Seat assembly and subassembly

Abstract

The invention relates to a seat assembly and subassembly. A seating system includes a plurality of seat components, a seat cushion material, and a trim cover. The seat components include at least a fan, an inflatable bladder, a heating pad, a foam layer, and an air distribution layer. A trim cover is disposed on the seat cushion material, and a seat component is disposed between the seat cushion material and the trim cover and secured together using at least one fastener.

Description

Technical Field

[0001] Various embodiments are directed to seat assemblies and subassemblies related to trim covers, vents, modularity, packaging, fluid line sheets, attachable bladders, and methods for making the assemblies, fluid line sheets, and attachable bladders. BRIEF DESCRIPTION OF THE DRAWINGS

[0002] Figure 1 is a partially cutaway front perspective view of a seat assembly according to some embodiments;

[0003] Figure 2 According to some embodiments Figure 1 A front elevation view of a modular packaged subassembly of a seat assembly;

[0004] Figure 3 According to some embodiments Figure 1 A front elevation view of a modular packaged subassembly of a seat assembly;

[0005] Figure 4 According to some embodiments Figure 1 A front elevation view of a modular packaged subassembly of a seat assembly;

[0006] Figure 5 yes Figure 4 A rear elevation view of the modular package subassembly;

[0007] Figure 6 yes Figure 4 A side elevation view of a modular package subassembly;

[0008] Figure 7 According to some embodiments Figure 1 a bottom view of a modular packaged subassembly of a seat assembly;

[0009] Figure 8 is a front perspective view of a seat assembly according to some embodiments;

[0010] Figure 9 yes Figure 8 a partial cross-sectional view of a subassembly of a seat assembly;

[0011] Figure 10 According to some embodiments Figure 9 Another partial cross-sectional view of a subassembly;

[0012] Figure 11 According to some embodiments Figure 9 Another partial cross-sectional view of a portion of a subassembly;

[0013] Figure 12 According to some embodiments Figure 9 Another partial cross-sectional view of a portion of a subassembly;

[0014] Figure 13 A method according to some embodiments is shown;

[0015] Figure 14 shows a schematic perspective view of a seat assembly having a fluid assembly for providing a fluid massage according to some embodiments;

[0016] Figure 15 illustrates a side elevation view of a fluid fitting of a fluid assembly according to some embodiments;

[0017] Figure 16 shows a side view of a fluid bladder according to some embodiments;

[0018] Figure 17 shows an exploded side view of a fluidics assembly according to some embodiments;

[0019] Figure 18 shows a side view of a fluid bladder of a fluidic assembly according to some embodiments;

[0020] Figure 19 shows an exploded perspective view of a portion of a fluidics assembly according to some embodiments;

[0021] Figure 20 shows a side view of a fluid bladder according to some embodiments;

[0022] Figure 21 shows an exploded side view of a fluidics assembly according to some embodiments;

[0023] Figure 22 shows an exploded side view of a fluidics assembly according to some embodiments; and

[0024] Figure 23 An exploded side view of a fluidics assembly is shown, according to some embodiments. Detailed description

[0025] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments described. However, it will be apparent to one of ordinary skill in the art that the various embodiments described may be practiced without these specific details. In other instances, well-known methods, processes, components, circuits, and networks have not been described in detail to avoid unnecessarily obscuring aspects of the embodiments.

[0026] It should be understood that the disclosed embodiments are merely exemplary and that various alternatives are possible. The drawings are not necessarily to scale; some features may be exaggerated or minimized to illustrate details of particular components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to variously implement embodiments according to the present disclosure.

[0027] “One or more” includes functions performed by one element, functions performed by more than one element (e.g., in a distributed fashion), functions performed by one element, functions performed by several elements, or any combination of the foregoing.

[0028] It should also be understood that although in some cases the terms first, second, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are simply used to distinguish one element from another. For example, a first layer can be referred to as a second layer, and similarly, a second layer can be referred to as a first layer without departing from the scope of the various embodiments described. Both the first layer and the second layer are layers, but they are not the same layer.

[0029] The terms used in the description of the various embodiments described herein are for the purpose of describing specific embodiments only and are not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that, as used herein, the term "and / or" refers to and includes any and all possible combinations of one or more of the relevant listed items. It will also be understood that, when used in this specification, the terms "includes," "including," "comprises," and / or "comprising" specify the presence of the features, integers, steps, operations, elements, and / or parts, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts, and / or groups thereof.

[0030] As used herein, the term “if” is optionally interpreted to mean “when” or “upon” or “in response to determining” or “in response to detecting”, as appropriate to the context. Similarly, the phrase “if it is determined” or “if [the condition or event] is detected” is optionally interpreted to mean “upon determining” or “in response to determining” or “upon detecting [the condition or event]” or “in response to detecting [the condition or event]”, as appropriate to the context.

[0031] In addition, all numerical values ​​in this disclosure should be understood to represent two examples, one of which is the numerical value itself and the other is a numerical value modified by the word "about" when describing the broader scope of the present disclosure. In addition, unless expressly stated to the contrary: percentages, "parts of..." and ratio values ​​are calculated by weight. The term "polymer" includes "oligomers", "copolymers", "terpolymers" and the like. The molecular weight provided for any polymer refers to the number-average molecular weight. The description of ingredients in chemical terms refers to the ingredients when added to any combination specified in the description and does not necessarily exclude chemical interactions between the ingredients of the mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation in this article and, after necessary modifications, to common grammatical variations of the initially defined abbreviation. Unless expressly stated to the contrary, the measurement of properties is determined by the same techniques as those mentioned above or below for the same property.

[0032] The present disclosure is not limited to the specific embodiments and methods described below, as specific components and / or conditions may vary. Additionally, the terminology used herein is used for the purpose of describing specific embodiments only and is not intended to be limiting in any way.

[0033] The terms "substantially" or "generally" may be used herein to describe the disclosed or claimed embodiments. The term "substantially" may modify a value or relative property disclosed or claimed in this disclosure. In this context, "substantially" and "generally" may mean that a value or relative property is within its manufacturing tolerance, or within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, or 10% of the value or relative property.

[0034] It should also be appreciated that integer ranges explicitly include all intermediate integers. For example, the integer range 1 to 10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4, ..., 97, 98, 99, 100. Similarly, when any range is required, the intermediate number obtained by dividing the difference between the upper and lower limits by 10 as an increment can be considered as an optional upper or lower limit. For example, if the range is 1.1 to 2.1, the following numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as the lower or upper limit.

[0035] The term controller can be provided as one or more controllers or control modules for various components and systems. Controllers and control systems can include any number of controllers and can be integrated into a single controller, or have various modules. Some or all controllers can be connected via a controller area network (CAN) or other systems. It should be appreciated that any controller, circuit or other electrical device disclosed herein can include any number of microprocessors, integrated circuits, memory devices (e.g., flash memory (FLASH), random access memory (RAM), read-only memory (ROM), electrically programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or other suitable variants of these memory devices) and software that work together to perform the operations disclosed herein. In addition, any one or more of the electrical devices disclosed herein can be configured to execute a computer program contained in a non-transitory computer-readable medium that is programmed to perform any number of functions disclosed herein.

[0036] refer to Figure 1 , discloses a seat assembly (e.g., system) 10. The seat assembly 10 can be used in a land vehicle, a watercraft, an aircraft, or the like. The seat assembly 10 can be a seat assembly in a passenger vehicle, a straddle-type vehicle, or the like. The seat assembly 10 can include one or more subassemblies 15-35. For example, the seat assembly 10 includes a trim subassembly (cover) 15 disposed above a cushion subassembly 20 supported by a frame subassembly 35. In some embodiments, the trim subassembly 15 includes a ventilation member. In some embodiments, the seat subassembly 10 also includes fluid subassemblies 25, 30. In some embodiments, the seat assembly 10 includes a temperature control subassembly 25, 30. In various embodiments, the fluid subassemblies 25, 30 are ventilation assemblies and / or massage assemblies. In some embodiments, the fluid subassemblies 25, 30 cooperate with the ventilation member in the trim subassembly 15, and in some embodiments, the fluid subassemblies 25, 30 include the ventilation member of the trim subassembly 15. In some embodiments, the fluid subassemblies 25, 30 include the temperature control subassembly 25, 30. The temperature control subassemblies 25, 30 include, for example, heat transfer subassemblies. In some embodiments, valve subassemblies are included to control the flow of fluids. In some embodiments, retainers or fasteners can attach various components to the pad.

[0037] According to some embodiments, the assemblies 10, 15, 20, 25, 30, 35 and subassemblies 10, 15, 20, 25, 30, 35 can each be provided separately. According to some embodiments, the assemblies 10, 15, 20, 25, 30, 35 and subassemblies 10, 15, 20, 25, 30, 35 can be provided as preassembled modules 10, 15, 20, 25, 30, 35. The assemblies 10, 15, 20, 25, 30 or subassemblies 10, 15, 20, 25, 30 can be preassembled to the frame subassembly 35. The assemblies 10, 15, 25, 30, 35 or subassemblies 10, 15, 25, 30, 35 can also be preassembled to the cushion subassembly 20. The assemblies 10, 20, 25, 30, 35 or subassemblies 10, 20, 25, 30, 35 can also be preassembled to the trim assembly 15. Components 10, 15, 25, 30, 35 or sub-components 10, 15, 25, 30, 35 may also be integrated into the seat cushioning material sub-assembly 20, for example into a foam or extruded thermoplastic mesh. The cushioning sub-assembly 20 may be a gasket and may include a fluid permeable spacer fabric. In some embodiments, the cushioning sub-assembly 20 may be formed by an additive manufacturing process, such as the process disclosed in U.S. Patent No. 11,440,791 B2 to Migneco et al., which was granted to Lear Corporation on September 13, 2022. Various options are available for preassembling the sub-assemblies 10, 15, 20, 25, 30, 35 or components 10, 15, 20, 25, 30, 35 as modules, or preassembling to the frame sub-assembly 35, or preassembling to the seat cushioning material sub-assembly 20.

[0038] Figure 2 and Figure 3 Multiple stacked layers of an assembly 15, 20, 25, 30 or subassembly 15, 20, 25, 30 are shown. The assembly 15, 20, 25, 30 or subassembly 15, 20, 25, 30 are shown preassembled by a plurality of fasteners 36. Fasteners 36 are mechanical devices that hold two or more objects together, such as for assembling or preassembling any combination of assemblies 15, 20, 25, 30 or subassemblies 15, 20, 25, 30. Fasteners 36 may extend through successive pairs of layers or any number of layers of an assembly 15, 20, 25, 30 or subassembly 15, 20, 25, 30. Fasteners 36 may also be aligned in various fastener arrays, such as Figure 2 and Figure 3. Components 15, 20, 25, 30 or subassemblies 15, 20, 25, 30 can be preassembled as modules, which are then assembled to the frame subassembly 35. Any combination of components 15, 20, 25, 30 or subassemblies 15, 20, 25, 30 can be preassembled to facilitate various manufacturing strategies, such as just-in-time manufacturing. Components 20, 25, 30 or subassemblies 20, 25, 30 can be preassembled and then subsequently assembled to the trim cover subassembly 15.

[0039] Figure 4-Figure 6 A subassembly 38 is shown according to some embodiments. In the depicted embodiment, the subassembly 38 is a seat module that is sized to be mounted to the seat assembly 10 ( Figure 1 ) of the seat back 40 (also Figure 1 ). The subassembly 38 includes a base plate 42 that is sized to fit into the seat back 40. In some embodiments, the subassembly 38 and base plate 42 are sized to fit into the seat bottom 44 ( Figure 1 ). The substrate 42 is formed of any suitable material. For example, in some embodiments, the substrate 42 is formed of a fluid-impermeable layer of thermoplastic polyurethane.

[0040] According to some embodiments, the subassembly 38 includes a massage subassembly 46 attached to the base plate 42. The massage subassembly 46 is provided with at least one and as shown a plurality of inflatable massage bladders 48 ( Figure 4 and Figure 6 The cushion subassembly 20 may include a plurality of recesses formed into the cushion to each receive one of the bladders 48. The recesses are bulk spaces, not void cells in the foam. The massage subassembly 46 is included in various areas of the seat assembly 10, such as in the lumbar region 66 ( Figure 1 According to some embodiments, the subassembly 38 and the massage subassembly 46 are sized to be received within the trim cover subassembly 15. In some other embodiments, the massage subassembly 46 is disposed externally to the trim cover subassembly 15 and the seat module subassembly 38.

