Vehicle seat assembly and subassembly thereof

Abstract

Seat assemblies and subassemblies for fluid actuation of seat actuators, such as massage bladders, are disclosed. The subassemblies include various valve assemblies to maximize output functionality while minimizing the number of components and optimizing valve assembly compactness. The valve assembly provides a two-sided linear valve, a gate valve matrix, fluid circuit control logic that multiplies the valve output by sharing the actuated valve output, multiplexes the valve output, and / or a three-position valve.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is a continuation-in-part of U.S. patent application No. 17 / 841,745 filed on June 16, 2022 (Attorney Docket No. LEAR20795PUS); claims the benefit of U.S. Provisional Patent Application No. 63 / 357,060 filed on June 30, 2022 (Attorney Docket No. LEAR21101PRV); claims the benefit of U.S. Provisional Patent Application No. 63 / 393,386 filed on July 29, 2022 (Attorney Docket No. LEAR21097PRV); claims the benefit of U.S. Provisional Patent Application No. 63 / 393,386 filed on July 29, 2022 (Attorney Docket No. LEAR21097PRV); 2 (Agent Docket No. LEAR21098PRV); claims the benefit of U.S. Provisional Patent Application No. 63 / 393,389 filed on July 29, 2022 (Agent Docket No. LEAR21099PRV); claims the benefit of U.S. Provisional Patent Application No. 63 / 354,079 filed on June 21, 2022 (Agent Docket No. LEAR20837PRV); claims the benefit of U.S. Provisional Patent Application No. 63 / 393,392 filed on July 29, 2022 (Agent Docket No. LEAR21040PRV); claims the benefit of U.S. Provisional Patent Application No. 63 / 393,393 filed on September 29, 2022 (Agent Docket No. LEAR21040PRV); claims the benefit of U.S. Provisional Patent Application No. 2022 (Agent Docket No. LEAR21182PRV); is a continuation-in-part of U.S. Patent Application No. 18 / 085,120 (Agent Docket No. LEAR21096PUS), filed December 20, 2022; claims the benefit of U.S. Provisional Patent Application No. 63 / 354,412 (Agent Docket No. LEAR20886PRV), filed June 22, 2022; claims the benefit of U.S. Provisional Patent Application No. 63 / 357,101 (Agent Docket No. LEAR21182PRV), filed June 30, 2022 0912PRV); is a continuation-in-part of U.S. Patent Application No. 18 / 087,223, filed December 22, 2022 (Attorney Docket No. LEAR21094PUS); claims the benefit of U.S. Provisional Patent Application No. 63 / 354,319, filed June 22, 2022 (Attorney Docket No. LEAR21102PRV); claims the benefit of U.S. Provisional Patent Application No. 63 / 356,324, filed June 28, 2022 (Attorney Docket No. LEAR20831PRV); claims priority to Danish Patent Application No. PA 2023 70030, filed January 19, 2023 (Attorney Docket No. LEAR20831PDK); claims the benefit of U.S. Provisional Patent Application No. 63 / 356,093, filed June 28, 2022 (Attorney Docket No. LEAR20905PRV);Claiming priority to Danish Patent Application No. PA 2023 70027 filed on January 19, 2023 (Attorney Docket No. LEAR20905PDK); Claiming the benefit of U.S. Provisional Patent Application No. 63 / 354,977 filed on June 23, 2022 (Attorney Docket No. LEAR20887PRV); Claiming the benefit of U.S. Provisional Patent Application No. 63 / 393,141 filed on July 28, 2022 (Attorney Docket No. LEAR21086PRV); Claiming the benefit of U.S. Provisional Patent Application No. 63 / 392,914 filed on July 28, 2022 (Attorney Docket No. LEAR21103PRV); Claiming the benefit of U.S. Provisional Patent Application No. 63 / 393,141 filed on July 28, 2022 (Attorney Docket No. LEAR21086PRV); Claiming the benefit of U.S. Provisional Patent Application No. 63 / 392,914 filed on July 28, 2022 (Attorney Docket No. LEAR21103PRV); Claiming the benefit of U.S. Provisional Patent Application No. 392,926 (Attorney Docket No. LEAR21104PRV), filed on November 9, 2022; a continuation-in-part of U.S. Provisional Patent Application No. 63 / 433,599 (Attorney Docket No. LEAR21149PRV), filed on December 19, 2022; and a continuation-in-part of U.S. Provisional Patent Application No. 18 / 087,850 (Attorney Docket No. LEAR21148PUS), filed on December 23, 2022, the disclosures of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure relates to seat assemblies and subassemblies thereof. More particularly, the present disclosure relates to vehicle seat assemblies and subassemblies, such as fluid assemblies (eg, ventilation and / or massage assemblies, valve assemblies), trim assemblies, cushion assemblies, and temperature control / transmission assemblies. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Figure 1 is a schematic perspective view of a seat assembly.

[0005] Figure 2 is a perspective view of the seat assembly.

[0006] Figure 3A is a schematic cross-sectional view of a ventilation assembly according to some embodiments.

[0007] Figure 3B is a schematic cross-sectional view of a ventilation assembly according to some embodiments.

[0008] Figure 4 A perspective view of a seat assembly is shown, according to some embodiments.

[0009] Figure 5 According to some embodiments and with Figure 4A cross-sectional view of a trim assembly used together with a seat assembly.

[0010] Figure 6 Shown Figure 5 A partial schematic diagram of a decorative component.

[0011] Figure 7 According to some embodiments and with Figure 4 A perspective view of a trim assembly for use with a seat assembly.

[0012] Figure 8 Shown Figure 7 Another perspective view of the decorative component.

[0013] Figure 9 Shown Figure 7 Another perspective view of the decorative component.

[0014] Figure 10 Methods of forming a trim assembly and assembling a seat are shown according to some embodiments.

[0015] Figure 11 is a front perspective view of a vehicle seat assembly according to some embodiments.

[0016] Figure 12 yes Figure 11 A partial cross-sectional view of a trim cover assembly of a vehicle seat assembly.

[0017] Figure 13 yes Figure 11 A partial cross-sectional view of the trim cover assembly of the illustrated embodiment.

[0018] Figure 14 is a partial cross-sectional view of a trim cover assembly according to some embodiments.

