Ventilated seat components

Abstract

A ventilated seat assembly includes a first rigid component, a foam layer, and a second rigid component. The first rigid component includes a formed cloth and has a bonding surface, a ventilation surface opposite the bonding surface, and a three-dimensional contour. The foam layer has an A surface and a B surface opposite the A surface, wherein the first rigid component is bonded to the B surface of the foam layer so that a portion of the B surface includes a three-dimensional contour. The second rigid component includes a polymer material attached to a portion of the ventilation surface of the first rigid component. The first and second rigid components define a cavity that includes a plurality of air channels defined by the three-dimensional contour of the first rigid component.

Description

Technical Field

[0001] The subject disclosure generally relates to formed cloth ventilating assemblies useful in automotive seating applications. Background Art

[0002] In recent years, there has been a focus on improving the "comfort" of vehicle seats, such as automobile and motorcycle seats. Global demand for improved performance from seat manufacturers and OEMs has resulted in climate controlled (heated and cooled) seats and a re-examination of many aspects of seat design to improve comfort and acoustics. Seats using seat cushions formed from polyurethane foam must now be designed to support seat heating and seat cooling infrastructure, such as ventilation, while still providing optimal comfort and acoustics. Prior art ventilation infrastructure (including plastic ducting, housings and bags) is rigid and heavy, and often results in occupant discomfort and uneven cooling (or heating) as well as increased energy consumption.

[0003] To this end, there is a need for an improved seat cushion assembly that provides an efficient ventilation infrastructure that maintains optimal comfort and acoustics while allowing for a reduction in cushion thickness and weight. Summary of the Invention

[0004] The present disclosure provides a ventilated seat assembly comprising a first rigid component, a foam layer, and a second rigid component. The first rigid component comprises a shaped cloth and has a bonding surface, a ventilation surface opposite the bonding surface, and a three-dimensional contour. The foam layer has an A surface and a B surface opposite the A surface, wherein the first rigid component is bonded to the B surface of the foam layer so that a portion of the B surface comprises a three-dimensional contour. The second rigid component comprises a polymer material attached to a portion of the ventilation surface of the first rigid component. The first and second rigid components define a cavity comprising a plurality of air channels defined by the three-dimensional contour of the first rigid component.

[0005] A method for forming a ventilated seat assembly includes bonding multiple layers, including at least one non-woven layer and at least one polymer layer, to form a first rigid component having a three-dimensional contour. Once formed, the first rigid component is inserted into a mold, and a polyurethane system is reacted in the mold to deposit a foam layer on a bonding surface of the first rigid component, such that a portion of the B-surface comprises the three-dimensional contour. A second rigid component is then bonded to the first rigid component to form a cavity comprising a plurality of air channels defined by the three-dimensional contour of the first rigid component.

[0006] Ventilated seat assemblies are particularly useful in the automotive industry, for example, in automotive seating applications. In automotive seating applications, ventilated seat assemblies are durable and lightweight, providing improved temperature control and occupant comfort. Furthermore, ventilated seat assemblies are highly efficient, minimizing the voltage consumption required to cool (and in some cases, heat) the occupants. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The advantages of the present disclosure will be readily appreciated as it is better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings.It should be understood that the drawings are merely illustrative and are not necessarily drawn to scale.

[0008] Figure 1 is a perspective view of a seat including a seat bottom including a ventilated seat assembly and a seat back including a ventilated seat assembly.

[0009] Figure 2 yes Figure 1 Isolated perspective view of the seat bottom.

[0010] Figure 3 yes Figure 2 Exploded view of the ventilated seat assembly.

[0011] Figure 4 yes Figure 2 A cross-sectional view of a ventilated seat assembly along 4-4.

[0012] Figure 5 yes Figure 2 A cross-sectional view of a ventilated seat assembly along 5-5.

[0013] Figure 6 yes Figure 2 A cross-sectional view of a ventilated seat assembly along 6-6.

[0014] Figure 7 yes Figure 1 An isolated perspective view of the seat back.

[0015] Figure 8 yes Figure 7 Exploded view of the ventilated seat assembly.

[0016] Figure 9 yes Figure 7 A cross-sectional view of a ventilated seat assembly along 9-9.

[0017] Figure 10 yes Figure 7 A cross-sectional view of a ventilated seat assembly along 10-10.

[0018] Figure 11 yes Figure 7 A cross-sectional view of a ventilated seat assembly along 11-11.

[0019] Figure 12 is a flow chart describing a method of forming a ventilated seat assembly.