[0041] According to some embodiments, the subassembly 38 further includes a pair of fluid actuator subassemblies 50, which are fan subassemblies 50. The fan subassemblies 50 are attached to the rear side 52 ( Figure 5 ) and is aligned with an aperture 54 through the base plate 42 to force air through the base plate 42 and out the front side 56 of the base plate 42.

[0042] According to some embodiments, the subassembly 38 may further include another fluid actuator subassembly 58, such as Figure 5 and Figure 6 As shown. The fluid actuator subassembly 58 may include a pump and a valve manifold to deliver fluid (such as pressurized air) to the massage subassembly 46. The fluid actuator subassembly 58 is also attached to the base plate 42. The fluid actuator subassembly 58 may include a controller that controls the pump and valve manifold of the fluid actuator subassembly 58. The controller may be a multi-function controller that also controls other functions in the vehicle. Alternatively, the controller may be provided separately from the fluid actuator subassembly 58.

[0043] According to some embodiments, the subassembly 38 can also include a vent subassembly 60 attached to the base plate 42. The vent subassembly 60 includes a plurality of conduits in fluid communication with the massage subassembly 46 and the valve / pump subassembly 58 to deliver pressurized fluid from the valve / pump subassembly 58 to the massage subassembly 46. Alternatively, the vent subassembly 60 can be integrally formed into the base plate 42, as is known in the art.

[0044] Each of the subassemblies 46, 50, 58, 60 of the seat module subassembly 38 is preassembled to the base plate 42 prior to installation in the seat assembly 10. Each of the subassemblies 46, 50, 58, 60 is fastened to the base plate 42 via a fastener 62. The fastener 62 may include an interlocking key and tab (e.g., a "t-tab"), a weld, a rivet, a tab, a barbed fastener, a ribbed rivet, a staple, a clip, an adhesive, a tie, a snap, a toggle, or the like. The rivet 62 may be a rivet as disclosed in U.S. Patent No. 10,065,543 B2 to Persson et al., issued September 4, 2018 to Kongsberg Automotive AB. The fastener 62 may allow the corresponding subassembly 46, 50, 58, 60 or base plate 42 to move longitudinally along the length of the fastener 62. One or more of the base plate 42, massage subassembly 46, fluid actuator subassemblies 50, 58, and ventilation subassembly 60 include a plurality of alignment apertures 64 for receiving fasteners 62. The plurality of alignment apertures 64 may include notches formed into their outer peripheries for alignment of the layers. The fasteners 62 may also be used to attach the subassembly 38 to the seat frame subassembly 35. The fasteners 62 may also include elastic bands to attach the subassembly 38 to the seat frame subassembly 35. The fasteners 62 may also attach the base plate 42 to the trim cover subassembly 15. The elastic bands may also be attached to the inner surface of the trim cover subassembly 15. The cushion subassembly 20 may include apertures to receive the elastic bands of the fasteners 62 through the cushion subassembly 20.

[0045] Reference again Figure 1, a heat transfer subassembly 68 can be disposed within the trim cover subassembly 15. The heat transfer subassembly 68 can be a heater pad for heating the seat assembly 10. The heat transfer subassembly 68 can also be preassembled with the other subassemblies 38, 46, 50, 58, 60.

[0046] In some embodiments, sensors 70 are disposed on the cushion subassembly 20 within the trim cover subassembly 15. One or more sensors 70 may be employed to measure data from the occupant. Wiring 72 is also enclosed within the trim cover subassembly 15 for communication and operation of the various subassemblies 38, 46, 50, 58, 60, 68.

[0047] Continue to refer Figure 1 , the decorative cover subassembly 15 is attached to the underlying substrate 42 to provide a chamber within the cover assembly 15 to surround or at least partially surround the cushion subassembly 20, the seat module subassembly 38, and the attached subassemblies 46, 50, 58, 60 between the cover assembly 15 and the substrate 42. According to some embodiments, the cover assembly 15 can also be formed from a fluid-impermeable layer (such as thermoplastic polyurethane). The cover assembly 15 can be attached to the substrate 42 along the periphery of the substrate 42. The cover assembly 15 can be joined to the substrate 42 for a fluid-tight chamber within the cover assembly 15. The cover assembly 15 can be welded, sewn, or otherwise attached to the substrate 42. The decorative cover assembly 15 includes a side wall 74 connected to the substrate 42. According to some embodiments, the side wall 74 is foldable. According to other embodiments, the side wall 74 includes multiple stackable portions that are corrugated bellows joints.

[0048] Figure 7 A seat module subassembly 76 is shown according to some embodiments. The seat module subassembly 76 is sized to be received within the seat bottom 44. The subassembly 76 includes a base plate 78 formed from one or more layers. A plurality of apertures 80 are formed through the base plate 78 (i.e., an air distribution layer) to cooperate with other subassemblies (such as ventilation or heat transfer subassemblies). A plurality of fan subassemblies 82 are fastened to the base plate 78 by fasteners 62. Wiring 84 is also provided to power and control the fan subassemblies 82. The seat module subassembly 76 and associated subassemblies 82 and components are housed (i.e., nested) within a chamber cavity of the trim cover subassembly 15.

[0049] An assembly (e.g., vehicle seat assembly 10, trim cover subassembly 15, cushion subassembly 20, fluid actuator subassemblies 25, 30, seat module subassembly 38, seat module subassembly 76) is described that can be a seat assembly or a subassembly thereof. The assembly (e.g., vehicle seat assembly 10, trim cover subassembly 15, cushion subassembly 20, fluid actuator subassembly 25, 30, seat module subassembly 38, seat module subassembly 76) includes a base plate (e.g., base plate 42) that is sized to be mounted in a seat bottom (e.g., seat bottom 44) or a seat back (e.g., seat back 40).

[0050] The base plate can be formed from a fluid-impermeable layer of thermoplastic polyurethane, which can be integrally formed with the cover. A massage subassembly (e.g., massage subassembly 46) is attached to the base plate (e.g., base plate 42). The massage subassembly can include one or more massage bladders that can be at least partially surrounded by the cover, disposed externally of the cover and base plate, or disposed between the cover and base plate.

[0051] A fluid actuator subassembly (e.g., fluid actuator subassembly 50, 58) is attached to a substrate (e.g., substrate 42). The fluid actuator subassembly can be a fan assembly, a valve subassembly, a pump in fluid communication with the valve subassembly, and at least one inflatable bladder assembly supported on a first fluid-impermeable layer to apply pressure to an occupant. The vehicle seat assembly can be provided with a seat bottom suitable for mounting to a vehicle floor. The vehicle seat assembly can be provided in any row of a vehicle. The vehicle seat assembly can include a seat back extending vertically from the seat bottom. The vehicle seat assembly can also include a head restraint extending above the seat back. The vehicle seat assembly can be used for any type of vehicle, including land vehicles, watercraft, aircraft, etc. The vehicle seat assembly can be any seat assembly, such as an office chair, furniture, etc. The vehicle seat assembly can be provided with a decorative cover above the seat bottom, seat back, and head restraint to conceal the frame, cushioning, and functional components.

[0052] The seat bottom may be provided with seat cushioning material. The seat cushioning material may be composed of strands of thermoplastic resin or foam. The vehicle seat assembly may also be provided with a controller and a pump. The controller and pump may be located in a module below the seat cushioning material and may be a multifunctional controller that also controls other functions in the vehicle.

[0053] In at least one embodiment, the non-foam material is formed from strands of a thermoplastic resin, such as a linear low density polyethylene (LLPDE) material, but other polymers and materials that effectively provide the desired properties and functionality are also considered, such as but not limited to polymers and materials based on polyamide, polyester, polyimide, polyolefin (e.g., polypropylene, polyethylene, etc.), polystyrene, or combinations thereof. At least one of the strands is looped and combined with at least one other strand, which forms a three-dimensional structure. The use of thermoplastics has several advantages over traditional polyurethane foams, such as reduced toxicity, reduced weight, reduced production costs, and increased recyclability. As will be understood, the material properties of the resin can be adjusted to change the material hardness, and therefore the resulting stiffness of the resulting cushion. Similarly, the density and orientation of the strands can be adjusted to change the stiffness, porosity, and the resulting airflow through the material, etc., of the resulting cushion.

[0054] In at least one embodiment, the strands of thermoplastic material are extruded. A container holding beads, particles, flakes, pellets or powder of the resin is dispensed, and the material is then melted and extruded through a die. The size and orientation of the holes through which the molten resin is extruded can be changed to achieve the different properties of the resulting pad. The extruded strands are then deposited in a water bath that is used to loop at least one of the strands and bond it to another strand in the strand to form a net, and to start a cooling process to return the strands from a molten state to a hardened state. The distance from the die to the water bath can be adjusted to affect the diameter of the resin strands, for example, due to the thinning that occurs when the distance the filaments extend increases and the material is in a molten, non-hardened state. The water bath can be provided with various rollers and conveyors to move the filaments through and out of the water bath, and the filament structure can be cut into desired size and shape to form a pad blank, for example, using a cutting wheel, a water jet or another technology.

[0055] In one embodiment, the result of this process is a mesh structure having relatively uniform dimensions, such as rectangular blocks or prisms. In other embodiments, the strands can be manipulated during any step of the process to produce a mesh structure having features such as shaping, notches, grooves, skins, etc. Such manipulations include, for example, varying the extrusion speed, varying the speed at which the strands are extracted from the water bath, introducing air or water streams blowing onto the strands before they reach the water bath, agitating the water bath, adding layers of permeable or impermeable material, etc.

[0056] In some embodiments, the mesh structure can be further processed to introduce new shapes and features into the mesh. For example, in one embodiment, the mesh structure is cut into blanks that are placed in a mold. In order to more permanently configure the shape of the blank, the gasket blank is heated to a temperature at which the polymer material from which the gasket blank is made begins to soften. The control of temperature and other manufacturing processes may cause some limited, unintentional local melting of the polymer material, but if this occurs, it will be negligible and the majority of the gasket blank will remain in a non-liquid state. Therefore, the gasket blank begins the molding process in a solid state and remains mostly or entirely solid throughout the process. In one embodiment, this is achieved by passing a first fluid having a first predetermined temperature through the mold and through the gasket blank itself. This introduces a first fluid stream through the gasket blank to bring the gasket blank to the desired temperature.

[0057] The fluid in the fluid stream can be a gas, a liquid, or some combination of a gas and a liquid. For example, the fluid can be air, steam, superheated steam, water, etc. The first predetermined temperature will depend on the specific material from which the liner blank 12 is made. For example, for a stranded web material made of linear low-density polyethylene as described above, the first predetermined temperature can be in the range of 85-100°C. Other types of polymer materials may have different temperature ranges within which they become plastic. For example, for high-density polyethylene or polypropylene, the first predetermined temperature can be 100-130°C.

[0058] Because the cushion blank is made of a stranded mesh material, the heated air is generally uniformly distributed throughout the thickness of the blank. This helps ensure even heating, making all the material in the cushion blank plastic.

[0059] Subsequently, a second fluid may be passed through the mold to achieve cooling of the liner and hardening of the liner to the mold shape. The second fluid may be air, steam, superheated steam, water, etc.

[0060] The seat subassembly can be provided with a second fluid-impermeable layer sized to be placed over the seat cushioning material. The first fluid-impermeable layer can be comprised of a cushioning material. The second fluid-impermeable layer can be formed of an impermeable polymeric material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene, or the like.

[0061] The first fluid-impermeable layer can be provided with a plurality of vents formed therethrough. Any number of vents can be used. The vents can direct airflow through the seat subassembly. If the trim cover has a plurality of holes formed therethrough, the first fluid-impermeable layer and the vents can be optional. The first fluid-impermeable layer can be insulating. The first fluid-impermeable layer and the second fluid-impermeable layer can be joined together by a seam that is sewn, adhered, welded, etc. around the peripheral edges of the layers. The second fluid-impermeable layer can cooperate with the first fluid-impermeable layer to provide a fluid chamber therebetween.