[0019] Figure 15 is a front perspective view of a vehicle seat assembly according to some embodiments.

[0020] Figure 16 yes Figure 15 A partial cross-sectional view of a trim cover assembly of a vehicle seat assembly.

[0021] Figure 17 yes Figure 16 Another partial cross-sectional view of the decorative cover assembly.

[0022] Figure 18 is a front perspective view of a vehicle seat assembly according to some embodiments.

[0023] Figure 19 yes Figure 18 A partial cross-sectional view of a trim cover assembly of a vehicle seat assembly.

[0024] Figure 20 is a front perspective view of a seat assembly shown with a seat cushion, according to some embodiments.

[0025] Figure 21 yes Figure 20 A rear perspective view of a seat cushion, shown with a massage component.

[0026] Figure 22 yes Figure 20 An enlarged front perspective view of a portion of a seat cushion of a seat assembly.

[0027] Figure 23 It is along Figure 22 An enlarged partial cross-sectional perspective view of a portion of the seat cushion taken along section line 23-23 in FIG.

[0028] Figure 24 It is along Figure 22 An enlarged partial cross-sectional perspective view of a portion of a seat cushion taken along section line 24 - 24 in FIG.

[0029] Figure 25 yes Figure 20 Another rear perspective view of the seat cushion.

[0030] Figure 26 According to some embodiments Figure 20 Front elevation view of a seat cushion.

[0031] Figure 27 is a schematic diagram of a seating system according to some embodiments.

[0032] Figure 28 According to some embodiments Figure 27 Schematic diagram of the massage component of the seating system.

[0033] Figure 29 According to some embodiments Figure 28 A flow chart of a method of massaging a component.

[0034] Figure 30 According to some embodiments Figure 27 Front elevation view of a massage assembly of a seating system.

[0035] Figure 31 According to some embodiments Figure 30 A flow chart of a method of massaging a component.

[0036] Figure 32 is a side perspective view of a first embodiment of a massage bladder.

[0037] Figure 33 is a top perspective view of a first embodiment of a massage bladder.

[0038] Figure 34 is a top perspective view of a conventional massage bladder.

[0039] Figure 35 It is a side view of a conventional massage bladder.

[0040] Figure 36 is a side view of a second embodiment of a massage bladder.

[0041] Figure 37 is a body pressure distribution (PBD) graph of the first embodiment of the massage assembly for a 5th percentile occupant.

[0042] Figure 38 is a PBD graph for a conventional massage assembly for a 5th percentile occupant.

[0043] Figure 39 is a PBD diagram of the first embodiment of the massage assembly for the 50th percentile occupant.

[0044] Figure 40 is a PBD plot for a conventional massage assembly for the 50th percentile occupant.

[0045] Figure 41 is a PBD diagram of the first embodiment of the massage assembly for the 95th percentile occupant.

[0046] Figure 42 is a PBD plot for a conventional massage assembly for the 95th percentile occupant.

[0047] Figure 43 is a schematic diagram of a massage assembly according to some embodiments.

[0048] Figure 44 is a perspective cross-sectional view of a portion of an inflatable passageway defined by a first sheet and a second sheet.

[0049] Figure 45 is a perspective view of a seat assembly, such as for a vehicle, with a partial cross-sectional view of the outer layer.

[0050] Figure 46 is a perspective view of a carrier plate with massage components disposed thereon.

[0051] Figure 47 is a perspective view of a carrier plate assembled in a seat back and supported by a seat frame.

[0052] Figure 48 is a cross-sectional view of a mold according to some embodiments.

[0053] Figure 49 is a flow chart of a method of making the capsules described herein.

[0054] Figure 50 is a partial cross-sectional side perspective view of a seat assembly.

[0055] Figure 51 is a front view of a conventional fluid system for a seat assembly.

[0056] Figure 52 is a front view of a first embodiment of a fluid system for a seat assembly.

[0057] Figure 53 is a front view of a second embodiment of a fluid system for a seat assembly.

[0058] Figure 54 is a front view of a larger occupant seated in a seat assembly having a second embodiment of a fluid system.

[0059] Figure 55 is a front view of a smaller occupant seated in a seat assembly having a second embodiment of a fluid system.

[0060] Figure 56 is a schematic diagram of a seat assembly including a controller and fluid system.

[0061] Figure 57 It is a flowchart of a method of applying massage.

[0062] Figure 58 is a schematic diagram of a valve actuator.

[0063] Figure 59 is a front perspective view of a seat assembly according to some embodiments;

[0064] Figure 60 According to some embodiments, Figure 59 Schematic diagram of the actuator assembly of the seat assembly.

[0065] Figure 61 According to some embodiments Figure 60 Top view of the valve assembly of the actuator assembly.

[0066] Figure 62 According to some embodiments Figure 61 A side view of the valve subassembly of the valve assembly.

[0067] Figure 63 yes Figure 62 A top view of the valve subassembly.

[0068] Figure 64 yes Figure 60 A partial perspective view of the valve assembly of FIG. 1, showing the valve assembly in the discharge position. Figure 62 valve subassembly.

[0069] Figure 65 yes Figure 60 Another partial perspective view of the valve assembly of , showing one of the valve subassemblies in the filling position.

[0070] Figure 66 yes Figure 62 A front perspective view of the valve subassembly.

[0071] Figure 67 yes Figure 62 Exploded front perspective view of the valve subassembly.

[0072] Figure 68 yes Figure 62 A front perspective view of the conductive subassembly of the valve subassembly.

[0073] Figure 69 yes Figure 62 An enlarged partial front elevation view of a valve subassembly illustrating the assembly steps.

[0074] Figure 70 is a schematic diagram of a seating system according to some embodiments.

[0075] Figure 71 According to some embodiments Figure 70 Front elevation view of the gate valve assembly of the seating system.

[0076] Figure 72 yes Figure 71 Rear elevation view of the gate valve assembly.

[0077] Figure 73 yes Figure 71 An enlarged front elevation view of a gate valve subassembly of a gate valve assembly shown in a first state.

[0078] Figure 74 yes Figure 73 An enlarged front perspective view of the gate valve subassembly.