[0020] Figure 13 according to Figure 12A method is provided, and is a perspective view of an assembly having a first rigid component, a foam layer, and a durable layer co-molded together after the steps of inserting the first rigid component into a mold and reacting the polyurethane system in the mold to position the foam layer on the bonding surface of the first rigid component such that a portion of the B surface includes a three-dimensional contour.

[0021] Figure 14 is after the step of bonding the second rigid component to the first rigid component to form the cavity Figure 13 A perspective view of an assembly of the present invention, the cavity comprising a plurality of air channels defined by the three-dimensional contour of the first rigid component.

[0022] FIG. 15 is a perspective view of Comparative Example 1. FIG.

[0023] Figure 15A This is an exploded view of Comparative Example 1.

[0024] FIG16 is a perspective view of Example 1. FIG.

[0025] Figure 16A This is an exploded view of Example 1.

[0026] FIG. 17 is a perspective view of Comparative Example 2. FIG.

[0027] Figure 17A This is an exploded view of Comparative Example 2.

[0028] FIG18 is a perspective view of Example 2.

[0029] Figure 18A This is an exploded view of Example 2. DETAILED DESCRIPTION

[0030] Referring to the drawings, wherein like numerals designate identical or corresponding parts throughout the several views, a ventilated seat assembly is generally indicated at 20. Figure 1 , a perspective view of a vehicle seat 10 is shown having a seat bottom 12 (including a ventilated seat assembly 20), a seat back 14 (also including a ventilated seat assembly 20), and a headrest 16. The seat back 14 is transverse to the seat bottom 12. The seat bottom 12 supports the occupant's legs, while the seat back 14 supports the occupant's back, and the headrest 16 supports the occupant's head. Of course, the ventilated seat assembly 20 can be located on different types of seats—such as bucket seats or bench seats, and in various seat components—such as the seat bottom 12, seat back 14, and even the headrest 16. The vehicle is typically a passenger car or truck. However, it should be understood that the vehicle can be any configuration used to provide transportation, such as a rocket, airplane, boat, all-terrain vehicle, tractor, etc. Of course, the ventilated seat assembly 20 is not limited to use in vehicle applications; use in furniture and bedding applications is also contemplated herein.

[0031] Now refer to Figure 2-6 , various views of the ventilated seat assembly 20 of the seat bottom 12 are illustrated. Figure 2 yes Figure 1 An isolated view of the seat bottom 12. The seat bottom 12 includes a ventilated seat assembly 20. Referring now to Figure 3 As shown in the exploded view Figure 2 FIG2 is an exploded view of a ventilated seat assembly 20 including a first rigid component 22, a foam layer 24, and a second rigid component 26. The ventilated seat assembly 20 is shown also including a durable layer 28. It should be understood that the terms include, include, including, and comprise are synonymous with comprise, comprise, and comprising when used in this disclosure.

[0032] The first rigid component 22 , foam layer 24 , second rigid component 26 and durable layer 28 of the ventilated seat assembly 20 are formed and shaped to correspond or “mate” with one another. Furthermore, as described in detail below, the first and second portions are also shaped to mate together to form a cavity 30 .

[0033] The first rigid component 22 comprises a forming cloth having a bonding surface 32, a ventilation surface 34 opposite the bonding surface 32, and a three-dimensional profile 36. The forming cloth comprises a plurality of layers. The forming cloth may comprise a cloth, a polymer binder, and other optional layers including various foams (e.g., polyurethane foam), various polymer films, scrims, and powders (e.g., polypropylene), and various fibers (e.g., fiberglass). The forming cloth is formed into a three-dimensional shape in a mold or by vacuum forming at various temperatures and pressures. The forming cloth is typically porous and can have various porosities depending on the amount of components, layers, and materials used to make the forming cloth.

[0034] The first rigid component 22, comprising the forming cloth, provides excellent adhesion to the foam layer 24—a significant improvement over prior art thermoplastic ventilation components. This excellent adhesion exhibited by the first rigid component 22 includes excellent adhesion to many types of polyurethane foam, including both viscoelastic and high-resilience polyurethane foams. Furthermore, the first rigid component 22, comprising the forming cloth, is lightweight, weighing significantly less than prior art ventilation components.

[0035] As described above, the forming cloth comprises multiple layers. The multiple layers typically include at least one fabric layer (e.g., at least one nonwoven layer or at least one woven layer) and at least one polymer binder layer. The nonwoven layer comprises fibers bonded together by physical means. The woven layer comprises a fabric comprising interwoven fibers. The fibers used are known in the art and can be natural, such as cotton, or synthetic, such as polyester. In one example, the nonwoven layer comprises polyethylene terephthalate (PET) and has a weight per unit area of ​​25 to 500, 50 to 300, or 100 to 200 gsm. A specific, non-limiting example of a nonwoven layer is a needle-punched nonwoven layer comprising a blend of 60% by weight PET and 40% by weight modified PET (i.e., a copolymer of PET). In some examples, the 60 / 40 blend can be adjusted to modify the stiffness and other properties of the forming cloth. Thus, various PET blends used can include 20 to 80% by weight PET and 20 to 80% by weight PET copolymer.