[0062] The inflatable bladder assembly may be supported on the first fluid impermeable layer and may be disposed within the fluid chamber.The inflatable bladder assembly may be disposed outside of the fluid chamber, such as between the second fluid impermeable layer and the seat cushioning material.

[0063] The controller can be in electrical communication with the pump, which in turn can be in fluid communication with the inflatable bladder assembly to inflate the assembly. The controller can be programmed to receive input indicating a manual adjustment and adjust the inflatable bladder assembly to apply pressure to the occupant. The controller can also be programmed to receive input indicating a massage program and operate the inflatable bladder assembly to apply a pressurized massage effect to the occupant.

[0064] The seat subassembly may also be provided with a fluid-permeable layer. The fluid-permeable layer may be formed from a resilient and porous material, such as a porous foam or an extruded thermoplastic resin mesh. The fluid-permeable layer may be sized to be contained within the fluid chamber and disposed over the inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly may be disposed between a first fluid-impermeable layer and a second fluid-impermeable layer. Any number of airbag assemblies may be employed.

[0065] The fluid-permeable layer can ensure that the first and second fluid-impermeable layers are not compressed together by the weight of an occupant. Without the permeable layer, the impermeable layers could be compressed when the weight of an occupant is applied, which could cut off airflow when a fan is used. The permeable layer can be omitted when the seat subassembly utilizes a compressor rather than a fan.

[0066] The seat subassembly may also be provided with a heat transfer layer disposed along the first fluid-impermeable layer and spaced apart from the second fluid-impermeable layer. The heat transfer layer may be disposed along the trim layer, or alternatively, between the second fluid-impermeable layer and the fan. The heat transfer layer may be disposed between the first fluid-impermeable layer and the first fluid-permeable layer. The heat transfer layer may be provided with a conductive heater pad. The seat subassembly may be provided as a preassembled module that is subsequently assembled to the seat cushioning material and / or seat trim cover.

[0067] The seat subassembly may also be provided with an outer decorative layer disposed over the first and second fluid-impermeable layers. The decorative layer may be perforated to allow fluid to pass through the outer decorative layer. The decorative layer may be glued to the first fluid-impermeable layer.

[0068] The seat subassembly can be provided with a fluid actuator, such as a fan. The fluid actuator can be directly welded to the second fluid-impermeable layer to seal the connection around the fan. The fan can be connected to the second fluid-impermeable layer via a retaining ring. The fan can be mounted between the trim cover and the seat cushioning material. The seat cushioning material can include a receptacle sized to receive the fan. Mounting the fan above the seat cushioning material can allow the fan to be displaced within the seat subassembly.

[0069] The fluid-impermeable layer, permeable layer, heat transfer layer, airbag assembly, and fluid actuator can all be pre-assembled within the seat subassembly so that the seat subassembly can be mounted to the seat frame as a whole. The seat subassembly can operate in conjunction with an air-permeable non-foam seat cushioning material formed from the twisted web described above. A second fluid-impermeable layer can provide a barrier between the fluid chamber and the seat cushioning material. When used with a foam or twisted cushion, the second fluid-impermeable layer can be omitted if the cushion is air-impermeable. In this case, the fluid actuator can be welded directly to the first fluid-impermeable layer to deliver fluid through the vents in the fluid-impermeable layer. The fluid actuator can be separate from the trim cover. The first and second fluid-impermeable layers can be provided with stitching along the perimeter. The stitching can seal the layers so that air cannot escape the fluid chamber. The layers can be attached with adhesive or welded together rather than utilizing stitching.

[0070] The second fluid-impermeable layer can be provided with a first portion and a second portion. The first portion can also be provided with a first wing. The first wing can be perforated to allow air to flow between areas or seams within the subassembly. The first wing can be segmented to allow air to flow between areas and / or within the fluid chamber. The second portion can also be provided with a second wing extending in a direction opposite to the first wing. The wing can be used to attach the subassembly to other seat components or subassemblies. The second wing can be connected to the seat cushioning material. The first portion and the second portion can be sewn, welded, adhered or otherwise fastened together. The first portion and the second portion can be ultrasonically welded or high-frequency friction welded together.

[0071] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may be provided with a first wing and a second wing. The first wing may be perforated to allow air to pass through the fluid chamber. The second wing may extend in a direction opposite to the first wing and may be attached to the seat cushioning material. The first wing and the second wing may be sewn, welded, adhered, or otherwise secured to the second fluid-impermeable layer. The first wing and the second wing may be ultrasonically welded or high-frequency friction welded to the second fluid-impermeable layer.

[0072] The base plate can be at least partially surrounded by a cover, with the fluid actuator subassembly disposed between the cover and the base plate. The vent subassembly (e.g., vent subassembly 60) is in fluid communication with the massage subassembly (e.g., massage subassembly 46) and the fluid actuator subassembly (e.g., fluid actuator subassemblies 50, 58). The vent subassembly can be formed into the base plate (i.e., embedded so as to be securely disposed therein, such as by overmolding), disposed within a cavity of a cover attached to the base plate, and / or at least partially surrounded by the cover.

[0073] The massage subassembly (e.g., massage subassembly 46), fluid actuator subassembly (e.g., fluid actuator subassembly 50, 58), and ventilation subassembly (e.g., ventilation subassembly 60) are preassembled to a base plate (e.g., base plate 42) prior to installation in a seat bottom (e.g., seat bottom 44) or a seat back (e.g., seat back 40). The massage subassembly, fluid actuator subassembly, and ventilation subassembly are preassembled and can be fastened together by welds, fasteners, rivets, tab pins, barbed fasteners, rib shank rivets, and the fasteners can attach the massage subassembly and / or fluid actuator subassembly to a base plate, or attach the assembly to a frame of a seat bottom or seat back, wherein the fasteners are mounted into one or more of the massage subassembly, fluid actuator subassembly, and ventilation subassembly, wherein the fasteners allow one or more of the base plate, massage subassembly, fluid actuator subassembly, and ventilation subassembly to move relative to the fasteners, wherein one or more of the base plate, massage subassembly, fluid actuator subassembly, and ventilation subassembly includes a plurality of alignment apertures, wherein the plurality of alignment apertures include notches formed into an outer periphery thereof.

[0074] In some embodiments, the fluid actuator subassembly (eg, fluid actuator subassembly 50 , 58 ) includes a fan assembly (eg, fan subassembly 50 ).

[0075] In some embodiments, the massaging subassembly (eg, massaging subassembly 46 ) further includes one or more massage bladders (eg, massage bladders 48 ).

[0076] In some embodiments, a vent subassembly (eg, vent subassembly 60 ) is formed into a substrate (eg, substrate 42 ).

[0077] In some embodiments, one or more of the base plate (e.g., base plate 42), the massage subassembly (e.g., massage subassembly 46), the fluid actuator subassembly (e.g., fluid actuator subassembly 50, 58), and the ventilation subassembly (e.g., ventilation subassembly 60) are fastened together by welding (e.g., fasteners 36, 62).

[0078] In some embodiments, fasteners (e.g., fasteners 36, 62) attach an assembly (e.g., vehicle seat assembly 10, trim cover subassembly 15, cushion subassembly 20, fluid actuator subassembly 25, 30, seat module subassembly 38, seat module subassembly 76) to a frame (e.g., frame subassembly 35) of a seat bottom (e.g., seat bottom 44) or a seat back (e.g., seat back 40).

[0079] In some embodiments, a cushion (e.g., cushion subassembly 20) is assembled to a base (e.g., base 42) with a plurality of recesses formed into the cushion (e.g., cushion subassembly 20), each of the recesses being sized to receive a bladder (e.g., massage bladder 48) of a massage subassembly (e.g., massage subassembly 46).

[0080] In some embodiments, a fluid actuator subassembly (eg, fluid actuator subassembly 50 , 58 ) includes a valve subassembly (eg, fluid actuator subassembly 58 ).

[0081] In some embodiments, the fluid actuator subassembly (eg, fluid actuator subassembly 50 , 58 ) further includes a pump (eg, fluid actuator subassembly 58 ) in fluid communication with the valve subassembly (eg, fluid actuator subassembly 58 ).

[0082] In some embodiments, a trim cover (eg, trim cover assembly 15 ) is attached to a base plate (eg, base plate 42 ).

[0083] In some embodiments, an elastic band (e.g., fasteners 36, 62) is attached to an inner surface of a trim cover (e.g., trim cover subassembly 15) in cooperation with one or more of a base plate (e.g., base plate 42), a massage subassembly (e.g., massage subassembly 46), a fluid actuator subassembly (e.g., fluid actuator subassembly 50, 58), and a ventilation subassembly (e.g., ventilation subassembly 60) for alignment. Fasteners (e.g., fasteners 36, 62) are attached to distal ends of the elastic band (e.g., fasteners 36, 62) to attach an assembly (e.g., vehicle seat assembly 10, trim cover subassembly 15, cushion subassembly 20, fluid actuator subassemblies 25, 30, seat module subassembly 38, seat module subassembly 76) to a seat frame (e.g., seat frame assembly 35).

[0084] In some embodiments, a cushion (e.g., cushion subassembly 20) is provided wherein the elastic band is a pull-through line that extends through an aperture in the cushion (e.g., cushion subassembly 20) to align the cushion (e.g., cushion subassembly 20) with an assembly (e.g., vehicle seat assembly 10, trim cover subassembly 15, cushion subassembly 20, fluid actuator subassemblies 25, 30, seat module subassembly 38, seat module subassembly 76). For example, tensioning the pull-through line aligns the seat component or subassembly with the seat cushioning material. In another example, the pull-through line comprises a buckle for securing the subassembly.

[0085] In some embodiments, a cover (e.g., decorative cover subassembly 15) is attached to a base plate (e.g., base plate 42) to provide a chamber to at least partially enclose a massage subassembly (e.g., massage subassembly 46), a fluid actuator subassembly (e.g., fluid actuator subassemblies 50, 58), or a ventilation subassembly (e.g., ventilation subassembly 60) between the cover (e.g., decorative cover subassembly 15) and the base plate (e.g., base plate 42).

[0086] In some embodiments, a lumbar subassembly (eg, massage subassembly 46 ) is disposed within the chamber.

[0087] In some embodiments, a massaging subassembly (eg, massaging subassembly 46 ) is disposed within the chamber.

[0088] In some embodiments, a ventilation subassembly (eg, ventilation subassembly 60 ) is disposed within the chamber.

[0089] In some embodiments, a heat transfer subassembly (eg, heat transfer subassembly 68 ) is disposed within the chamber.

[0090] In some embodiments, a sensor (eg, sensor 70 ) is disposed within the chamber.

[0091] In some embodiments, wiring (eg, wiring 72 ) is disposed within the chamber.

[0092] In some embodiments, the cover (eg, the trim cover subassembly 15 ) and the base plate (eg, the base plate 42 ) are integrally formed.

[0093] In some embodiments, the cover (eg, trim cover subassembly 15 ) and the substrate (eg, substrate 42 ) include thermoplastic polyurethane.

[0094] In some embodiments, a massage subassembly (eg, massage subassembly 46 ) is disposed between a cover (eg, cover subassembly 15 ) and a base plate (eg, base plate 42 ).

[0095] In some embodiments, the massage subassembly (eg, massage subassembly 46 ) is disposed externally to the cover (eg, cover subassembly 15 ) and the base (eg, base 42 ).

[0096] In some embodiments, foldable sidewalls (eg, sidewalls 74 ) interconnect the cover (eg, cover subassembly 15 ) and the base plate (eg, base plate 42 ).

[0097] In some embodiments, the sidewalls (eg, sidewall 74 ) include corrugated bellows.

[0098] In some embodiments, a cushion (eg, cushion subassembly 20 ) is disposed within the chamber.

[0099] In some embodiments, the cushion (eg, cushion subassembly 20) comprises a fluid permeable spacer fabric.