[0079] Figure 75 It is along Figure 73 A cross-sectional view of the gate valve subassembly taken along section line 75-75.

[0080] Figure 76 yes Figure 73 An enlarged front elevation view of a gate valve subassembly shown in a second state.

[0081] Figure 77 It is along Figure 76 A cross-sectional view of the gate valve subassembly taken along section line 77-77 in FIG.

[0082] Figure 78 yes Figure 71 An enlarged front perspective view of another gate valve subassembly of the gate valve assembly is shown in a first state.

[0083] Figure 79 A perspective schematic diagram of a seat assembly is shown, according to some embodiments.

[0084] Figure 80 According to some embodiments and with Figure 79 A partially assembled valve system for use with a seat assembly.

[0085] Figure 81 shows integration into a fluid system and with Figure 79 Used together with the seat components Figure 80 Schematic diagram of the system.

[0086] Figure 82 Shown Figure 80 A partial cross-sectional view of a system showing a pair of valves and associated actuators.

[0087] Figure 83 Shown Figure 80 A partial schematic diagram of the valve system.

[0088] Figure 84 Shown in a first configuration Figure 80 and Figure 83 Schematic diagram of the check valve in the system.

[0089] Figure 85 Shown in the second configuration Figure 80 and Figure 83 Schematic diagram of the check valve in the system.

[0090] Figure 86 Shown in the third configuration Figure 80 and Figure 83 Schematic diagram of the check valve in the system.

[0091] Figure 86B Methods according to some embodiments are shown.

[0092] Figure 87 A perspective view of a seat assembly is shown, according to some embodiments.

[0093] Figure 88 A perspective view showing various materials used in the trim assembly.

[0094] Figure 89 A partial schematic diagram of a non-foam layer for use with a trim assembly is shown.

[0095] Figure 90 A schematic cross-sectional view of a decoration assembly according to some embodiments is shown.

[0096] Figure 91A schematic cross-sectional view of a decoration assembly according to some embodiments is shown.

[0097] Figure 92 A schematic cross-sectional view of a decoration assembly according to some embodiments is shown.

[0098] Figure 93 A schematic cross-sectional view of a decoration assembly according to some embodiments is shown.

[0099] Figure 94 Schematic cross-sectional views of decoration assemblies according to further embodiments are shown.

[0100] Figure 95 Methods according to some embodiments are shown.

[0101] Figure 96 A schematic cross-sectional view of a decoration assembly according to some embodiments is shown.

[0102] Figure 96B Methods according to some embodiments are shown.

[0103] Figure 97 is a partial perspective view of a mesh body with a seat cover tie-down strap held by a spiral retainer.

[0104] Figure 98 is a schematic elevational view of a portion of a seat cover held by a tie-down strap held in a mesh body by a spiral retainer.

[0105] Figure 99 It is along Figure 98 A cross-sectional view taken along line 99-99 in FIG.

[0106] Figure 100 is an elevational view showing the mesh body being bent to open the groove to receive the tie strap prior to insertion of the spiral retainer.

[0107] Figure 101 is an exploded perspective view of a mesh body defining a groove for receiving a tie band having a spiral retainer, and a guide comb for aligning the spiral retainer with an aperture defined in the tie band.

[0108] Figure 101B Methods according to some embodiments are shown.

[0109] Figure 102 is a front perspective view of a vehicle seat assembly according to some embodiments.

[0110] Figure 103 yes Figure 102 A top perspective view of a seat cushion and retainer of a vehicle seat assembly.

[0111] Figure 104 yes Figure 103 Perspective view of the retainer.

[0112] Figure 105 It is along Figure 103 The line 105-105 is intercepted and installed in Figure 102 In a seat cushion of a vehicle seat assembly Figure 103 A cross-sectional view of the retainer.

[0113] Figure 106 is partially inserted Figure 102 In a seat cushion of a vehicle seat assembly Figure 103 A cross-sectional view of the retainer.

[0114] Figure 107 Partially assembled Figure 102 A side perspective view of a vehicle seat assembly.

[0115] Figure 108 Partially assembled Figure 102 A side perspective view of a vehicle seat assembly showing the insertion of the seat cushion into the Figure 103 retainer.

[0116] Figure 109 is a cross-section of a seat assembly according to some embodiments, wherein the retainer assembly is partially inserted into the seat cushion.

[0117] Figure 110 yes Figure 109 Another cross-sectional view of the seat assembly showing further assembly.

[0118] Figure 110 B shows a method according to some embodiments.

[0119] Figure 111 is a plan view of a polymer sheet showing a layout of a blank cut to form a balloon and catheter according to one embodiment of the present disclosure.

[0120] Figure 112 is based on Figure 111 Elevation view of a balloon and catheter being processed according to an embodiment of the present invention.

[0121] Figure 113 is based on Figure 111 Elevation view of the completed balloon and catheter of an embodiment of FIG.

[0122] Figure 114 is shown as manufactured Figure 111 A process flow diagram of the steps performed in accordance with an embodiment of the present invention.

[0123] Figure 115is a plan view of a polymer sheet showing a layout of a blank to be cut to form two balloons and a dual catheter according to a second embodiment of the present disclosure.

[0124] Figure 116 and Figure 117 is based on Figure 115 Elevation view of the balloon and double catheter being processed according to an embodiment of the present invention.

[0125] Figure 118 is based on Figure 115 Elevation view of the completed balloon and dial catheter of an embodiment.

[0126] Figure 119 Is the description for manufacturing Figure 115 A process flow diagram of the steps performed in accordance with an embodiment of the present invention.

[0127] Figure 120 It is a fluid system for seat components.

[0128] Figure 121 is a top view of a first embodiment of a compression-resistant support structure for facilitating fluid movement.

[0129] Figure 122 is a bottom view of a first embodiment of a compression-resistant support structure.

[0130] Figure 123 is a side view of a first embodiment of a compression resistant support structure.

[0131] Figure 124 are various embodiments of compression resistant support structures.

[0132] Figure 125 is a top view of a second embodiment of a compression-resistant support structure for facilitating fluid movement.

[0133] Figure 126 FIG. 4 is a schematic cross-sectional view of a third embodiment of an anti-compression support structure.

[0134] Figure 127 Part of the second or third embodiment of the compression-resistant support structure.