[0036] The polymer binder layer may include a thermoplastic or a thermosetting material. In one example, the polymer binder layer includes a thermoplastic. Exemplary thermoplastics include, but are not limited to, acrylic acid, ABS, nylon, PLA, polybenzimidazole, polycarbonate, polyethersulfone, polyoxymethylene, polyetheretherketone, polyetherimide, polyethylene, polyphenylene oxide, polyphenylene sulfide, polypropylene, polystyrene, polyvinyl chloride, polyvinylidene fluoride, and polytetrafluoroethylene (Teflon). The melting temperature of the thermoplastic may be greater than 65, 70, 75, 80, 85, 90, or 95°C, but less than 250°C. For example, the polymer binder layer may include polyethylene. In a specific example, the first rigid component 22 includes a non-woven layer and a polymer binder layer. In another specific example, the first rigid component 22 includes two non-woven layers and a polymer binder layer disposed therebetween. In these two examples, the polymer binder layer may include polyethylene.

[0037] The first rigid component 22 is formed by a molding process at an elevated temperature. Once formed, the first rigid component 22 is impermeable. In many examples, the weight per unit area of ​​the first rigid component 22 is 100 to 500, 100 to 450, or 100 to 400 g / m 2 Furthermore, in many examples, the thickness of the first rigid component 22 is 0.2 to 5, 0.3 to 2, or 0.5 to 1.5 mm.

[0038] The foam layer 24 has an A surface 38 and a B surface 40 opposite to the A surface 38. Figure 4-6As best shown in the cross-sectional view of FIG, the first rigid component 22 is bonded to the B surface 40 of the foam layer 24 such that a portion of the B surface 40 includes a three-dimensional contour 36. As is known in the art, polyurethane foam is formed by the exothermic reaction of an isocyanate-reactive resin composition and an isocyanate in the presence of a blowing agent. The isocyanate-reactive resin composition, isocyanate, and blowing agent are collectively referred to as a polyurethane system.

[0039] The foam layer 24 generally comprises the reaction product of an isocyanate and an isocyanate-reactive component (e.g., an active hydrogen-containing compound such as a polyol) in the presence of a blowing agent. More specifically, the foam layer 24 is formed by the exothermic reaction of an isocyanate-reactive resin composition (including an isocyanate-reactive component) and an isocyanate in the presence of a blowing agent. The isocyanate-reactive resin composition, isocyanate, and blowing agent are collectively referred to as a polyurethane system.

[0040] The foam layer 24 can be an isocyanate-based polymer selected from polyurethane, urea-modified polyurethane, and carbodiimide-modified polyurethane. The term "modified," when used with polyurethane, means that up to 50% of the polymer backbone-forming bonds have been substituted. Suitable polyurethane foams and systems are commercially available from The Woodbridge Group of Woodbridge, ON.

[0041] The foam layer 24 is described as comprising a polyurethane foam formed from a polyurethane system. However, it should be understood that the scope of the present disclosure is not limited to ventilated seat assemblies including a foam layer 24 comprising polyurethane foam. It will be apparent to those skilled in the art that the present disclosure is applicable to other types of foam chemistries, including but not limited to foams comprising latex, neoprene, polyvinyl chloride (PVC), and methods thereof.

[0042] The second rigid component 26 comprises a polymer material. The second rigid component 26 may comprise molded plastic or formed cloth (as described above with reference to the first rigid component 22). In a preferred embodiment, the second rigid component 26 comprises or is formed from the formed cloth described above. Like the first rigid component 22, the second rigid component 26 is impermeable. The second rigid component 26 is attached to a portion of the ventilated surface 34 of the first rigid component 22. The first and second rigid components 22, 26 may be bonded with an adhesive, or even molded or welded together. In a typical embodiment, the first and second rigid components 22, 26 are airtightly bonded to each other. In the illustrated embodiment, a bonding portion 42 is disposed around the exterior of the first rigid component 22, and a corresponding bonding portion 44 is disposed around the second rigid component 26 and is shaped to receive the bonding portion 42 of the first rigid component 22. The ventilated seat assembly 20 may also include a durable layer 28. In some embodiments, the durable layer 28 is located on the periphery of the bonding surface 32 of the first rigid component 22 and on the periphery of the B surface 40 of the foam layer 24. A portion of the durable layer 28 can be positioned between a portion of the periphery of the bonding surface 32 of the first rigid component 22 and the periphery of the B-surface of the foam layer 24. In one embodiment, the durable layer 28 comprises a nonwoven layer or even a formed cloth. In one embodiment, the durable layer 28 is a nonwoven layer comprising a blend of PET and PET copolymers having a weight of 50 to 250, or 90 to 190 gsm, and / or a thickness of 0.1 to 2.5, or 0.25 to 0.75 mm, depending on the seat application. If included, the durable layer 28 provides additional durability to the foam layer 24 of the ventilated seat assembly 20.