[0100] In some embodiments, a substrate (e.g., substrate 42) includes a fluid-impermeable layer, which may be thermoplastic polyurethane. A cover (e.g., trim cover subassembly 15) includes a fluid-impermeable layer, which may be thermoplastic polyurethane. The cover (e.g., trim cover subassembly 15) is attached to the substrate (e.g., substrate 42) along a perimeter of the substrate (e.g., substrate 42) to create a fluid-tight chamber between the cover (e.g., cover assembly 15) and the substrate (e.g., substrate 42).

[0101] In some embodiments, the cover (eg, cover subassembly 15 ) is sewn to a base plate (eg, base plate 42 ).

[0102] In some embodiments, fasteners (eg, fasteners 36 , 62 ) interconnect a cover (eg, trim cover subassembly 15 ) and a base plate (eg, base plate 42 ).

[0103] In some embodiments, the fasteners (eg, fasteners 36 , 62 ) include rivets (eg, rivet 62 ), which may be tab pins, barbed fasteners, or rib shank rivets.

[0104] In some embodiments, fasteners (eg, fasteners 36 , 62 ) are mounted into a base plate (eg, base plate 42 ).

[0105] In some embodiments, fasteners (eg, fasteners 36, 62) attach the massage subassembly and / or the fluid actuator subassembly to the base plate.

[0106] In some embodiments, fasteners (e.g., fasteners 36, 62) are installed in one or more of a massage subassembly (e.g., massage subassembly 48), a fluid actuator subassembly (e.g., fluid actuator subassemblies 50, 58), and a vent subassembly (e.g., vent subassembly 60).

[0107] In some embodiments, a fastener (e.g., fasteners 36, 62) allows one or more of a base plate (e.g., base plate 42), a massage subassembly (e.g., massage subassembly 46), a fluid actuator subassembly (e.g., fluid actuator subassembly 50, 58), and a ventilation subassembly (e.g., ventilation subassembly 60) to move relative to the fastener (e.g., fasteners 36, 62).

[0108] In some embodiments, one or more of the substrate (e.g., substrate 42), the massage subassembly (e.g., massage subassembly 46), the fluid actuator subassembly (e.g., fluid actuator subassemblies 50, 58), and the vent subassembly (e.g., vent subassembly 60) include a plurality of alignment orifices (e.g., orifice 64).

[0109] In some embodiments, a plurality of alignment apertures (eg, aperture 64 ) include notches formed into their outer perimeters.

[0110] Figure 8 A vehicle seat assembly 110 is shown according to some embodiments. The vehicle seat assembly 110 is provided with a seat bottom 112 adapted to be mounted to the vehicle floor. The vehicle seat assembly 110 can be positioned in any row of a vehicle. The vehicle seat assembly 110 includes a seat back 114 extending vertically from the seat bottom 112. The vehicle seat assembly 110 also includes a head restraint 116 extending above the seat back 114. The vehicle seat assembly 110 can be used in any type of vehicle, including land vehicles, watercraft, aircraft, or the like. The vehicle seat assembly 110 can be any seat assembly, such as an office chair, furniture, or the like.

[0111] Vehicle seat assembly 110 is provided with a trim cover 118 over seat bottom 112, seat back 114, and head restraint 116 to conceal the frame, cushioning components, and functional components. Seat bottom 112 is provided with seat cushioning material 120. Seat cushioning material 120 may be formed from a twisted mesh or foam, as described above. Vehicle seat assembly 110 is also provided with a controller and pump 144. Controller and pump 144 may be located in a module below seat cushioning material 120 and may be a multifunctional controller that also controls other functions in the vehicle.

[0112] Figure 9A seat subassembly 122 is shown, according to some embodiments. Seat subassembly 122 is provided with a first fluid-impermeable layer 124 and a second fluid-impermeable layer 128, which are sized to be placed over seat cushioning material 120. First fluid-impermeable layer 124 can be comprised of a cushioning material such as foam. Second fluid-impermeable layer 128 can be formed from an impermeable polymer material (e.g., a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene, etc.). According to some embodiments, first fluid-impermeable layer 124 is provided with a plurality of vents 126 formed therethrough. While a plurality of vents 126 are illustrated and described, any number of vents 126 may be utilized. Vents 126 direct airflow through seat subassembly 122. According to some embodiments, first fluid-impermeable layer 124 and vents 126 may be optional if trim cover 118 has a plurality of apertures formed therethrough. Alternatively, first fluid-impermeable layer 124 may be insulating. The first fluid impermeable layer 124 and the second fluid impermeable layer 128 may be joined together by a seam that is sewn, adhered, welded, etc. around the peripheral edges of the layers 124 , 128 .

[0113] The second fluid-impermeable layer 128 is cooperatively disposed with the first fluid-impermeable layer 124 to provide a fluid chamber 130 between the second fluid-impermeable layer 128 and the first fluid-impermeable layer 124. The seat subassembly 122 is further provided with an inflatable bladder assembly 132. According to some embodiments, the inflatable bladder assembly 132 is supported on the first fluid-impermeable layer 124 and disposed within the fluid chamber 130. According to some embodiments, the inflatable bladder assembly 132 can be displaced outside of the fluid chamber 130, such as between the second fluid-impermeable layer 128 and the seat cushioning material 120.

[0114] Controller 144 is in electrical communication with pump 144, which in turn is in fluid communication with inflatable bladder assembly 132 to inflate assembly 132. Controller 144 is programmed to receive input indicating a manual adjustment and adjust inflatable bladder assembly 132 to apply pressure to the occupant. Similarly, controller 144 can also be programmed to receive input indicating a massage program and operate inflatable bladder assembly 132 to apply a pressurized massage effect to the occupant.

[0115] The seat subassembly 122 is further provided with a fluid-permeable layer 134. The fluid-permeable layer 134 is formed of a resilient and porous material, such as a porous foam or an extruded thermoplastic resin web as described above. The fluid-permeable layer 134 is sized to be received within the fluid chamber 130, over the inflatable bladder assembly 132. The fluid-permeable layer 134 and the inflatable bladder assembly 132 are disposed between the first fluid-impermeable layer 124 and the second fluid-impermeable layer 128. Although a plurality of inflatable bladder assemblies 132 are shown, any number of bladder assemblies 132 may be employed.

[0116] The fluid-permeable layer 134 ensures that the first and second fluid-impermeable layers 124, 128 are not compressed together by the weight of the occupant. Without the permeable layer 134, the impermeable layers 124, 128 could be compressed when the weight of the occupant is applied, which could cut off airflow when the fan 140 is used. The permeable layer 134 can be omitted when the seat subassembly 122 utilizes a compressor instead of the fan 140.

[0117] The seat subassembly 122 is also provided with a heat transfer layer 138 that is displaced along the first fluid-impermeable layer 124 and spaced apart from the second fluid-impermeable layer 128. In some embodiments, the heat transfer layer 138 can be disposed along the trim layer 118, or alternatively, between the second fluid-impermeable layer 128 and the fan 140. In some embodiments, the heat transfer layer 138 can be disposed between the first fluid-impermeable layer 124 and the first fluid-permeable layer 134. The heat transfer layer 138 is provided with a conductive heater pad.

[0118] According to some embodiments, the seat subassembly 122 is provided as a preassembled module that is subsequently assembled to the seat cushioning material 120 and / or the seat trim cover 118. According to some embodiments, the seat subassembly 122 is also provided with an outer trim layer 118 disposed over the first fluid-impermeable layer 124 and the second fluid-impermeable layer 128. The trim layer 118 is perforated to allow fluid to pass through the outer trim layer 118. According to some embodiments, the trim layer 118 is glued to the first fluid-impermeable layer 124.

[0119] Continue to refer Figure 9, the seat subassembly 122 is provided with a fluid actuator 140, such as a fan 140. The fluid actuator 140 is directly welded to the second fluid-impermeable layer 128 to seal the connection around the fan 140. According to some embodiments, the fan 140 is connected to the second fluid-impermeable layer 128 by a retaining ring. The fan 140 is mounted between the trim cover 118 and the seat cushion material 120. The seat cushion material 120 includes a receptacle cavity sized to receive the fan 140. For example, the fan 140 has a fan profile, and the cavity has a cavity geometry similar to the fan profile to provide a tight fit for the fan 140. Conventional fans are mounted below the vehicle seat cushion and outside the trim cover assembly. Mounting the fan 140 above the seat cushion material 120 allows the fan 140 to be positioned within the seat subassembly 122.

[0120] Prior art seat assemblies with heating and cooling features typically place the fan and massage bladder assembly beneath the cushioning. The fluid conduit is then assembled through the cushioning and trim cover of the conventional seat assembly. Fluid-impermeable layers 124, 128, permeable layer 134, heat transfer layer 138, air bladder assembly 132, and fluid actuator 140 are all preassembled within seat subassembly 122, allowing it to be installed as a single unit onto the seat frame. This preassembly reduces manufacturing costs and time compared to prior art designs.

[0121] The seat subassembly 122 can be used with an air-permeable non-foam seat cushioning material 120 formed from a yarn mesh, as described above. The second fluid-impermeable layer 128 provides a barrier between the fluid chamber 130 and the seat cushioning material 120. When used with a foam cushion 120, the second fluid-impermeable layer 128 can be omitted if the cushion 120 is air-impermeable. In this case, the fluid actuator 140 can be welded directly to the first fluid-impermeable layer 124 to deliver fluid through the vents 126 of the fluid-impermeable layer 124. Alternatively, the fluid actuator 140 can be separate from the trim cover.

[0122] Figure 10 A first fluid impermeable layer 124 and a second fluid impermeable layer 128 are shown with stitching 142 along the perimeter. The stitching 142 seals the layers 124, 128 so that air cannot escape the fluid chamber 130. Alternatively, the layers 124, 128 may be attached with adhesive or welded together.

[0123] Figure 11A second fluid-impermeable layer 128 is shown, according to some embodiments. The second fluid-impermeable layer 128 is provided with a first portion 146 and a second portion 148. The first portion 146 is further provided with a first flap 166. In some embodiments, the first flap 166 is perforated to allow air to flow between regions or seams within the subassembly 122. In some embodiments, the first flap 166 can be segmented to allow air to flow between regions and / or within the fluid chamber 130. The second portion 148 is further provided with a second flap 168 extending in a direction opposite to the first flap 166. The flaps 166, 168 can be used to attach the subassembly 122 to other seat components or subassemblies. For example, in some embodiments, the second flap 168 can be connected to the seat cushioning material 120. The first portion 146 and the second portion 148 can be sewn, welded, adhered, or otherwise fastened together. The first portion 146 and the second portion 148 can be ultrasonically welded or high-frequency friction welded together.

[0124] Figure 12 The second fluid-impermeable layer 128 is shown as a continuous sheet according to some embodiments. The second fluid-impermeable layer 128 is provided with a first flap 160 and a second flap 162. The first flap 160 can be perforated to allow air to pass through the fluid chamber 130. The second flap 162 extends in a direction opposite to the first flap 160 and can be attached to the seat cushioning material 120. The first flap 160 and the second flap 162 can be sewn, welded, adhered, or otherwise fastened to the second fluid-impermeable layer 128. The first flap 160 and the second flap 162 can be ultrasonically welded or high-frequency friction welded to the second fluid-impermeable layer 128.

[0125] Figure 13 A method 170 is shown according to some embodiments. The method 170 is provided and can be used to install at least one inflatable bladder assembly 132, as well as to install the first fluid-impermeable layer 124. The method 170 can have more or fewer steps than described below, and the various steps can be performed in another order, sequentially, or simultaneously.

[0126] Method 170 includes: installing (172) at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132) supported on a first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) to apply pressure to an occupant; and installing (174) the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) on a seat cushioning material.

[0127] A vehicle seat assembly can be provided with a seat bottom adapted to be mounted to a vehicle floor. The vehicle seat assembly can be provided in any row of a vehicle. The vehicle seat assembly can include a seat back extending vertically from the seat bottom. The vehicle seat assembly can also include a head restraint extending above the seat back. The vehicle seat assembly can be used in any type of vehicle, including land vehicles, watercraft, aircraft, etc. The vehicle seat assembly can be any seat assembly, such as an office chair, furniture, etc. The vehicle seat assembly can be provided with a decorative cover over the seat bottom, seat back, and head restraint to conceal the frame, cushioning, and functional components.