[0135] Figure 128 is a top view of a fourth embodiment of a compression-resistant support structure for facilitating fluid movement.

[0136] Figures 129-130 Such as Figure 128 A schematic cross-sectional view of an embodiment of a compression-resistant support structure having a unit for facilitating fluid movement.

[0137] Figures 131-132 They are Figures 129-130 Schematic cross-section of an embodiment in which the cells are filled with foam.

[0138] Figure 133 are schematic cross-sectional views of some embodiments of compression-resistant support structures.

[0139] Figure 134 is a top view of an embodiment of a compression-resistant support structure having a honeycomb structure.

[0140] Figure 135 is a side perspective view of a sheet material used to form a honeycomb structure.

[0141] Figure 136 Is to use Figure 135 A top perspective view of a honeycomb structure of multiple sheets is shown.

[0142] Figures 137-139 are top views of three additional embodiments of compression-resistant support structures.

[0143] Figure 140 is a top view of the bridged anti-compression support structure.

[0144] Figures 141-142 is a perspective side view of a bridged anti-compression support structure.

[0145] Figure 143 is a perspective view of a seat assembly with a portion of the seat removed to provide a cross-sectional view.

[0146] Figure 144 is a perspective view of an embodiment of a seat assembly with a portion of a trim cover and cushion removed, presenting a partial cross-sectional view.

[0147] Figure 145 is a perspective view of an embodiment of a non-foam / non-foam cushion having a portion of a fluid system disposed therein.

[0148] Figure 146 is a side view of a non-foam / non-foam cushion assembly having a portion of a fluid system disposed therein.

[0149] Figure 147 yes Figure 146 Figure 2 is a side view of a non-foam / no-foam cushion assembly with the fluid system removed.

[0150] Figure 148 is a cross-sectional side view of an embodiment of a system for making a non-foam / non-foam cushion.

[0151] Figure 149 is a bottom view of the die head (ie, crush plate).

[0152] Figure 150 is a schematic diagram of multiple polymer strands dispensed from a die.

[0153] Figure 151 is a flow chart depicting a method of making a non-foam / non-foam cushion.

[0154] Figure 152 is a perspective view of an embodiment of a seat assembly with a portion of a trim cover and cushion removed.

[0155] Figure 153 is a perspective view of an embodiment of a non-foam / no-foam cushion.

[0156] Figure 154 is a schematic cross-sectional view of a non-foam / non-foam cushion assembly.

[0157] Figure 155 It is a cross-sectional schematic diagram of a conventional gasket assembly.

[0158] Figure 156 is a perspective view of a portion of a non-foam / non-foam cushion depicting a cavity and a fluid system disposed therein.

[0159] Figure 157 is a cross-sectional side view of an embodiment of a manufacturing system.

[0160] Figure 158 is a schematic diagram of a plurality of polymer strands being distributed.

[0161] Figure 159 is a flow chart illustrating an embodiment of a method for producing a variable non-foam cushion using a crush plate mold.

[0162] Figure 160 are top views of some embodiments of crush plate molds for dispensing resin to make non-foam / non-foam gaskets.

[0163] Figure 161 yes Figure 160 A cross-sectional view of a portion of a crushing plate.

[0164] Figure 162 Is from Figure 161 Magnified view of a single orifice of the crushing plate.

[0165] Figure 163 A perspective schematic diagram of a seat assembly is shown, according to some embodiments.

[0166] Figure 164 According to some embodiments and with Figure 163 A top view of a bladder assembly for use with a vehicle seat assembly.

[0167] Figure 165 Shown Figure 164 Schematic side view of the bladder assembly during inflation.

[0168] Figure 166 Shows that during the discharge Figure 164 Schematic side view of the capsule assembly.

[0169] Figure 167 Shown is an alternative embodiment of Figure 164 A side schematic view of a bladder and valve used together with a bladder assembly, with the valve in a closed position.

[0170] Figure 168 Shown Figure 167 Schematic side view of the bladder and valve, with the valve in the open position.

[0171] Figure 169 According to some embodiments and with Figure 163 A top view of a bladder assembly for use with a vehicle seat assembly.

[0172] Figure 170 Shown Figure 169 A schematic partial side view of a bladder of a bladder assembly.

[0173] Figure 171 A seat assembly having a heat transfer system is shown, according to some embodiments.

[0174] Figure 172 Shown Figure 171 heat transfer system.

[0175] Figure 173 Shown Figure 171 Another view of the heat transfer system.

[0176] Figure 174 A therapeutic device having a heat transfer system is shown, according to some embodiments.

[0177] Figure 175 Shown Figure 174 Schematic diagram of a part of the heat transfer system.

[0178] Figure 176 Shown Figure 174 A perspective view of a portion of a heat transfer system.

[0179] Figure 177 A seat assembly having a heat transfer system is shown, according to some embodiments.

[0180] Figure 178 is a front perspective view of the seat assembly.

[0181] Figure 179 is used for Figure 178 Schematic diagram of the actuator assembly of the seat assembly.

[0182] Figure 180 is used for Figure 178Schematic diagram of the first pneumatic network of the seat assembly.

[0183] Figure 181 It is in the first state for Figure 180 Schematic diagram of a network of signal valves.

[0184] Figure 182 It is in the second state Figure 181 Schematic diagram of the signal valve.

[0185] Figure 183 It is in the first state for Figure 180 Schematic diagram of a network of NOT-type valves.

[0186] Figure 184 It is in the second state Figure 183 Schematic diagram of a NOT type valve.

[0187] Figure 185 is used for Figure 180 Schematic diagram of a network of AND type valves.

[0188] Figure 186 is a schematic diagram of a second type signal valve in a first state.

[0189] Figure 187 It is in the second state Figure 186 Schematic diagram of the second type of signal valve.

[0190] Figure 188 It is the use of Figure 186 and Figure 188 The second type of signal valve is used for Figure 178 Schematic diagram of the second pneumatic network of the seat assembly.

[0191] Figure 189 is a schematic diagram of the third type of signal valve.

[0192] Figure 190 is used for Figure 178 Schematic diagram of the third pneumatic network of the seat assembly.