[0043] The ventilated seat assembly 20 may also include a foam pad or pads on the A-surface 38 of the foam layer 24. Furthermore, the ventilated seat assembly 20 is typically trimmed to include a trim cover. The trim cover is typically a laminate material comprising multiple layers and may have varying thicknesses. The trim cover is sewn together with a plastic retainer that hooks onto the bottom of the trim cover to secure it. A zipper may also be used in place of the plastic retainer.

[0044] like Figure 4-6 As best shown in the cross-sectional view of FIG, the first and second rigid components 22, 26 define a cavity 30 that includes a plurality of air channels 50 defined by the three-dimensional profile 36 of the first rigid component 22. The plurality of air channels 50 comprises more than two or more individual channels. The shapes of the first and second components correspond to one another, or "fit together," to form a pathway for airflow. Thus, the three-dimensional profile 36 of the first rigid component 22 cooperates with the second rigid component 26 to define the plurality of air channels 50.

[0045] In the illustrated example, the three-dimensional profile 36 defines a plurality of peaks and a plurality of valleys that define a plurality of air channels 50. In this example, the first plurality of rows of air channels 50a and the second plurality of rows of air channels 50b are angularly offset. That is, the air channels 50 are organized into a first plurality of rows of air channels 50a that are parallel to the longitudinal axis (L) and a second plurality of rows of air channels 50b that are perpendicular to the longitudinal axis. To this end, the first rigid component 22 cooperates with the second rigid component 26 to define the first plurality of rows of air channels 50a and the second plurality of rows of air channels 50b, with the second plurality of rows of air channels 50b being angularly offset (in this example by 90°) from the first plurality of rows of air channels 50a.

[0046] Although the air channels 50 in the examples are organized (e.g., at 90° angles to form longitudinal and lateral rows), some examples of the ventilated seat assembly 20 have a random plurality of air channels 50. In other words, the three-dimensional profile 36 of the first rigid component 22 does not include rows of air channels 50. For example, the peaks and valleys of the three-dimensional profile may be arranged irregularly so as not to form rows of air channels, but rather to retain a large number of channels to each exhaust port. Various channel configurations are contemplated herein, where the effectiveness of the plurality of air channels 50 is that they allow fluid communication along various paths and in various directions within the cavity 30 of the ventilated seat assembly 20.

[0047] exist Figure 3-6 In the cross-sectional view of the ventilated seat assembly 20, aspects of the ventilation passage 56, the plurality of ventilation ports 52, the cavity 30, and the plurality of air channels 50 are shown. Figure 4 In FIG, the cross-sectional view taken along 4-4 ​​shows some of the plurality of ventilation ports 52 and the corresponding ventilation passages, as well as the plurality of air channels forming a row perpendicular to the longitudinal axis. Figure 5 In FIG, a cross-sectional view taken along 5-5 shows one of the plurality of ventilation ports 52 and the corresponding ventilation passage, as well as a plurality of air channels 50 forming a row perpendicular to the longitudinal axis. Figure 6 6 , the cross-sectional view taken along 6 - 6 shows two of the plurality of ventilation ports 52 and the corresponding ventilation passages, as well as a portion of the first plurality of rows of air channels 50 parallel to the longitudinal axis and the second plurality of rows of air channels 50 perpendicular to the longitudinal axis.

[0048] In addition to forming the air channels 50 on the ventilated surface 34 of the first rigid component 22, the three-dimensional contour 36 of the first rigid component 22 is integral to the strength and rigidity of the ventilated seat assembly 20. In a typical embodiment, the foam layer 24 is co-molded onto the first rigid component 22 during the formation of the ventilated seat assembly 20. As a result, the B-surface 40 of the foam layer 24 is at least partially disposed within the three-dimensional contour 36 (e.g., peaks and valleys) of the first rigid component 22. In many embodiments, the B-surface 40 of the foam layer 24 contacts greater than 50, 60, 70, 80, 90, 95, or 99% of the total surface area of ​​the bonding surface 32 of the first rigid component 22. This contact and delamination, combined with the three-dimensional contour 36 of the foam layer 24 and the first rigid component 22, impart surprisingly strong and durable properties to the lightweight first rigid component 22. This imparted strength provides improved occupant comfort, even at reduced power consumption, increased occupant loads, and cooling when thousands of occupants are seated.