[0128] The seat bottom may be provided with seat cushioning material. The seat cushioning material may be formed from the stranded thermoplastic mesh or foam discussed above. The vehicle seat assembly may also be provided with a controller and a pump. The controller and pump may be located in a module beneath the seat cushioning material and may be a multi-function controller that also controls other functions in the vehicle.

[0129] The seat subassembly can be provided with a second fluid-impermeable layer that is sized to be placed over the seat cushioning material. The first fluid-impermeable layer can be made of a cushioning material such as foam. The second fluid-impermeable layer can be formed of an impermeable polymer material (e.g., a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene, or the like). The first fluid-impermeable layer can be provided with a plurality of vents formed therethrough. Any number of vents can be used. The vents can direct airflow through the seat subassembly. If the trim cover has a plurality of holes formed therethrough, the first fluid-impermeable layer and the vents can be optional. The first fluid-impermeable layer can be insulating. The first fluid-impermeable layer and the second fluid-impermeable layer can be joined together by a seam that is sewn, adhered, welded, etc. around the peripheral edges of the layers.

[0130] The inflatable bladder assembly may be supported on the first fluid impermeable layer and may be disposed within the fluid chamber.The inflatable bladder assembly may be disposed outside of the fluid chamber, such as between the second fluid impermeable layer and the seat cushioning material.

[0131] The controller can be in electrical communication with the pump, which in turn can be in fluid communication with the inflatable bladder assembly to inflate the assembly. The controller can be programmed to receive input indicating a manual adjustment and adjust the inflatable bladder assembly to apply pressure to the occupant. The controller can also be programmed to receive input indicating a massage program and operate the inflatable bladder assembly to apply a pressurized massage effect to the occupant.

[0132] The seat subassembly may also be provided with a fluid-permeable layer. The fluid-permeable layer may be formed from a resilient and porous material, such as a porous foam or an extruded thermoplastic resin mesh. The fluid-permeable layer may be sized to be contained within the fluid chamber and disposed over the inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly may be disposed between a first fluid-impermeable layer and a second fluid-impermeable layer. Any number of airbag assemblies may be employed.

[0133] The fluid-permeable layer can ensure that the first and second fluid-impermeable layers are not compressed together by the weight of an occupant. Without the permeable layer, the impermeable layers could be compressed when the weight of an occupant is applied, which could cut off airflow when a fan is used. The permeable layer can be omitted when the seat subassembly utilizes a compressor rather than a fan.

[0134] The seat subassembly may also be provided with a heat transfer layer disposed along the first fluid-impermeable layer and spaced apart from the second fluid-impermeable layer. The heat transfer layer may be disposed along the decorative layer, or alternatively, between the second fluid-impermeable layer and the fan. The heat transfer layer may be disposed between the first fluid-impermeable layer and the first fluid-permeable layer. The heat transfer layer may be provided with a conductive heater pad.

[0135] The seat subassembly can be provided as preassembled modules that are stacked together and subsequently secured to the seat cushioning material and / or seat trim cover. For example, securing means assembling to prevent opening or separation. The seat subassembly can also be provided with an outer decorative layer that is disposed above the first fluid-impermeable layer and the second fluid-impermeable layer. The decorative layer can be perforated to allow fluid to pass through the outer decorative layer. The decorative layer can be glued to the first fluid-impermeable layer. The fluid actuator can be welded directly to the second fluid-impermeable layer to seal the connection around the fan. The fan can be connected to the second fluid-impermeable layer by a retaining ring. The fan can be mounted between the trim cover and the seat cushioning material. The seat cushioning material can include a container sized to receive the fan. Mounting the fan above the seat cushioning material can allow the fan to be disposed within the seat subassembly.

[0136] The fluid impermeable layer, permeable layer, heat transfer layer, airbag assembly and fluid actuator can all be pre-assembled within the seat subassembly so that the seat subassembly can be mounted to the seat frame as a whole. The seat subassembly can operate in conjunction with an air permeable non-foam seat cushioning material formed from a thermoplastic mesh. A second fluid impermeable layer can provide a barrier between the fluid chamber and the seat cushioning material. When used with a foam cushion, the second fluid impermeable layer can be omitted if the cushion is air impermeable. In this case, the fluid actuator can be welded directly to the first fluid impermeable layer to deliver fluid through the vents in the fluid impermeable layer. The fluid actuator can be separate from the trim cover.

[0137] The first and second fluid-impermeable layers can be provided with stitches along their perimeters. The stitches can seal the layers so that air cannot escape the fluid chamber. Instead of stitches, the layers can be attached with adhesives or welded together.

[0138] The second fluid-impermeable layer can be provided with a first portion and a second portion. The first portion can also be provided with a first wing. The first wing can be perforated to allow air to flow between areas or seams within the subassembly. The first wing can be segmented to allow air to flow between areas and / or within the fluid chamber. The second portion can also be provided with a second wing extending in a direction opposite to the first wing. The wing can be used to attach the subassembly to other seat components or subassemblies. The second wing can be connected to the seat cushioning material. The first portion and the second portion can be sewn, welded, adhered or otherwise fastened together. The first portion and the second portion can be ultrasonically welded or high-frequency friction welded together.

[0139] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may be provided with a first wing and a second wing. The first wing may be perforated to allow air to pass through the fluid chamber. The second wing may extend in a direction opposite to the first wing and may be attached to the seat cushioning material. The first wing and the second wing may be sewn, welded, adhered, or otherwise secured to the second fluid-impermeable layer. The first wing and the second wing may be ultrasonically welded or high-frequency friction welded to the second fluid-impermeable layer.

[0140] In some embodiments, method 170 includes attaching a second portion (e.g., second portion 148, first flap 160, second flap 162) as a retainer (e.g., first flap 160, second flap 162, first flap 166, second flap 168) to a first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146), such as by welding. The second fluid-impermeable layer can be provided with a first portion and a second portion. The first portion can also be provided with a first flap. The first flap can be perforated to allow air to flow between areas or seams within the subassembly. The first flap can be segmented to allow air to flow between areas and / or within the fluid chamber. The second portion can also be provided with a second flap extending in a direction opposite to the first flap. The flap can be used to attach the subassembly to other seat components or subassemblies. The second flap can be connected to the seat cushioning material. The first portion and the second portion can be sewn, welded, adhered, or otherwise fastened together. The first portion and the second portion can be ultrasonically welded or high-frequency friction welded together.

[0141] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may be provided with a first wing and a second wing. The first wing may be perforated to allow air to pass through the fluid chamber. The second wing may extend in a direction opposite to the first wing and may be attached to the seat cushioning material. The first wing and the second wing may be sewn, welded, adhered, or otherwise secured to the second fluid-impermeable layer. The first wing and the second wing may be ultrasonically welded or high-frequency friction welded to the second fluid-impermeable layer.

[0142] In some embodiments, method 170 includes welding the second portion (e.g., second portion 148, first winglet 160, second winglet 162) to the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124). The first portion may also be provided with a first winglet. The first winglet may be perforated to allow air to flow between regions or seams within the subassembly. The first winglet may be segmented to allow air to flow between regions and / or within the fluid chamber. The second portion may also be provided with a second winglet extending in a direction opposite to the first winglet. The winglet may be used to attach the subassembly to other seat components or subassemblies. The second winglet may be connected to the seat cushioning material. The first portion and the second portion may be sewed, welded, adhered, or otherwise fastened together. The first portion and the second portion may be ultrasonically welded or high-frequency friction welded together.

[0143] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may be provided with a first wing and a second wing. The first wing may be perforated to allow air to pass through the fluid chamber. The second wing may extend in a direction opposite to the first wing and may be attached to the seat cushioning material. The first wing and the second wing may be sewn, welded, adhered, or otherwise secured to the second fluid-impermeable layer. The first wing and the second wing may be ultrasonically welded or high-frequency friction welded to the second fluid-impermeable layer.

[0144] In some embodiments, method 170 includes attaching another seat component (e.g., decorative layer 118, heat transfer layer 138, fan 140) to the second portion (e.g., second portion 148, first winglet 160, second winglet 162). The seat subassembly can also be provided with a heat transfer layer disposed along the first fluid-impermeable layer and spaced apart from the second fluid-impermeable layer. The heat transfer layer can be disposed along the decorative layer, or alternatively, between the second fluid-impermeable layer and the fan. The heat transfer layer can be disposed between the first fluid-impermeable layer and the first fluid-permeable layer. The heat transfer layer can be provided with a conductive heater pad.

[0145] The seat subassembly can be provided as a pre-assembled module that is subsequently assembled to the seat cushioning material and / or the seat trim cover. The seat subassembly can also be provided with an outer decorative layer disposed above the first fluid-impermeable layer and the second fluid-impermeable layer. The decorative layer can be perforated to allow fluid to pass through the outer decorative layer. The decorative layer can be glued to the first fluid-impermeable layer. The fluid actuator can be welded directly to the second fluid-impermeable layer to seal the connection around the fan. The fan can be connected to the second fluid-impermeable layer by a retaining ring. The fan can be mounted between the trim cover and the seat cushioning material. The seat cushioning material can include a container sized to receive the fan. Mounting the fan above the seat cushioning material can allow the fan to be displaced within the seat subassembly.

[0146] The fluid impermeable layer, permeable layer, heat transfer layer, airbag assembly and fluid actuator can all be pre-assembled within the seat subassembly so that the seat subassembly can be mounted to the seat frame as a whole. The seat subassembly can operate in conjunction with an air permeable non-foam seat cushioning material formed from a thermoplastic mesh. A second fluid impermeable layer can provide a barrier between the fluid chamber and the seat cushioning material. When used with a foam cushion, the second fluid impermeable layer can be omitted if the cushion is air impermeable. In this case, the fluid actuator can be welded directly to the first fluid impermeable layer to deliver fluid through the vents in the fluid impermeable layer. The fluid actuator can be separate from the trim cover.

[0147] The first and second fluid-impermeable layers can be provided with stitches along their perimeters. The stitches can seal the layers so that air cannot escape the fluid chamber. Instead of stitches, the layers can be attached with adhesives or welded together.

[0148] The second fluid-impermeable layer can be provided with a first portion and a second portion. The first portion can also be provided with a first wing. The first wing can be perforated to allow air to flow between areas or seams within the subassembly. The first wing can be segmented to allow air to flow between areas and / or within the fluid chamber. The second portion can also be provided with a second wing extending in a direction opposite to the first wing. The wing can be used to attach the subassembly to other seat components or subassemblies. The second wing can be connected to the seat cushioning material. The first portion and the second portion can be sewn, welded, adhered or otherwise fastened together. The first portion and the second portion can be ultrasonically welded or high-frequency friction welded together.

[0149] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may be provided with a first wing and a second wing. The first wing may be perforated to allow air to pass through the fluid chamber. The second wing may extend in a direction opposite to the first wing and may be attached to the seat cushioning material. The first wing and the second wing may be sewn, welded, adhered, or otherwise secured to the second fluid-impermeable layer. The first wing and the second wing may be ultrasonically welded or high-frequency friction welded to the second fluid-impermeable layer.

[0150] An assembly (e.g., vehicle seat assembly 110, seat subassembly 122) is described that can be a seat assembly or a subassembly of a seat assembly. The assembly (e.g., vehicle seat assembly 110, seat subassembly 122) includes: a first fluid-impermeable layer (e.g., first fluid-impermeable layer 124) sized to rest on seat cushioning material; and at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132) supported on the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124) to apply pressure to an occupant. The vehicle seat assembly can be provided with a seat bottom adapted to be mounted to a vehicle floor. The vehicle seat assembly can be provided in any row of a vehicle. The vehicle seat assembly can include a seat back extending vertically from the seat bottom. The vehicle seat assembly can also include a head restraint extending above the seat back. The vehicle seat assembly can be used in any type of vehicle, including land vehicles, watercraft, aircraft, and the like. The vehicle seat assembly may be any seat assembly, such as an office chair, furniture, or the like.