[0193] Figure 191 is a front perspective view of a seat assembly according to some embodiments;

[0194] Figure 192 Is suitable for Figure 191 Schematic diagram of the pneumatic system in the holding position used in the seat assembly.

[0195] Figure 193 It is in inflated state Figure 192 Schematic diagram of the pneumatic system.

[0196] Figure 194 It is in a deflated state Figure 192 Schematic diagram of the pneumatic system.

[0197] Figure 195 It is a schematic diagram of a vehicle seat.

[0198] Figure 196 It passes through Figure 195 A cross-sectional view of a seat cushion assembly (such as a bottom seat cushion) of a seat.

[0199] Figure 197 Is a multi-layer decorative cover (such as Figure 196 Exploded view of the seat cushion assembly's trim cover.

[0200] Figure 198 is a flow chart of a method of deactivating a massage actuator.

[0201] Figure 199 is a flow chart of a method of assembling a trim assembly.

[0202] Figure 200 is a flow chart of a method of producing a seat assembly.

[0203] Figure 201 is a flow chart of a method of assembling a seat assembly.

[0204] Figure 202 is a flow chart of a method of assembling a seat.

[0205] Figure 203 is a flow chart of a method of operating a heat transfer system.

[0206] Figure 204 is a flow chart of a method of operating a heat transfer system.

[0207] Detailed description

[0208] 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.

[0209] It should be understood that the disclosed embodiments are merely exemplary and that various alternatives are possible. The drawings are not necessarily drawn 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 implement the embodiments according to the present disclosure in various ways.

[0210] “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.

[0211] 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 surface can be referred to as a second surface, and similarly, a second surface can be referred to as a first surface without departing from the scope of the various embodiments described. The first surface and the second surface are both surfaces, but they are not the same surface.

[0212] 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 the terms "and / or" as used herein refer to and encompass 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 "comprises" and / or "comprising" indicate the presence of recited features, wholes, steps, operations, elements, and / or parts, without excluding the presence or addition of one or more other features, wholes, steps, operations, elements, parts, and / or groups thereof.

[0213] 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.

[0214] Furthermore, unless expressly stated otherwise, all numerical quantities in this disclosure should be understood as being modified by the word "about" in a manner that describes the broader scope of the disclosure. Practice within the stated numerical limits is generally preferred. Furthermore, unless expressly stated to the contrary: percentages, "portions of," and ratio values ​​are calculated by weight. The term "polymer" includes "oligomers," "copolymers," "terpolymers," and the like. Unless expressly stated otherwise, a description of a group or class of materials as suitable or preferred for a given purpose implies that mixtures of any two or more members of that group or class are also suitable or preferred. The molecular weight provided for any polymer refers to the number-average molecular weight. Descriptions of ingredients in chemical terms refer to the ingredients at the time of addition to any combination specified in the description and do not necessarily preclude chemical interactions between the ingredients of the mixture once mixed. The initial definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation herein and, mutatis mutandis, to common grammatical variations of the initially defined abbreviation. Unless expressly stated to the contrary, measurements of properties are determined by the same techniques as those mentioned previously or later for the same property.

[0215] 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.

[0216] 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.

[0217] 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.

[0218] 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.

[0219] refer to Figure 1 , discloses a seat assembly 10 including one or more subassemblies 15-35. For example, the seat assembly 10 includes a decorative assembly 15 disposed on a cushion assembly 20, which is supported by a frame assembly 35. In some embodiments, the decorative assembly 15 includes a ventilation device. In some embodiments, the seat assembly 10 also includes a fluid assembly 20. In some embodiments, the seat assembly 10 includes temperature control assemblies 25, 30. In various embodiments, the fluid assembly 20 is a ventilation assembly and / or a massage assembly. In some embodiments, the fluid assembly 20 cooperates with the ventilation device in the decorative assembly 15, and in some embodiments, the fluid assembly 20 includes the decorative assembly 15 ventilation device. The temperature control assemblies 25, 30 include, for example, heat transfer assemblies. In some embodiments, a valve assembly is included to control the flow of fluid. In some embodiments, retainers or fasteners can attach various components to the cushion.

[0220] 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 assembly 35. The assemblies 10, 15, 25, 30, 35 or subassemblies 10, 15, 25, 30, 35 can also be preassembled to the cushion assembly 20. Components 10, 15, 25, 30, 35 or sub-assemblies 10, 15, 25, 30, 35 may also be integrated into the material of seat cushion assembly 20, such as into a foam or extruded thermoplastic mesh. In some embodiments, cushion assembly 20 may be formed by an additive manufacturing process, such as that disclosed in U.S. Patent No. 11,440,791 B2 to Migneco et al., issued to Lear Corporation on September 13, 2022, and incorporated herein by reference in its entirety. Various options are available for pre-assembling sub-assemblies 10, 15, 20, 25, 30, 35 or components 10, 15, 20, 25, 30, 35 as modules, or pre-assembling to frame assembly 35, or pre-assembling to seat cushion assembly 20.

[0221] refer to Figure 2 , discloses a seat assembly 100, such as a vehicle seat assembly. The seat assembly 100 includes a seat frame 102 and a subassembly 104, such as a ventilation subassembly. The subassembly 104 can be supported by the seat frame 102. Figure 2 3 , the subassembly 200 includes a trim cover 210 secured to a membrane 220 , one or more additional layers 240 , such as a gasket, and / or a substrate 250 .

[0222] The decorative cover 210 is configured to be positioned adjacent to the seat occupant, i.e., the decorative cover may include an outermost layer or include a surface serving as the outermost surface. The decorative cover 210 may cover the remaining components of the seat assembly 100 and be the primary contact surface with the occupant. The decorative cover 210 may be configured to provide ventilation to the occupant while seated and during operation. For example, the decorative cover 210 may include one or more perforations 211 and / or be permeable to a fluid (such as air). The decorative cover 210 may include a first surface 212 (e.g., an exposed surface) and a second surface 213 (e.g., an unexposed surface) opposite the first surface 212. The first surface 212 may be a surface of fabric, artificial leather, or leather. For example, the fabric or artificial leather may be cotton, polyester, polyurethane, nylon, or any other suitable fabric. In a variation, the fabric or artificial leather may be polyester or polyurethane. The decorative cover 210 may also include one or more layers, such as an outer layer 214 and an inner layer 215. For example, outer layer 214 may be polyurethane leatherette or polyester fabric, while inner layer 215 may be a spacer fabric or a thin polyurethane foam pad (e.g., 0.05 mm to 5 mm, or more preferably 0.1 mm to 3 mm, or even more preferably 0.25 mm to 1.25 mm). Inner layer 215 may be permeable to fluid flow, such as air, but outer layer 214 may be made of an impermeable material, such as leatherette or leather. If outer layer 214 is an impermeable material, it may be perforated so that when outer layer 214 receives fluid flow from inner layer 215, it can provide ventilation to adjacent occupants.