[0049] As shown in the figure, but Figure 3 As more clearly shown in FIG, the first rigid component 22 defines a plurality of ventilation ports 52, and the second rigid component 26 defines ports 54, while the cavity 30 is otherwise hermetically sealed. Furthermore, the foam layer 24 defines a plurality of ventilation pathways that are in fluid communication with the plurality of ventilation ports 52 of the first rigid component 22. In one example, when the ports 54 on the second rigid component 26 are in fluid communication (i.e., the ventilation system includes a fan connected to the ports), the seat bottom 12 or seat back 14 is cooled. In this example, air near the A-surface 38 of the foam layer 24 is drawn into the ventilation pathways 56 and the plurality of ventilation ports 52, passes through the cavity 30, and exits through the ports 54 and enters the fan, thereby cooling the bottom or back of the occupant. In other words, the ventilation pathways 56, ventilation ports 52, cavity 30, and ports 54 create a path for air to flow to and from the A-surface 38 of the foam layer 24, allowing for various climate control heating and cooling configurations.

[0050] Further references Figure 4-6 (and similarly Figure 9-11 ), the ventilated seat assembly 120 is very flexible from a design perspective because it does not increase the thickness of the foam layer 124 and can be considered a modification of the B surface 140 of the foam layer 124. Since the ventilation system minimally affects the thickness, it can be used with virtually any type of seat or seat design.

[0051] As mentioned above, the ventilated seat assembly 20 of the present disclosure may be incorporated into the seat bottom 12 or the seat back 14. Figure 7 In the Figure 1 An isolated perspective view of the seat back 14. Figure 8 In the Figure 714. An exploded view of the ventilated seat assembly 120 of the seat back 14 is shown. As described above, the ventilated seat assembly 120 includes a first rigid component 122, a foam layer 124, a second rigid component 126, and a durable layer 128. The first rigid component 122 includes a formed cloth and has a bonding surface 132, a ventilated surface 134 opposite the bonding surface 132, and a three-dimensional contour 136. The foam layer 124 has an A surface 138 and a B surface 140 opposite the A surface 138, wherein the first rigid component 122 is bonded to the B surface 140 of the foam layer 124 such that a portion of the B surface 140 includes the three-dimensional contour 136. The first rigid component 122 includes a bonding portion 142 disposed about an exterior thereof, and the second rigid component 126 includes a corresponding bonding portion 144 disposed about an exterior thereof and shaped to receive the bonding portion 42 of the first rigid component 22. The first and second rigid components 122, 126 define a cavity 130 that includes a plurality of air passages 150 defined by the three-dimensional profile 136 of the first rigid component 122. As described above, the plurality of air passages 150 include a plurality of distinct passages extending from a plurality of ventilation ports 152 generally located on the first rigid component 122 to ports 154 generally located on the second rigid component 126, which may also be referred to as fan ports.

[0052] exist Figure 9-11 In the cross-sectional view of the ventilated seat assembly 120, aspects of the ventilation passage 156, the plurality of ventilation ports 152, the cavity 130, and the plurality of air channels 150 are shown. Figure 9 In FIG, a cross-sectional view taken along 9-9 shows some of the plurality of ventilation ports 152 and corresponding ventilation passages 156, as well as a second plurality of air passages 150b perpendicular to the longitudinal axis. Figure 10 In FIG, a cross-sectional view taken along line 10-10 shows another of the plurality of ventilation ports 152 and a corresponding ventilation passage 156, as well as a second plurality of air passages 150b perpendicular to the longitudinal axis. Figure 11 11 - 11 shows three of the plurality of ventilation ports 152 and corresponding ventilation passages 156 , as well as a portion of first multiple rows of air channels 150 a parallel to the longitudinal axis and a portion of second multiple rows of air channels 150 b perpendicular to the longitudinal axis.

[0053] Now refer to Figure 12, also disclosed herein is a method 100 for forming a ventilated seat assembly 20. The method 100 includes combining a plurality of layers including at least one non-woven layer and at least one polymer layer to form a first rigid component 22 (102) having a three-dimensional profile 36. Once formed, the first rigid component 22 is inserted into a mold (104) and the polyurethane system is reacted in the mold to position the foam layer 24 on the bonding surface 32 of the first rigid component 22 such that a portion of the B surface 40 includes the three-dimensional profile 36 (106). The second rigid component 26 is then bonded to the first rigid component 22 to form a cavity 30 including a plurality of air channels 50 (108) defined by the three-dimensional profile 36 of the first rigid component 22. The first rigid component 22 including a formed cloth (and the second rigid component 26 optionally including a formed cloth) provides design flexibility and manufacturing flexibility.