[0151] The vehicle seat assembly may be provided with a decorative cover over the seat bottom, seat back, and head restraint to conceal the frame, cushioning, and functional components. The seat bottom may be provided with seat cushioning material. The seat cushioning material may be composed of a twisted thermoplastic mesh or foam as described above. The vehicle seat assembly may also be provided with a controller and a pump. The controller and pump may be located in a module below the seat cushioning material and may be a multifunctional controller that also controls other functions in the vehicle.

[0152] The seat subassembly can be provided with a second fluid-impermeable layer sized to be placed over the seat cushioning material. The first fluid-impermeable layer can be comprised of a cushioning material such as foam. The second fluid-impermeable layer can be formed from an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene, or the like. The first fluid-impermeable layer can be provided with a plurality of vents formed therethrough. Any number of vents can be used. The vents can direct airflow through the seat subassembly. If the trim cover has a plurality of holes formed therethrough, the first fluid-impermeable layer and the vents can be optional. The first fluid-impermeable layer can be insulating.

[0153] The first fluid-impermeable layer and the second fluid-impermeable layer can be joined together by a seam stitched, adhered, welded, or the like around the peripheral edges of the layers. The second fluid-impermeable layer can be arranged in cooperation with the first fluid-impermeable layer to provide a fluid chamber therebetween. The inflatable bladder assembly can be supported on the first fluid-impermeable layer and can be arranged within the fluid chamber. The inflatable bladder assembly can be arranged outside the fluid chamber, such as between the second fluid-impermeable layer and the seat cushioning material.

[0154] The controller can be in electrical communication with the pump, which in turn can be in fluid communication with the inflatable bladder assembly to inflate the assembly. The controller can be programmed to receive input indicating a manual adjustment and adjust the inflatable bladder assembly to apply pressure to the occupant. The controller can also be programmed to receive input indicating a massage program and operate the inflatable bladder assembly to apply a pressurized massage effect to the occupant.

[0155] The seat subassembly may also be provided with a fluid permeable layer. The fluid permeable layer may be formed from an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh. The fluid permeable layer may be sized to be contained within the fluid chamber and disposed over the inflatable bladder assembly. The fluid permeable layer and the inflatable bladder assembly may be disposed between a first fluid impermeable layer and a second fluid impermeable layer. Any number of airbag assemblies may be employed. The fluid permeable layer may ensure that the first fluid impermeable layer and the second fluid impermeable layer are not compressed together by the weight of the occupant. Without the permeable layer, the impermeable layer may be compressed when the weight of the occupant is applied, which may cut off airflow when a fan is used. The permeable layer may be omitted when the seat subassembly utilizes a compressor rather than a fan.

[0156] The seat subassembly may also be provided with a heat transfer layer disposed along the first fluid-impermeable layer and spaced apart from the second fluid-impermeable layer. The heat transfer layer may be disposed along the decorative layer, or alternatively, between the second fluid-impermeable layer and the fan. The heat transfer layer may be disposed between the first fluid-impermeable layer and the first fluid-permeable layer. The heat transfer layer may be provided with a conductive heater pad.

[0157] The seat subassembly can be provided as a preassembled module that is subsequently assembled to the seat cushioning material and / or seat trim cover. The seat subassembly can also be provided with an outer decorative layer disposed above the first and second fluid-impermeable layers. The decorative layer can be perforated to allow fluid to pass through the outer decorative layer. The decorative layer can be glued to the first fluid-impermeable layer.

[0158] The seat subassembly can be provided with a fluid actuator, such as a fan. The fluid actuator can be directly welded to the second fluid-impermeable layer to seal the connection around the fan. The fan can be connected to the second fluid-impermeable layer via a retaining ring. The fan can be mounted between the trim cover and the seat cushioning material. The seat cushioning material can include a receptacle sized to receive the fan. Mounting the fan above the seat cushioning material can allow the fan to be displaced within the seat subassembly.

[0159] The fluid impermeable layer, permeable layer, heat transfer layer, airbag assembly and fluid actuator can all be pre-assembled within the seat subassembly so that the seat subassembly can be mounted to the seat frame as a whole. The seat subassembly can operate in conjunction with an air permeable non-foam seat cushioning material formed from a thermoplastic mesh. A second fluid impermeable layer can provide a barrier between the fluid chamber and the seat cushioning material. When used with a foam cushion, the second fluid impermeable layer can be omitted if the cushion is air impermeable. In this case, the fluid actuator can be welded directly to the first fluid impermeable layer to deliver fluid through the vents in the fluid impermeable layer. The fluid actuator can be separate from the trim cover.

[0160] The first and second fluid-impermeable layers can be provided with stitches along their perimeters. The stitches can seal the layers so that air cannot escape the fluid chamber. Instead of stitches, the layers can be attached with adhesives or welded together.

[0161] The second fluid-impermeable layer can be provided with a first portion and a second portion. The first portion can also be provided with a first wing. The first wing can be perforated to allow air to flow between areas or seams within the subassembly. The first wing can be segmented to allow air to flow between areas and / or within the fluid chamber. The second portion can also be provided with a second wing extending in a direction opposite to the first wing. The wing can be used to attach the subassembly to other seat components or subassemblies. The second wing can be connected to the seat cushioning material. The first portion and the second portion can be sewn, welded, adhered or otherwise fastened together. The first portion and the second portion can be ultrasonically welded or high-frequency friction welded together.

[0162] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may be provided with a first wing and a second wing. The first wing may be perforated to allow air to pass through the fluid chamber. The second wing may extend in a direction opposite to the first wing and may be attached to the seat cushioning material. The first wing and the second wing may be sewn, welded, adhered, or otherwise secured to the second fluid-impermeable layer. The first wing and the second wing may be ultrasonically welded or high-frequency friction welded to the second fluid-impermeable layer.

[0163] In some embodiments, at least one vent (e.g., vent 126) is formed through the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146). Any number of vents may be used. The vents may direct airflow through the seat subassembly. If the trim cover has a plurality of apertures formed therethrough, the first fluid-impermeable layer and the vents may be optional.

[0164] In some embodiments, a second fluid-impermeable layer (e.g., second fluid-impermeable layer 128) is cooperatively arranged with the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) to provide a fluid chamber (e.g., fluid chamber 130) therebetween. The second fluid-impermeable layer can be sized to be placed over the seat cushioning material. The second fluid-impermeable layer can be formed from an impermeable polymer material (e.g., a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene, or the like). The first and second fluid-impermeable layers can be joined together by a seam stitched, adhered, welded, or the like around the peripheral edges of the layers. The fluid-impermeable layer, permeable layer, heat transfer layer, airbag assembly, and fluid actuator can all be pre-assembled within the seat subassembly so that the seat subassembly can be mounted to the seat frame as a whole. The seat subassembly can operate in conjunction with an air-permeable non-foam seat pad formed from a twisted thermoplastic mesh as described above. The second fluid-impermeable layer can provide a barrier between the fluid chamber and the seat cushioning material. When used with a foam liner, the second fluid-impermeable layer can be omitted if the liner is air-impermeable. In this case, the fluid actuator can be welded directly to the first fluid-impermeable layer to deliver fluid through the vents in the fluid-impermeable layer. The fluid actuator can be separate from the trim cover. The first and second fluid-impermeable layers can be provided with stitching along their perimeters. The stitching can seal the layers, preventing air from escaping the fluid chamber. The layers can be attached with adhesive or welded together, rather than stitching.

[0165] In some embodiments, the second fluid actuator (e.g., fan 140) is directly attached to the second fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146). The fluid-permeable layer ensures that the first and second fluid-impermeable layers are not compressed together by the weight of an occupant. Without a permeable layer, the impermeable layer could be compressed when the weight of the occupant is applied, potentially cutting off airflow when the fan is in use. The permeable layer can be omitted when the seat subassembly utilizes a compressor rather than a fan. The fluid actuator can be welded directly to the second fluid-impermeable layer to seal the connection around the fan. The fan can be connected to the second fluid-impermeable layer via a retaining ring. The fan can be mounted between the trim cover and the seat cushioning material. The seat cushioning material can include a receptacle sized to receive the fan. Mounting the fan above the seat cushioning material allows the fan to be displaced within the seat subassembly. The seat subassembly can operate with air-permeable, non-foam seat cushioning material formed from a stranded thermoplastic mesh. The second fluid-impermeable layer can provide a barrier between the fluid chamber and the seat cushioning material. When used with a foam cushion, the second fluid-impermeable layer can be omitted if the cushion is air-impermeable. In this case, the fluid actuator can be welded directly to the first fluid-impermeable layer to deliver fluid through the vents in the fluid-impermeable layer. The fluid actuator can be separate from the trim cover.

[0166] In some embodiments, the second fluid actuator (e.g., fan 140) is welded to the second fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146). The fluid-permeable layer ensures that the first and second fluid-impermeable layers are not compressed together by the weight of the occupant. Without a permeable layer, the impermeable layer could be compressed when the weight of the occupant is applied, potentially cutting off airflow when the fan is in use. The permeable layer can be omitted when the seat subassembly utilizes a compressor rather than a fan. The fan can be connected to the second fluid-impermeable layer via a retaining ring. The fan can be mounted between the trim cover and the seat cushioning. The seat cushioning can include a receptacle sized to receive the fan. Mounting the fan above the seat cushioning allows for displacement of the fan within the seat subassembly. The seat subassembly can operate with air-permeable non-foam seat cushioning formed from a stranded thermoplastic mesh. The second fluid-impermeable layer can provide a barrier between the fluid chamber and the seat cushioning. When used with a foam cushioning pad, the second fluid-impermeable layer can be omitted if the cushioning padding is air-impermeable. In this case, the fluid actuator may be welded directly to the first fluid impermeable layer to deliver fluid through the vents of the fluid impermeable layer.The fluid actuator may be separate from the trim cover.

[0167] In some embodiments, the second fluid actuator also includes a fan (e.g., fan 140). The fluid-permeable layer ensures that the first and second fluid-impermeable layers are not compressed together by the weight of the occupant. Without the permeable layer, the impermeable layer could be compressed when the weight of the occupant is applied, potentially cutting off airflow when the fan is in use. The permeable layer can be omitted when the seat subassembly utilizes a compressor rather than a fan. The fluid actuator can be welded directly to the second fluid-impermeable layer to seal the connection around the fan. The fan can be connected to the second fluid-impermeable layer via a retaining ring. The fan can be mounted between the trim cover and the seat cushioning. The seat cushioning can include a receptacle sized to receive the fan. Mounting the fan above the seat cushioning allows for displacement of the fan within the seat subassembly. The seat subassembly can operate with air-permeable non-foam seat cushioning formed from a twisted thermoplastic mesh. The second fluid-impermeable layer can provide a barrier between the fluid chamber and the seat cushioning. When used with a foam cushioning pad, the second fluid-impermeable layer can be omitted if the cushioning pad is air-impermeable. In this case, the fluid actuator may be welded directly to the first fluid impermeable layer to deliver fluid through the vents of the fluid impermeable layer.The fluid actuator may be separate from the trim cover.

[0168] In some embodiments, at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132) is disposed within a fluid chamber (e.g., fluid chamber 130). The inflatable bladder assembly can be supported on a first fluid-impermeable layer and can be disposed within the fluid chamber. The inflatable bladder assembly can be disposed outside the fluid chamber, such as between a second fluid-impermeable layer and a seat cushioning material. The fluid-permeable layer can be formed from an elastic and porous material, such as a porous foam or an extruded thermoplastic resin web. The fluid-permeable layer can be sized to be contained within the fluid chamber and disposed on the inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly can be disposed between the first fluid-impermeable layer and the second fluid-impermeable layer. Any number of airbag assemblies can be used. The fluid-impermeable layer, permeable layer, heat transfer layer, airbag assembly, and fluid actuator can all be pre-assembled within the seat subassembly so that the seat subassembly can be mounted to the seat frame as a whole.