[0223] The trim cover 210 can be secured and / or sealed to the membrane 220 such that the membrane 220 cannot be removed without damaging the trim cover 210, the membrane 220, or the securing / sealing medium (e.g., stitching or welding). In a variation, the trim cover 210 and the membrane 220 can be secured and / or sealed at least partially along or near the outer perimeter or periphery of, for example, the seat surface 218. In a variation, the trim cover 210 can be secured / sealed to the membrane 220 such that the attachment interface is impermeable or does not leak fluid, such as air. In a refinement, secured can refer to a permanent connection, such that peel and stick adhesives that can be easily disconnected without damaging the material are excluded. The membrane 220 can be disposed between the trim cover 210 and the substrate 250. In a variation, the membrane 220 can be adjacent to the trim cover 210. The membrane 220 can also be disposed adjacent to one or more additional layers 240. The one or more additional layers 240 can be disposed between the membrane 220 and the substrate 250. In other words, the assembly may include the trim cover 210 connected to and adjacent to the film 220 , with the film 220 adjacent to one or more additional layers opposite the trim cover 210 .

[0224] In one refinement, the membrane 220 may be formed into a breathable pocket 222 defining a cavity, such as Figure 3A-3BIn yet another refinement, the film 220 and the decorative cover 210 can work together to form a Figure 3A-3B The cavity shown. The cavity may include a channel. Alternatively, the membrane 220 or the breathable bag may further define a channel in fluid communication with the cavity. Thus, the channel is disposed opposite the decorative cover and extends away from the decorative cover toward and near the outlet of the blower 260. The channel is configured to receive a fluid flow from the blower 260. For example, in a variation, the channel may be disposed and sealed around the outlet of the blower 260, such as by an annular gasket or an annular snap fastener. Alternatively, the channel may be disposed in the outlet or engaged with the base 250.

[0225] The membrane 220 is made of an impermeable fabric that does not allow fluids such as air to transfer through the fabric. For example, the membrane 220 can be a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane and / or felt, such as The breathable bag can have a spacer 230 disposed in the cavity defined by the breathable bag. The spacer 230 can be any suitable structure that resists compression that would impede fluid flow through it. For example, the spacer 230 can be an air-permeable spacer fabric. The breathable bag can also be formed from one or more sheets.

[0226] For example, the membrane 220 can be formed by a first sheet 224 and a second sheet 225 fixed to each other to define a cavity. The first sheet 224 and the second sheet 225 can be fixed so that they form a seal. For example, the first sheet 224 and the second sheet 225 can be fixed to each other by seaming, heat riveting, ultrasonic riveting, hot plate welding, hot die forging, cold pressing, etc., so that they do not allow fluid flow to escape except through one or more designated holes. In a variation, the first sheet 224 can be permeable to fluid flow (such as air). Therefore, the breathable bag 222 can be configured to provide fluid communication with the decorative cover 210. In one improvement, the first sheet 224 can be arranged adjacent to the decorative cover 210, and the second sheet 225 can be arranged opposite to the decorative cover 210, so that the first sheet 224 is arranged between the decorative cover 210 and the second sheet 225.

[0227] One or more additional layers 240 may include padding or comfort material 241. Padding or comfort material 241 may provide comfort to the occupant while seated. For example, padding or comfort material may be foam. In a variation, padding or comfort material 241 may be a non-foam mesh. In one refinement, ventilation assembly 200 and / or seat assembly 100 may be non-foam. In another refinement, ventilation assembly may be non-foam so that it does not include foam padding. In other words, the seat assembly may be non-foam.

[0228] Non-foam can refer to one or more stacked layers of non-foam material. Each layer can be formed from a knitted monofilament fabric material. An example of such a material is polyester, such as polyethylene terephthalate. The material can also be formed from recycled materials to reduce material costs and reduce waste. The material can be non-woven, woven and / or knitted to provide structure, while also being spaced apart to provide porosity, breathability and compliance. The non-foam material can be made from a monofilament fabric. For example, additional details of non-foam or non-foam materials can be found in application identified by serial number 17 / 218,663, filed on March 31, 2021, the entire contents of which are incorporated herein by reference.

[0229] In a variation, the non-foam or foam-free material can be a non-woven thermoplastic resin mesh. The mesh can be formed by extruding a pressurized molten thermoplastic resin from an extruder through an extrusion die. The extrusion die may include multiple outlet ports or nozzles to distribute multiple strands of molten thermoplastic resin. The strands are distributed into a fluid chamber with a fluid (e.g., water) to block and cool the strands. The fluid blocks the flow of the strands, causing the strands to bend, loop, and / or intersect with adjacent strands. The solidified and interwoven strands form an integral non-woven thermoplastic mesh pad. For example, additional details of the process are disclosed in the application identified by serial number 17 / 741,639, filed on May 11, 2022, the entire contents of which are incorporated herein by reference.

[0230] The one or more additional layers 240 may define apertures such that the membrane 220 may pass from the trim cover 210 through the one or more additional layers 240 to the blower 260 for receiving a fluid flow from the blower 260 during operation.

[0231] The one or more additional layers 240 may also include a base 250 that can support multiple components, such as the blower 260, pump, circuitry, ventilation assembly 200, and / or massage / bladder assembly, in which case the base 250 may be referred to as a carrier. The base 250 may be suspended from the seat frame 102 of the seat assembly 100, for example, by a suspension system (e.g., a suspension line). The base 250 may be a rigid plate, such as a plastic plate. The base 250 or carrier may define an orifice so that a fluid flow can be received from the blower 260 through the orifice during operation. Alternatively, the blower 260 may be directly connected to the breathable bag.