[0054] As an example, the first rigid component 22 is formed by first heating a plurality of layers and then molding the heated plurality of layers into shape. The first rigid component 22 having the three-dimensional profile 36 is then cut (e.g., die-cut) to form. In this example, a plurality of vent ports 52 are also cut, thereby completing the formation of the first rigid component 22. These same steps can be repeated to form the second rigid component 26.

[0055] Once formed, the first rigid component 22 is inserted into the mold. In some examples, a plurality of ventilation ports 52 may be used to position the first rigid component 22 within the mold. If a durable layer 28 is included, the durable layer 28 may also be positioned within the mold. Once the mold is closed, the polyurethane system reacts within the mold to position the foam layer 24 on the bonding surface 32 of the first rigid component 22 such that a portion of the B-surface 40 includes the three-dimensional contour 36. Figure 13 and Figure 14 Shown according to Figure 12 The method of stepwise assembling the ventilated seat assembly 20 . Figure 13 is a perspective view of an assembly in which the first rigid component 22, foam layer 24, and durable layer 28 are co-molded together after inserting the first rigid component 22 into a mold and reacting the polyurethane system in the mold to dispose the foam layer 24 on the bonding surface 32 of the first rigid component 22 such that a portion of the B surface 40 includes the three-dimensional contour 36. That is, Figure 13 is an illustration of the assembly after molding as described above, but before the second rigid component 26 is joined to the first rigid component 22 .

[0056] In this example, adhesive is then applied to the periphery of the first and / or second rigid components 22 , 26 (the bonding portions / the corresponding bonding portions 42 , 44 ) and the first rigid component 22 to the second rigid component 26 . Figure 14This is after the step of bonding the second rigid component 26 to the first rigid component 22 to form the cavity 30. Figure 13 As shown in the perspective view of the assembly, the cavity 30 includes a plurality of air passages 50 defined by the three-dimensional contour 36 of the first rigid component 22. That is, Figure 13 is an illustration of the ventilated seat assembly 20 after the second rigid component 26 has been joined to the first rigid component 22 .

[0057] Several embodiments have been discussed in the foregoing description. However, the embodiments discussed herein are not intended to be exhaustive or to limit the disclosure to any particular form. The terminology used is intended to be descriptive rather than restrictive. In light of the above teachings, many modifications and variations are possible, and the disclosure may be implemented in ways other than those specifically described.

[0058] The following examples are intended to illustrate the present disclosure and should not be construed in any way as limiting the scope of the present disclosure.

[0059] Example

[0060] The ventilated seat assemblies of Examples 1 and 2 and the comparative ventilated seat assemblies of Comparative Examples 1 and 2 are seat back and seat bottom assemblies, respectively. The ventilated seat assemblies of Examples 1 and 2 are in accordance with the present disclosure, while the ventilated seat assemblies of Comparative Examples 1 and 2 are not formed in accordance with the present disclosure and are included to highlight the advantages of the ventilated seat assemblies described herein.

[0061] Referring now to Figures 15 and 15A, schematic diagrams illustrating the seat bottom structure of Comparative Example 1 are shown. More specifically, schematic diagrams showing perspective and exploded views of Comparative Example 1 are shown. The assembled ventilated seat assembly of Comparative Example 1 is shown on the left, followed by an isolated view of the foam layer, an isolated view of the durable layer, and an isolated view of the plastic ventilated seat assembly on the left.

[0062] Referring now to Figures 16 and 16A, schematic diagrams of the seat bottom structure of Example 1 are shown. More specifically, schematic diagrams showing a perspective view and an exploded view of Example 1 are shown. The assembled ventilated seat assembly of Example 1 is shown on the left, and then, moving from left to right, an isolated view of the foam layer is shown, moving from left to right, an isolated view of the first rigid component is shown, and, moving from left to right, an isolated view of the second rigid component is shown, and an isolated view of the durable layer is shown.

[0063] The ventilated seat assembly of Comparative Example 1 includes a plastic ventilated seat assembly and a durable layer, while the ventilated seat assembly of Example 1 includes a first rigid component, a second rigid component, and a durable layer. The ventilated seat assembly of Example 1 weighs less than the ventilated seat assembly of Comparative Example 1.

[0064] Referring now to Figures 17 and 17A, schematic diagrams illustrating the seat back structure of Comparative Example 2 are shown. More specifically, schematic diagrams showing perspective and exploded views of Comparative Example 2 are shown. Referring now to a portion of the schematic diagram of Figure 17 representing Comparative Example 2, the assembled ventilated seat assembly is shown on the left, and then, moving from left to right, an inside view of the seat bottom foam layer is shown, moving from left to right, isolated views of the first and second portions of the plastic ventilated seat assembly are shown, and an isolated view of the durability layer is shown on the right.