[0169] In some embodiments, a first fluid-permeable layer (e.g., first fluid-permeable layer 134) is sized to be received within a fluid chamber (e.g., fluid chamber 130), wherein the first fluid-permeable layer (e.g., first fluid-permeable layer 134) is displaced over an inflatable bladder assembly (e.g., inflatable bladder assembly 132). The inflatable bladder assembly can be disposed over the first fluid-impermeable layer and can be disposed within the fluid chamber. The inflatable bladder assembly can be disposed outside the fluid chamber, such as between the second fluid-impermeable layer and the seat cushioning material.

[0170] The fluid permeable layer can be formed from an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh. The fluid permeable layer can be sized to be contained within the fluid chamber and displaced on the inflatable bladder assembly. The fluid permeable layer and the inflatable bladder assembly can be disposed between a first fluid impermeable layer and a second fluid impermeable layer. Any number of airbag assemblies can be used. The fluid permeable layer can ensure that the first fluid impermeable layer and the second fluid impermeable layer are not compressed together by the weight of the occupant. Without the permeable layer, the impermeable layer may be compressed when the weight of the occupant is applied, which may cut off airflow when a fan is used. The permeable layer can be omitted when the seat subassembly utilizes a compressor rather than a fan.

[0171] The fluid impermeable layer, permeable layer, heat transfer layer, airbag assembly and fluid actuator can all be pre-assembled within the seat subassembly so that the seat subassembly can be mounted to the seat frame as a whole. The seat subassembly can operate in conjunction with an air permeable non-foam seat cushioning material formed from a twisted thermoplastic web. A second fluid impermeable layer can provide a barrier between the fluid chamber and the seat cushioning material. When used with a foam cushion, the second fluid impermeable layer can be omitted if the cushion is air impermeable. In this case, the fluid actuator can be welded directly to the first fluid impermeable layer to deliver fluid through the vents in the fluid impermeable layer. The fluid actuator can be separate from the trim cover.

[0172] In some embodiments, a heat transfer layer (e.g., heat transfer layer 138) is disposed along a first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) spaced apart from a second fluid-impermeable layer (e.g., second fluid-impermeable layer 128). The seat subassembly may also be provided with a heat transfer layer disposed along the first fluid-impermeable layer and spaced apart from the second fluid-impermeable layer. The heat transfer layer may be disposed along the decorative layer, or alternatively, between the second fluid-impermeable layer and the fan. The heat transfer layer may be disposed between the first fluid-impermeable layer and the first fluid-permeable layer. The heat transfer layer may be provided with a conductive heater pad. The fluid-impermeable layer, permeable layer, heat transfer layer, airbag assembly, and fluid actuator may all be pre-assembled within the seat subassembly so that the seat subassembly can be mounted to the seat frame as a whole.

[0173] In some embodiments, the heat transfer layer (eg, heat transfer layer 138 ) further includes a conductive heater pad.

[0174] In some embodiments, a controller (e.g., controller and pump 144) is electrically connected to at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132) and is programmed to: receive input indicating manual adjustment; and adjust the at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132), such as by inflating or deflation, to apply pressure to the occupant. The controller and pump can be located in a module beneath the seat cushioning material and can be a multifunctional controller that also controls other functions in the vehicle. The inflatable bladder assembly can be supported on a first fluid-impermeable layer and disposed within the fluid chamber. The inflatable bladder assembly can be disposed outside the fluid chamber, such as between a second fluid-impermeable layer and the seat cushioning material. The controller can be electrically connected to the pump, which can in turn be fluidically connected to the inflatable bladder assembly to inflate the assembly. The controller can be programmed to receive input indicating manual adjustment and adjust the inflatable bladder assembly to apply pressure to the occupant. The controller can also be programmed to receive input indicating a massage program to operate the inflatable bladder assembly to apply a pressurized massage effect to the occupant. The fluid-permeable layer can be formed from a resilient and porous material, such as a porous foam or an extruded thermoplastic resin mesh. The fluid-permeable layer can be sized to be contained within the fluid chamber and displaced over the inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly can be disposed between a first fluid-impermeable layer and a second fluid-impermeable layer. Any number of bladder assemblies can be employed.

[0175] In some embodiments, the first fluid-impermeable layer (eg, first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) is insulating.

[0176] In some embodiments, a plurality of vents (e.g., vents 126) are formed through the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146). Any number of vents may be used. The vents may direct airflow through the seat subassembly. If the trim cover has a plurality of apertures formed therethrough, the first fluid-impermeable layer and the vents may be optional.

[0177] In some embodiments, at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132) further includes a plurality of inflatable bladder assemblies (e.g., inflatable bladder assemblies 132) disposed within a fluid chamber (e.g., fluid chamber 130). The inflatable bladder assemblies can be disposed on the first fluid-impermeable layer and can be disposed within the fluid chamber. The inflatable bladder assemblies can be disposed outside the fluid chamber, such as between the second fluid-impermeable layer and the seat cushioning material.

[0178] The controller can be electrically connected to the pump, which in turn can be fluidically connected to the inflatable bladder assembly to inflate the assembly. The controller can be programmed to receive input indicating manual adjustment and adjust the inflatable bladder assembly to apply pressure to the occupant. The controller can also be programmed to receive input indicating a massage program to operate the inflatable bladder assembly to apply a pressurized massage effect to the occupant. The fluid permeable layer can be formed from an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh. The fluid permeable layer can be sized to be contained within the fluid chamber and displaced on the inflatable bladder assembly. The fluid permeable layer and the inflatable bladder assembly can be oriented between a first fluid-impermeable layer and a second fluid-impermeable layer. Any number of airbag assemblies can be used.

[0179] In some embodiments, a seam (e.g., stitching 142) extends through the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146). The first and second fluid-impermeable layers can be provided with stitching along their perimeters. The stitching can seal the layers so that air does not escape the fluid chamber. The layers can be attached together with adhesive or welded together instead of stitching.

[0180] In some embodiments, the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) further includes a first portion (e.g., first portion 146, first wing 160) and a second portion (e.g., second portion 148, first wing 160, second wing 168) extending away from the first portion (e.g., first portion 146, first wing 160) to provide a retainer (e.g., first wing 160, second wing 162, first wing 166, second wing 168). The second fluid-impermeable layer can be provided with a first portion and a second portion. The first portion can also be provided with a first wing. The first wing can be perforated to allow air to flow between areas or seams within the subassembly. The first wing can be segmented to allow air to flow between areas and / or within the fluid chamber. The second portion can also be provided with a second wing extending in a direction opposite to the first wing. The wing can be used to attach the subassembly to other seat components or subassemblies. The second wing can be connected to the seat cushioning material. The first portion and the second portion can be sewn, welded, adhered or otherwise fastened together. The first portion and the second portion can be ultrasonically welded or high-frequency friction welded together.

[0181] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may be provided with a first wing and a second wing. The first wing may be perforated to allow air to pass through the fluid chamber. The second wing may extend in a direction opposite to the first wing and may be attached to the seat cushioning material. The first wing and the second wing may be sewn, welded, adhered, or otherwise secured to the second fluid-impermeable layer. The first wing and the second wing may be ultrasonically welded or high-frequency friction welded to the second fluid-impermeable layer.

[0182] A seat assembly (e.g., vehicle seat assembly 110) is described, including a seat bottom (e.g., seat bottom 112). A seat back (e.g., seat back 114) extends from the seat bottom (e.g., seat bottom 112) in an upright position. Seat cushioning material is attached to the seat bottom (e.g., seat bottom 112) or the seat back (e.g., seat back 114). An assembly (e.g., seat subassembly 122) is mounted to the seat cushioning material. The seat bottom can be provided with seat cushioning material. The seat cushioning material can be composed of a twisted thermoplastic mesh or foam as described above.

[0183] Figure 14 A seat assembly 220 is shown according to some embodiments. In some embodiments, seat assembly 220 is a vehicle seat assembly 220, as depicted. Although seat assembly 220 is shown and described, any seat assembly 220 may be used. For example, assembly 220 may also be used in an office chair, a comfort chair, furniture, cushioning, or other padding. Assembly 220 may be used in vehicle seats, aircraft seats, boat seats, and the like. Assembly 220 may also be used in mattresses, camping mattresses, hospital beds, and the like.

[0184] Assembly 220 includes a fluid assembly 222 having at least two sheets 224, 226 of air-impermeable material. The first sheet 224 and the second sheet 226 of air-impermeable material overlap and are connected to form a fluid chamber 228 therebetween. The first sheet 224 and the second sheet 226 of air-impermeable material can be connected via welding, adhesive bonding, solvent bonding, mechanical fastening, etc. The sheets 224, 226 can be formed of a polymeric material, including but not limited to plastics, such as thermoplastic polyurethane (TPU).

[0185] Further references Figure 14, a first fitting 230 is connected to the first sheet 224 or the second sheet 226 within the perimeter of the first sheet 224 or the second sheet 226. The fitting 230 is in fluid communication with the fluid cavity 228 and provides a fluid connection to the fluid cavity 228. The fitting 230 can be formed from a polymeric material, including but not limited to a plastic such as thermoplastic polyurethane (TPU). The fitting 230 can also be formed from an elastomeric material. The fitting 230 can be annular and radially symmetrical about a central axis passing through the fitting 230.

[0186] Assembly 220 may function as a seat assembly, including a seat frame 232 having a seat back 234 and a seat bottom 236. Fluid assembly 222 may be installed in seat back 234 and / or seat bottom 236.

[0187] Assembly 220 may also include a pump 238 connected to assembly 220. Pump 238 is operable to inflate and drain one or more fluid bladders during operation. Pump 238 may also include a valve assembly and a controller, wherein the controller is programmed to actuate the pump 238 and the valve assembly to inflate and drain the fluid assembly 220.

[0188] In further embodiments, the fluid assembly 222 can include a plurality of fluid chambers 228 formed between overlapping first and second sheets of air-impermeable material 224, 226. Each fluid chamber 228 has a fitting 230 in fluid communication therewith. Figure 15 A fluid cavity 228 is shown in fluid communication with a fitting 230 .

[0189] Figure 16 A fluid sac 240 is shown. The fluid sac 240 is formed from a plurality of sheets of air-impermeable material (e.g., a first sheet 242, a second sheet 244, a third sheet 246, and a fourth sheet 248). The first sheet 242, the second sheet 244, the third sheet 246, and the fourth sheet 248 can be made of a polymeric material, including but not limited to plastics such as thermoplastic polyurethane. The first sheet 242, the second sheet 244, the third sheet 246, and the fourth sheet 248 can be sequentially connected near the periphery of the adjoining sheet to provide the fluid sac 240. The first sheet 242, the second sheet 244, the third sheet 246, and the fourth sheet 248 of the air-impermeable material can be connected near the periphery via welding, adhesive bonding, solvent bonding, mechanical fastening, etc. The sheets 242, 244, 246, and 248 of the sac 240 together provide a bellows-type sac 240. Fluid entering fluid chamber 250 expands bladder 240, while conversely, fluid exiting fluid chamber 250 collapses bladder 240. Fluid bladder 240 is arranged in seat assembly 220 with first sheet 242 facing the occupant contact surface or seat surface. Inflation of bladder 240 applies a pressurized massage effect to the occupant.

[0190] Now refer to Figure 16 and Figure 17 The fluid sac 240 may further include a second fitting 252 in fluid communication with the sac cavity 250. The second fitting 252 is sized to be coupled to the first fitting 230 of the fluid assembly 222 for fluid communication between the first fitting 230 and the second fitting 252. The first fitting 230 and the second fitting 252 may be engaged by a snap fit, such as an interference fit. The second fitting 252 may also be a snap ring 252 sized to be received within the first fitting 230. The second fitting 252 may be formed of a polymeric material, including but not limited to a plastic such as thermoplastic polyurethane (TPU). The first fitting 230 and the second fitting 252 form a fluid-tight seal to transfer fluid from the fluid chamber 228 of the fluid assembly 222 to the fluid chamber 250 of the fluid sac 240.

[0191] like Figure 15 and Figure 17 As shown, one of the fittings 230, 252, such as the first fitting 230, includes a cylindrical body 254 for passing fluid through a port 256 in the body 254. A radial retainer 258 extends inwardly from the body 254 to provide a fastener for the fitting 230. The first fitting 230 can be joined to the first sheet 224 by welding, adhesive, or the like.