[0232] Blower 260 may include a motor in mechanical communication with the fan so that it is configured to provide a fluid flow during operation. Blower 260 may include an inlet for receiving a fluid such as air and an outlet for delivering the fluid flow during operation. Therefore, in one or more embodiments, ventilation assembly 200 may be configured to receive a fluid flow from blower 260 or deliver a fluid flow to blower 260 so that the fluid flow can travel along membrane 220 or through a breathable bag formed by membrane 220 to and through trim cover 210, or vice versa, to provide ventilation to a seated occupant during operation and when assembled in a seat assembly. In other words, the blower may be configured to provide airflow to the occupant or to draw airflow from the occupant to provide ventilation (i.e., the blower may be configured to pull or push air).

[0233] In some embodiments, a ventilation assembly (e.g., 200) for a seat (e.g., 100) for a vehicle (e.g., motorcycle, automobile, locomotive, boat, aircraft) includes a trim cover (e.g., 210), a subassembly (e.g., 200) (e.g., a breathable bag 222), and a spacer (e.g., 230) such as a spacer fabric. The trim cover (e.g., 210) is configured to contact an occupant during operation when assembled in the seat (e.g., 100) and provide ventilation from a fluid flow (e.g., air flow). The breathable bag (e.g., 222) defines a cavity and a channel in fluid communication with the cavity and disposed opposite the trim cover (e.g., 210), the channel being configured to connect to a blower (e.g., 260) via one or more additional layers (e.g., 240) (e.g., a cushioning / comfort material (e.g., 241) (which may be a non-foamed mesh)), a substrate (e.g., 250) (e.g., a carrier plate, a rigid plate, a plastic plate). The breathable bag (eg, 222) is secured to the trim cover (eg, 210) such that fluid flow (eg, air flow) travels from the breathable bag (eg, 222) to the trim cover (eg, 210), or vice versa. A spacer (eg, 230), such as a spacer fabric, is disposed in the cavity.

[0234] In various embodiments, the breathable bag (eg, 222 ) is sewn or welded to the trim cover (eg, 210 ).

[0235] In one or more embodiments, a breathable bag (eg, 222 ) is secured to the trim cover (eg, 210 ) at least partially along an outer perimeter.

[0236] In some embodiments, one or more additional layers (eg, 240 ) include a substrate (eg, 250 ), such as a carrier plate, a rigid plate, or a plastic plate, configured to support an air mover (eg, 260 ).

[0237] In various embodiments, one or more additional layers (e.g., 240) include a non-foam mesh, such as a non-foam mesh liner (e.g., 241). The subassembly (e.g., 200) (e.g., a ventilation assembly) also includes a blower (e.g., 260) supported by a base (e.g., 250) (e.g., a carrier plate, a rigid plate, a plastic plate).

[0238] In one or more embodiments, the breathable bag (e.g., 222) includes a first sheet (e.g., 224) (e.g., a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt ... ) and with a first sheet (e.g., 224) (e.g., a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, such as ) are fitted (e.g., sealed by stitching, heat riveting, ultrasonic riveting, hot plate welding, hot die forging, cold pressing, etc., so that they do not allow fluid flow to escape except through one or more designated holes) and a second sheet (e.g., 225) (e.g., a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane and / or felt, such as) opposite the decorative cover (e.g., 210). ), such that the first and second sheets (e.g., 224, 225) (e.g., plastic and / or fabric sheets, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, e.g. ) define cavities and channels.

[0239] In some embodiments, one or more additional layers (eg, 240 ) do not include a foam padding.

[0240] In one or more embodiments, the outer perimeter is the outer perimeter of a face (eg, 218 ) of the seat assembly.

[0241] In one or more embodiments, a vehicle seat (eg, 100 ) includes a subassembly (eg, 200 ), such as a vent assembly, and a seat frame (eg, 102 ) supporting the subassembly (eg, vent assembly).

[0242] A seat subassembly (e.g., 100) comprising a trim cover (e.g., 210), a carrier (e.g., 250) (e.g., a rigid plastic sheet), a first sheet (e.g., 224) (e.g., a plastic and / or fabric sheet, e.g., polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, e.g., ), a second sheet (e.g., 225) (e.g., a plastic and / or fabric sheet, e.g., polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, e.g. ), spacers (eg, 230, such as a spacer fabric), and one or more additional layers (eg, 240).

[0243] In one or more embodiments, the decorative cover (eg, 210 ) has a first surface (eg, 212 ) (eg, exposed surface) and a second surface (eg, 213 ) (eg, unexposed surface) opposite the first surface (eg, 212 ) (eg, exposed surface).

[0244] In various embodiments, a trim cover (e.g., 210) is configured to provide ventilation to an occupant adjacent a first surface (e.g., 212) (e.g., an exposed surface) when receiving a fluid flow (e.g., air flow) at a second surface (e.g., 213) (e.g., an unexposed surface).

[0245] In some embodiments, a carrier (eg, 250 ) is configured to support a blower (eg, 260 ).

[0246] In various embodiments, the carrier (e.g., 250) defines an aperture for receiving a fluid flow (e.g., air flow) from a blower (e.g., 260). A first sheet (e.g., 224) (e.g., a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, such as ) are mated to the trim cover (e.g., 210) (e.g., secured to the trim cover by stitching, heat riveting, ultrasonic riveting, hot plate welding, hot die forging, cold pressing, etc., such that they do not allow fluid flow to escape except through one or more designated holes) and are between the trim cover (e.g., 210) and the carrier (e.g., 250) (e.g., a rigid plastic sheet). A second sheet (e.g., 225) (e.g., a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, such as ) is located on a first sheet (e.g., 224) (e.g., a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, such as ) and a carrier (eg, 250) (eg, a rigid plastic plate).

[0247] In various embodiments, a second sheet material (e.g., 225) (e.g., a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, such as ) and a first sheet (e.g., 224) (e.g., a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, such as ) are fitted (e.g., sealed to the first sheet by seaming, heat riveting, ultrasonic riveting, hot plate welding, hot die forging, cold pressing, etc., such that they do not allow fluid flow, such as air flow, to escape except through one or more designated holes) so that the first sheet and the second sheet (e.g., 224, 225) (e.g., plastic and / or fabric sheets, such as polyethylene, polyurethane, thermoplastic polyurethane and / or felt, such as ) defines a cavity including a channel.