[0065] Referring now to Figures 18 and 18A , schematic diagrams illustrating the seat back structure of Embodiment 2 are shown. More specifically, schematic diagrams showing a perspective view and an exploded view of Embodiment 2 are shown. Referring now to a portion of the schematic diagram of Figure 18 representing Embodiment 2, the assembled ventilated seat assembly is shown on the left, and then, moving from left to right, an isolated view of the seat bottom foam layer is shown, moving from left to left, an isolated view of the first rigid component is shown, moving from left to right, an isolated view of the second rigid component is shown, and an isolated view of the durability layer is shown on the right.

[0066] The ventilated seat assembly of Comparative Example 2 includes a two-part plastic ventilated seat assembly and a durable layer, while the ventilated seat assembly of Example 2 includes a first rigid component, a second rigid component, and a durable layer. The ventilated seat assembly of Example 2 weighs less than the ventilated seat assembly of Comparative Example 2.

[0067] The performance comparisons of Examples 1 and 2 and Comparative Examples 1 and 2 are shown in Table 1 below, where Δ- indicates a disadvantage, Δ indicates no change, and Δ+ indicates an advantage.

[0068] Table 1

[0069]

[0070] Referring now to Table 1 above, the formed cloth ventilation of Examples 1 and 2 exhibits improved performance over the ventilated seat assemblies of Comparative Examples 1 and 2 over a wide range of properties.

[0071] A series of four additional tests were conducted on Examples 1 and 2 and Comparative Examples 1 and 2:

[0072] Thermocouple test: A person sits in the seat for 10 minutes (conditioning / preheating), and thermocouples are attached to the seat at specific locations to record the temperature rise. Next, while the person is seated, the ventilation system is activated for 10 minutes, and the cooling temperature is recorded.

[0073] Airflow Test: Turn on the ventilation system and press the airflow device firmly against the seat insert area. After 30 seconds, take the reading, average the results, and record them in CFM.

[0074] Thermal imaging test: In this test, a heat lamp is aligned with the seat insert area, heated to 90°F, and an image is captured. The ventilation system is turned on for 5 minutes and an image is captured.

[0075] Durability test: 80,000 sitting cycles.

[0076] Testing confirmed that the multiple air channels of the ventilated seat assemblies of Examples 1 and 2 provided improved air flow and cooling under loaded conditions compared to the ventilated seat assemblies of Comparative Examples 1 and 2. Furthermore, the air flow and cooling performance of Examples 1 and 2 remained stable and actually improved slightly after 80,000 durability cycles.

Claims

1. A ventilated seat assembly comprising: a first rigid component comprising a forming cloth and having a bonding surface, a ventilation surface opposite the bonding surface, and a three-dimensional contour, wherein the three-dimensional contour is defined by each of the bonding surface and the ventilation surface; a foam layer having an A surface and a B surface opposite the A surface, wherein the bonding surface of the first rigid component is bonded to the B surface of the foam layer such that a portion of the B surface of the foam layer is shaped to correspond to the three-dimensional contour of the bonding surface of the first rigid component; and a second rigid component comprising a polymer material attached to a portion of the three-dimensional contour of the ventilation surface of the first rigid component, the first and second rigid components cooperating and defining a cavity therebetween, wherein the cavity comprises a plurality of air channels defined by the three-dimensional contour of the ventilation surface of the first rigid component and the second rigid component. 2 . The ventilated seat assembly of claim 1 , wherein the first rigid component defines a plurality of ventilation ports. 3 . The ventilated seat assembly of claim 2 , wherein the foam layer defines a plurality of ventilation passages in fluid communication with the ventilation ports.

4. The ventilated seat assembly of any one of the preceding claims, wherein the second rigid component defines a port.

5. The ventilated seat assembly of any one of claims 1-3, wherein the first rigid component comprises a plurality of layers.

6. The ventilated seat assembly of claim 5, wherein the first rigid component comprises two non-woven layers and a polymeric binder layer disposed therebetween.

7. The ventilated seat assembly of claim 5, wherein the first rigid component comprises a non-woven layer and a polymeric binder layer.

8. The ventilated seat assembly of claim 6, wherein the polymeric binder layer comprises polyethylene.

9. The ventilated seat assembly of claim 6, wherein the non-woven layer comprises polyethylene terephthalate.

10. The ventilated seat assembly of any one of claims 1-3, wherein the second rigid component comprises a formed cloth.

11. The ventilated seat assembly according to any one of claims 1 to 3, wherein the weight per unit area of ​​the first rigid component is 100 to 500 g / m 2 .