[0192] Reference again Figure 16 and Figure 17 The other of the fittings 230, 252, for example, the second fitting 252, includes a cylindrical body 260 sized to be received in the port 256 of the first fitting 230. The cylindrical body 260 also includes a central port 262 in fluid communication with the port 256 in the first fitting 230. A recess 264 is formed in the body 260 that is sized to receive the retainer 258 of the first fitting 230. During assembly of the second fitting 252 to the first fitting 230, the body 260 of the second fitting 252 is inserted into the port 256 of the first fitting 230. The body 260 deforms the retainer 258, which elastically bends, thereby allowing the body 260 of the second fitting 252 to pass until the retainer 258 aligns with the recess 264, whereupon the retainer 258 springs back into the recess 264. The retainer 258 cooperates with the recess 264 to secure the second fitting 252 to the first fitting 230 while maintaining a fluid seal between the fittings 230, 252. The second fitting 252 can be bonded to the fluid bladder 240 by welding (such as friction welding or sonic welding), adhesives, etc. Although the first fitting 230 is depicted on the fluid assembly 222 and the second fitting 252 is shown and described on the fluid bladder 240, the fittings 230, 252 can be interchanged.

[0193] Figure 18 A fluid bladder 266 with a fitting 268 is shown according to some embodiments. The fluid bladder 266 can be similar to the fluid bladder 240 of the previous embodiment. The fitting 268 can be similar to the second fitting 252 of the previous embodiment. The fitting 268 can connect the fluid bladder 266 to the first fitting 230 of the fluid assembly 222 via a snap fit to provide a fluid-tight seal. Additionally, a protrusion 270 can be formed on the body 260 of the fitting 268. When the fluid bladder 266 is compressed and deflated, the protrusion 270 can contact the second sheet 226 of the fluid assembly 222 to prevent the second sheet 226 from closing the port 262 of the fitting 268 when pressure is applied from the weight of the occupant.

[0194] Figure 19 Shown Figure 18 FIG2 is an exploded view of a fitting 268. Fitting 268 may include a radial retainer 272 as a separate component that aligns with first fitting 230. First fitting 230 may be installed through first sheet 224. Subsequently, retainer ring 272 is installed on first fitting 230 to retain first fitting 230 to first sheet 224. The use of retainer ring 272 may eliminate the need for additional welding. Retainer ring 272 may be used as an alternative to welding.

[0195] Figure 20 A fluid bladder assembly 240 according to another embodiment is shown. The fluid bladder assembly includes interconnectable fluid bladders 241 and 243. Fluid bladder 241 includes a first sheet 242 and a second sheet 244 of air-impermeable material, which can be sequentially connected around an adjacent perimeter. First sheet 242 and second sheet 244 can be connected around the perimeter via welding, adhesive bonding, solvent bonding, mechanical fastening, etc. Fluid bladder 243 includes a third sheet 246 and a fourth sheet 248 of air-impermeable material, which can be sequentially connected around an adjacent perimeter via welding, adhesive bonding, solvent bonding, mechanical fastening, etc. Second sheet 244 can include a third fitting 274. Third fitting 274 can connect the first and second sheets to a fourth fitting 276 on third sheet 246 via a snap fit or interference fit. The snap fit can provide a fluid-tight seal between the second and third sheets.

[0196] Although the third fitting 274 is depicted on the second sheet 244 and the fourth fitting 276 is depicted on the third sheet 246, the fittings 274 and 276 can be interchanged. In some embodiments, the fluid bladder 241 provides an intermediate fluid bladder 241, wherein a pair of sheets 246 and 248 acts as a bellows. The fluid bladder 243 provides an end fluid bladder 243, wherein another pair of sheets 242 and 244 acts as another bellows. The number of bellows can be increased by adding more than one intermediate fluid bladder 241 between the end fluid bladder 243 and the first fitting 230. Under this process, various fluid bladder assemblies 240 can be assembled according to the applicable bladder displacement.

[0197] Figure 21 A fluid bladder 278 is shown according to another embodiment. The fluid bladder 278 can be similar to the fluid bladder 240 of the previous embodiment. The second fitting 252 of the fluid bladder 278 can include an extension tube 280. The extension tube 280 allows the second fitting 252 of the fluid bladder 278 to pass through a material, including but not limited to foam, and connect to the first fitting 230 of the assembly on the other side. The foam can include seat cushioning material or padding. The extension tube 280 can be formed from the same material as the second fitting 252. The central port 262 extends axially through the extension tube 280 for fluid communication with the port 256 of the first fitting 230.

[0198] Figure 22 A fluid bladder 282 is shown according to some embodiments. The fluid bladder 282 can include a fifth sheet 284 of air-impermeable material. The fifth sheet 284 can be formed from the same material as the first sheet 242, the second sheet 244, the third sheet 246, and the fourth sheet 248. The fifth sheet 284 can be connected to the fourth sheet 248 around the adjacent perimeter via welding, adhesive bonding, solvent bonding, mechanical fastening, etc. The fifth sheet 284 can be in physical contact with the second fitting 252. The fifth sheet 284 can allow the second fitting 252 of the fluid bladder 282 to pass through a material such as a gasket.

[0199] Figure 23A method for connecting a plurality of fluid bladders 240 to an assembly 220 in a single step is shown. The plurality of fluid bladders 240 can be manufactured and physically connected together using a gang strip 286 that aligns the bladders 240 for installation. The gang strip 286 can physically contact each of the plurality of fluid bladders 240. The fluid bladders 240 can be connected to each other at a specific distance 288 that corresponds to the distance between the first fittings 230 on the assembly 220. The fluid bladders 240 can be arranged in a specific pattern that corresponds to the pattern in which the first fittings 230 are arranged on the assembly 220. While the fluid bladders 240 are depicted as a linear pattern, other patterns are contemplated, including but not limited to linear or radial arrays, or a zigzag pattern. The second fitting 252 of each of the fluid bladders 240 can then be connected to each of the first fittings 230 of the assembly 220 in a single step. The strip of material 286 can be formed from a polymeric material, including but not limited to plastic.

[0200] The various embodiments of the airbag assembly 220 provide flexibility and modularity in the design and assembly of the airbag assembly 220 for specific applications. The fittings 230, 252 allow for flexibility in installation without requiring welding at every seam, which can be difficult to automate for larger airbag assemblies. The fittings 230, 252 also reduce the manufacturing time required to set up, weld, and cool the various sheets.

[0201] In other embodiments, a method is provided. The method includes stacking a first sheet and a second sheet of air-impermeable material, and bonding the first sheet to the second sheet to form a fluid cavity therebetween. Next, the method includes forming an orifice through one of the first sheet and the second sheet into the fluid cavity. Finally, the method includes attaching a fitting to the orifice in fluid communication with the fluid cavity.

[0202] In some embodiments, the method can be used to manufacture a fluid bladder. At least two sheets can be joined near their perimeters. The sheets can be joined near their perimeters by welding, adhesive bonding, solvent bonding, mechanical fastening, or the like. The sheets can collectively provide an internal fluid cavity within a bellows-type bladder. An orifice can then be formed through one of the sheets to provide access to the fluid cavity. A fitting can be mounted to the orifice in fluid communication with the fluid cavity. The fitting can be formed to mount to a corresponding fitting on a component. For example, the fitting can correspond to a fitting on a fluid component.

[0203] In other embodiments, the method can be used to manufacture a fluid assembly. At least two sheets of air-impermeable material can be joined together to provide at least one fluid line passing through the sheets. The sheets can be joined by welding, adhesive bonding, solvent bonding, mechanical fastening, or the like. Alternatively, the sheets can be joined together to provide multiple fluid lines passing through the sheets. The multiple fluid lines can be arranged in parallel. An orifice passing through one of the sheets can be installed at one end of each fluid line. A fitting in fluid communication with the fluid line can be installed in each orifice. The fitting can be formed to correspond to another fitting, including, for example, a fitting on a fluid bladder.

[0204] In other embodiments, the method can be used to manufacture components. For example, the method can be used to manufacture a massage component. A fluid component having multiple fluid lines can be manufactured according to the method. The fluid lines can be arranged in parallel, but other patterns are also contemplated. A fitting can be installed in an orifice in each fluid line. Multiple fluid sacs can be manufactured with fittings corresponding to fittings on the fluid component. The fluid sacs can be manufactured as individual sacs or as a unit comprising multiple sacs. If a unit, the sacs can be arranged in a pattern that allows the fittings on the fluid sacs to align with corresponding fittings on the fluid component. The fluid sacs can then be assembled to the fittings on the fluid component. The fluid sacs can be assembled to the fittings on the fluid component individually or as a unit. A pump, valve assembly, and controller can be connected to the component. The controller can be programmed to actuate the pump and valve assembly to inflate and drain the fluid sacs. The fluid sacs can be repeatedly inflated and drained for massage purposes.

[0205] Although various embodiments have been described above, this does not mean that these embodiments describe all possible forms according to the present disclosure. In this regard, the words used in the specification are descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of the present disclosure. In addition, the features of the various embodiments of implementation may be combined to form additional embodiments according to the present disclosure.

Claims

1. A seating system comprising: a plurality of seat components, the seat components comprising at least a fan, an inflatable bladder, a heating pad, a foam layer, and an air distribution layer; Seat cushioning materials; A decorative cover is provided on the seat cushion material, and the seat component is provided between the seat cushion material and the decorative cover and fixed together using at least one fastener.

2. The seating system of claim 1 further comprising a corrugated joint between the trim cover and the seat cushioning material.

3. The seat system according to claim 1, wherein: The fan is embedded in the seat cushioning material.

4. The seating system according to claim 1, wherein: The foam layer has one or more cavities (eg, large volumes recessed into the surface, rather than void cells in the foam), and the inflatable bladder is disposed in the one or more cavities.

5. The seating system according to claim 1, wherein: The at least one fastener is selected from the group consisting of interlocking keys and tabs, a plurality of tag pins, a stitched seam, a snap lock, a fir tree push-in fastener, a cable tie, a metal ring, a push pin, a toggle, and combinations thereof.

6. The seating system of claim 1, wherein: The seat components together provide a seat component subassembly, and the at least one fastener secures the seat component subassembly and the trim cover together.

7. The seating system according to claim 6, wherein: The seat subassembly is sealed to be airtight.

8. The seating system according to claim 6, wherein: The seat component subassembly includes a pocket, and the fan is disposed in the pocket.

9. The seating system of claim 1, wherein: The trim cover includes a pocket, and at least one of the seat components is disposed in the pocket.

10. The seating system of claim 1, wherein: The seat cushion material has a first side and a second side opposite the first side, the first side including one or more cavities.

11. The seating system of claim 10, wherein: At least one of the seat components nests with one or more of the cavities.

12. The seating system of claim 10, wherein: The seat cushioning material is multi-layered.

13. The seating system of claim 10, wherein: The seat cushioning material and / or the seat component include alignment features.

14. The seating system of claim 13, wherein: The alignment feature includes a drawstring connected to the seat component and extending through the seat cushioning material, whereby tensioning of the drawstring aligns the seat component with the seat cushioning material.

15. The seating system of claim 14, wherein: The drawstring is elastic.

16. The seating system of claim 14, wherein: The pull cord includes a toggle.

17. The seating system of claim 10, wherein: The fan defines a fan profile, and the one or more cavities have a cavity geometry similar to the fan profile.

18. A method comprising: stacking together at least one fan, the inflatable bladder, the heating pad, the foam layer, and the air distribution layer to form a seat component subassembly; securing the seat component subassemblies together using at least one fastener; securing the seat component subassembly using a trim cover; and The trim cover having the seat component subassembly is secured to a seat cushioning material, the seat component subassembly being disposed between the seat cushioning material and the trim cover.

19. The method of claim 18, further comprising performing a dimensional inspection of the seating system using at least one of a camera or a laser.

20. The method according to claim 18, wherein The seat cushioning material has a first side and a second side opposite the first side, the first side including one or more cavities, and the method includes combining the seat component subassembly and the seat cushioning material together, wherein when combining the seat component subassembly and the seat cushioning material together, one or more portions of the seat component subassembly are nested into the one or more cavities in the seat cushioning material.

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