable distance to define a corresponding shape of the opening 242. While Figure 7 illustrates the exemplary single opening 230 having the same shape as the top layer, it is contemplated that the opening can have any suitable shape and size for directing air toward any portion of the cover layer.

[0034] Referring to Figure 7, the top peripheral edge 230 of the top layer 228 is sealingly coupled to the bottom peripheral edge 226 of the bottom layer 222 so as to enclose an interior chamber 232. More specifically, the air distribution device 210 includes one or more non-adhesive mechanical fasteners 233 for attaching the bottom and top peripheral edges 226, 230 to one another. Examples of these mechanical fasteners 233 (Figures 4A-4C) can include stitching, staples, hook-and-loop fasteners, other suitable mechanical fasteners, or any combination thereof. In this example, each one of the bottom and top peripheral edges 226, 230 is not folded radially inward (Figure 4D) but rather remains unfolded and extends radially outward (Figure 4A). However, it is contemplated that the bottom and top peripheral edges may be folded radially inward (Figure 4D).

[0035] The air distribution device 210 further includes a spacer layer 240 disposed within the interior chamber 232 between the top and bottom layers 228, 222. The spacer layer 240 is air permeable and configured to space apart the top and bottom layers 228, 222 from one another and prevent the interior chamber 232 from collapsing when, for example, a vehicle occupant is positioned on the vehicle seat. While this embodiment of the spacer layer 240 is a spacer mesh, other embodiments of the spacer layer can be a porous material, a reticulated foam, or any suitable air permeable support. [0036] It is to be appreciated that the above embodiments of the air distribution device may be used individually, as described above, or in combination with one another to pull and/or push air toward a vehicle occupant.

[0037] The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. As is now apparent to those skilled in the art, many modifications and variations of the subject invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.

Claims

CLAIMS What is claimed is:

1. A vehicle seat for a passenger cabin of a vehicle, the vehicle seat comprising:

a seat bottom including a cover layer formed of air permeable material and a seat cushion having an A side facing toward the cover layer and a B side facing away from the cover layer; a seatback pivotally coupled to the seat bottom; and

a ventilation system integrated within the seat bottom, the ventilation system comprising: a fan; and

an air distribution device fluidly coupled to the fan, the air distribution device comprising:

a bottom layer formed of air impermeable material, with the bottom layer having a bottom peripheral edge and defining a single hole spaced from the bottom peripheral edge in fluid communication with the fan;

a top layer having a top peripheral edge, with the bottom and top layers attached to one another along the respective bottom and top peripheral edges to define an interior chamber;

a spacer layer disposed within the interior chamber between the bottom and top layers with the spacer layer formed of air permeable material; and at least one non-adhesive mechanical fastener sealingly attaching the bottom peripheral edge of the bottom layer and the top peripheral edge of the top layer to one another.

2. The vehicle seat of claim 1 wherein the top layer is formed of a sheet of air permeable material fabric comprising a plurality of fibers spaced apart from one another to define a plurality of passages through the fabric capable of flowing air through only the plurality of passages in the fabric disposed between the seat cushion and the spacer layer.

3. The vehicle seat of claim 1 wherein the top layer is formed of a sheet of air impermeable material defining a single opening capable of flowing air through only the single opening.

4. The vehicle seat of claim 1 wherein the top peripheral edge of the top layer defines a central surface area configured to direct air toward a portion of the cover layer corresponding in size with the central surface area of the top layer.

5. The vehicle seat of claim 1 wherein the seat bottom further comprises at least one foam padding element positioned adjacent to the A side of the seat cushion, with the air distribution device positioned adjacent to the B side of the seat cushion.

6. The vehicle seat of claim 5 wherein the seat bottom further comprises an air permeable heating mat positioned between the cover layer and the at least one foam padding element.

7. A ventilation system of a vehicle seat for a passenger cabin of a vehicle, the ventilation system comprising:

a fan; and

an air distribution device fluidly coupled to the fan, and the air distribution comprising: a bottom layer formed of air impermeable material, with the bottom layer having a bottom peripheral edge and defining a single hole spaced from the bottom peripheral edge in fluid communication with the fan;

a spacer layer disposed within the interior chamber between the bottom and top layers with the spacer layer formed of air permeable material; and

at least one non-adhesive mechanical fastener sealingly attaching the bottom peripheral edge of the bottom layer and the top peripheral edge of the top layer to one another.

8. The ventilation system of claim 7 wherein the top layer is formed of a sheet of air permeable material fabric comprising a plurality of fibers spaced apart from one another to define a plurality of passages through the fabric capable of flowing air through only the plurality of passages in the fabric.

9. The ventilation system of claim 7 wherein the top layer is formed of a sheet of air impermeable material defining a single opening capable of flowing air through only the single opening.

10. An air distribution device for use with a fan of a ventilation system of a vehicle seat, the air distribution device comprising:

a top layer having a top peripheral edge, the top layer being formed of a sheet of air permeable fabric comprising a plurality of fibers spaced apart from one another to define a plurality of passages through the fabric capable of flowing air through only the plurality of passages in the fabric, with the bottom and top layers attached to one another along the respective bottom and top peripheral edges to define an interior chamber;

11. The air distribution device of claim 10 wherein the air permeable fabric is a woven fabric with the plurality of fibers woven together to define the plurality of passages within the fabric.

12. The air distribution device of claim 10 wherein the air permeable fabric is a nonwoven fabric.

13. The air distribution device of claim 10 wherein each of the bottom and top peripheral edges is unfolded and extends radially outward.

14. The air distribution device of claim 10 wherein at least one of the bottom and top peripheral edges is folded radially inward.

15. The air distribution device of claim 10 wherein the at least one non-adhesive mechanical fastener comprises at least one of a stitching, a hook-and-loop fastener, and a staple.

16. The air distribution device of claim 10 further comprising a barrier formed of air impermeable material coupled to a portion of the top layer for selectively directing air through a central portion of the top layer.

17. An air distribution device for use with a fan of a ventilation system of a vehicle seat, the air distribution device comprising:

a top layer having a top peripheral edge, the top layer being formed of homogeneous material having a porous structure defining a plurality of passages through the top layer capable of flowing air through only the plurality of passages in the top layer, with the bottom and top layers attached to one another along the respective bottom and top peripheral edges to define an interior chamber;

18. The air distribution device of claim 17 wherein the homogeneous material is formed of a sheet of open-cell porous foam.

19. An air distribution device for use with a fan of a ventilation system of a vehicle seat, the air distribution device comprising:

a top layer having a top peripheral edge, the top layer is formed of a sheet of air impermeable material defining a single opening capable of flowing air through the single opening, with the bottom and top layers attached to one another along the respective bottom and top peripheral edges to define an interior chamber;

20. The air distribution device of claim 19 wherein each one of the bottom and top peripheral edges is unfolded and extends radially outward.

21. The air distribution device of claim 19 wherein at least one of the bottom and top peripheral edges is folded radially inward.

22. The air distribution device of claim 19 wherein the at least one non-adhesive mechanical fastener comprises at least one of a stitching, a hook-and-loop fastener, and a staple.

23. The air distribution device of claim 19 wherein the spacer layer is air permeable and configured to space apart the top layer and the bottom layer from one another and prevent the interior chamber from collapsing.

24. The air distribution device of claim 19 wherein the top layer includes an inner rim, which is spaced radially inward from the top peripheral edge to define a corresponding shape of the single opening.