12. The ventilated seat assembly of any one of claims 1-3, wherein the three-dimensional contour of the first rigid component cooperates with the second rigid component to define a first plurality of rows of air channels and a second plurality of rows of air channels angularly offset from the first plurality of rows of air channels.

13. The ventilated seat assembly of any one of claims 1-3, wherein the three-dimensional profile of the first rigid component defines a plurality of peaks and a plurality of valleys, the first rigid component and the second rigid component cooperating to define the plurality of air channels.

14. The ventilated seat assembly of any one of claims 1-3, wherein the plurality of air channels are random.

15. The ventilated seat assembly of any one of claims 1-3, wherein the plurality of air channels are organized.

16. The ventilated seat assembly of any one of claims 1-3, wherein the first rigid component defines a bonding portion disposed about an exterior of the first rigid component and the second rigid component is shaped to receive the bonding portion.

17. The ventilated seat assembly of any one of claims 1-3, wherein the first rigid component and the second rigid component are airtightly bonded to each other.

18. The ventilated seat assembly of any one of claims 1-3, wherein the first rigid component is bonded to the foam layer by co-molding.

19. The ventilated seat assembly according to any one of claims 1 to 3, further comprising a durable layer located on an outer periphery of the bonding surface of the first rigid component and on an outer periphery of the B-surface of the foam layer.

20. A method of forming a ventilated seat assembly, the ventilated seat assembly comprising a foam layer, a first rigid component, and a second rigid component, the first rigid component comprising a formed cloth having a three-dimensional contour, and the second rigid component comprising a polymeric material adhered to the three-dimensional contour of the first rigid component, the method comprising the steps of: combining a plurality of layers including at least one nonwoven layer and at least one polymeric layer to form a first rigid component having a bonding surface, a ventilation surface, and a three-dimensional profile, wherein the three-dimensional profile is defined by each of the bonding surface and the ventilation surface; inserting the first rigid component into a mold; reacting the polyurethane system in the mold to dispose a foam layer having an A surface and a B surface on the first rigid component, wherein the bonding surface of the first rigid component is bonded to the B surface of the foam layer such that a portion of the B surface of the foam layer is shaped to correspond to the three-dimensional contour of the bonding surface of the first rigid component; and The second rigid component is bonded to the three-dimensional contour of the ventilation surface of the first rigid component to form a cavity therebetween, the cavity including a plurality of air channels defined by the three-dimensional contour of the ventilation surface of the first rigid component and the second rigid component.

21. The method of claim 20, further comprising the step of heating the plurality of layers.

22. The method of claim 20 or 21, wherein the step of bonding the plurality of layers is further defined as molding the plurality of layers to form the first rigid component.

23. The method of claim 20 or 21, wherein the step of combining the plurality of layers is further defined as combining two non-woven layers with a polymer binder layer disposed therebetween to form a non-woven fabric having a weight per unit area of ​​100 to 500 g / m 2 The first rigid component.

24. The method of claim 20 or 21, further comprising the step of forming a plurality of ventilation ports in the first rigid component.

25. The method of claim 20 or 21, further comprising the step of positioning the first rigid component into a mold having the plurality of ventilation ports.

26. The method of claim 20 or 21, further comprising the step of inserting a durable layer into the mold and positioning the durable layer in the mold to create contact between the durable layer and the periphery of the bonding surface of the first rigid component and contact between the durable layer and the periphery of the B-surface of the foam layer.

27. The method of claim 20 or 21, further comprising the step of applying adhesive to a periphery of the first rigid component and / or the second rigid component before the step of bonding the first rigid component to the second rigid component.

28. A ventilation system for a seat, the ventilation system comprising: a foam layer having an A surface and a B surface opposite to the A surface; and a first rigid component comprising a shaped cloth, the first rigid component having a bonding surface, a ventilation surface opposite the bonding surface, and a three-dimensional contour, wherein the three-dimensional contour is defined by each of the bonding surface and the ventilation surface, the first rigid component further defining a plurality of ventilation ports, wherein the bonding surface of the first rigid component is bonded to the B-surface of the foam layer such that a portion of the B-surface of the foam layer is shaped to correspond to the three-dimensional contour of the bonding surface of the first rigid component; and A second rigid component comprising a forming cloth, the second rigid component being attached to the first rigid component and defining a port, the first and second rigid components defining a cavity therebetween, the cavity including a plurality of air channels defined by the three-dimensional contour of the ventilating surface of the first rigid component and the second rigid component, and a fan connected to the port and in fluid communication with the cavity.

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