[0248] In various embodiments, the channel is configured to receive a fluid flow (eg, air flow) from a blower (eg, 260) through an orifice. In some embodiments, a spacer (eg, 230) (eg, a spacer fabric) is disposed in the cavity.

[0249] In various embodiments, one or more additional layers (e.g., 240) are disposed over a second sheet (e.g., 225) (e.g., a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, e.g., ) and a carrier (e.g., 250) (e.g., a rigid plastic sheet) such that the channel provides a passage through one or more additional layers (e.g., 240) (e.g., such as a cushioning / comfort material (e.g., 241), such as a foam-free mesh), wherein ventilation is provided to or from a blower (e.g., 260) and to or from an occupant of an adjacent decorative cover (e.g., 210) through the cavity.

[0250] In one or more embodiments, the first sheet (eg, 224 ) is secured to the trim cover (eg, 210 ) by sewing or welding.

[0251] In some embodiments, a spacer (e.g., 230) (e.g., a spacer fabric) is disposed between the first sheet and the second sheet (e.g., 224, 225) (e.g., a plastic and / or fabric sheet, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, e.g., )between.

[0252] In some embodiments, a seat frame (eg, 102 ) supports one of the subassemblies described herein.

[0253] In one or more embodiments, a subassembly (eg, 200 ), such as a ventilation assembly for a seat (eg, 100 ), includes a trim cover (eg, 210 ), a carrier (eg, 250 ), a cushion (eg, 241 ), and a membrane (eg, 220 ).

[0254] In various embodiments, a carrier (eg, 250 ) (eg, a rigid plastic plate) is configured to support a blower (eg, 260 ).

[0255] In some embodiments, the carrier (eg, 250 ) defines a first aperture configured to receive a fluid flow (eg, air flow) from a blower (eg, 260 ) during operation.

[0256] In one or more embodiments, a pad (eg, 241 ), such as a non-foamed fiber non-woven mesh pad, is disposed between the trim cover (eg, 210 ) and the carrier (eg, 250 ).

[0257] In some embodiments, a liner (eg, 241 ) is adjacent to a carrier (eg, 250 ) and defines a second aperture.

[0258] In various embodiments, a membrane (eg, 220 ) is disposed between a liner (eg, 241 ) and a trim cover (eg, 210 ) and extends through the second aperture.

[0259] In one or more embodiments, a membrane (e.g., 220) is secured to a trim cover (e.g., 210) such that a fluid flow (e.g., air flow) is received or delivered to the trim cover (e.g., 210) through a first orifice and provides ventilation through the trim cover (e.g., 210) to an occupant adjacent to the trim cover (e.g., 210) during operation.

[0260] In some embodiments, the membrane (eg, 220 ) is secured to the trim cover (eg, 210 ) along an outer perimeter.

[0261] In various embodiments, the membrane (eg, 220 ) is sewn or welded to the trim cover (eg, 210 ).

[0262] In some embodiments, the membrane (eg, 220) is sewn to the trim cover (eg, 210). In other embodiments, the membrane (eg, 220) is welded to the trim cover (eg, 210).

[0263] In one or more embodiments, a vehicle seat (eg, 100 ) includes a seat frame (eg, 102 ) and a subassembly (eg, 200 ), such as a vent assembly supported by the seat frame (eg, 102 ).

[0264] refer to Figure 4 , illustrates a seat assembly 320, such as a vehicle seat assembly 320. In other examples, the seat assembly 320 can be shaped and sized to serve as a front driver seat or front passenger seat, a second row seat, a third row seat, or other rear seat, and can include a bench-style seat, a bucket seat, or other seat styles as shown. Additionally, the seat assembly can be a non-stowable seat or a stowable seat that can be folded and stowed in a cavity in the vehicle floor. Additionally, the seat assembly 320 can be configured for use with other non-vehicle applications.

[0265] The seat assembly 320 has a support structure 322 that can be provided by one or more support members. The support members can be provided by a frame and / or a base. The seat assembly has seat components, and these seat components include at least a seat bottom 324 and a seat back 326. The seat bottom 324 can be sized to accommodate a seated occupant to support the occupant's pelvis and thighs. The seat back 326 can be sized to extend upright from the seat bottom 324 to support the occupant's back. The seat assembly can also have a head restraint (not shown). The seat bottom 324 has a seat bottom cushion 328. The seat back 326 has a seat back cushion 330. The frame 322 can include a wire suspension mat or other structure to support the cushions 328, 330.

[0266] The support structure 322 provides rigid structural support for seat components, such as the seat bottom 324 and the seat back 326, and can be configured as a plurality of frame members and / or substrates or panels that are movable relative to one another to provide adjustment of the seat assembly. The support structure 322 can be formed from stamped steel alloys, fiber-reinforced polymers, or any suitable structural material.

[0267] One or more trim assemblies 332 are used to cover the seat bottom cushion 328 and / or the seat back cushion 330 and provide a seating surface for the seat assembly 320. The vehicle seat assembly 320 is shown with the trim cover assembly 332 partially cut away. In one example, the trim cover assembly 332 covers both cushions 328 and 330. In other examples, multiple trim cover assemblies are provided to cover the seat bottom cushion and the seat back cushion. The trim cover assembly 332 according to various embodiments is described in further detail below. The trim assembly 332 provides a decorative surface, or visible surface or A-surface, of the seat assembly 320. The trim assembly 332 may also include additional material layers as described below and may also provide ventilation for the seat. The seat assembly 332 may be provided as a modular component for assembly to the seat assembly 320.

[0268] In one example, and as shown, one or more of the trim components 332 are in fluid communication with a fluid system 350, such as an air system, to provide air flow through the trim components for ventilation. The air system 350 is provided with a fan 352 and / or an air pump 352 to provide pressurized air flow to the trim components 332.

[0269] The seat cushion 340 is described in further detail below, and this description can be similarly applied to the seat bottom cushion 328 or the seat back cushion 330. According to various examples, the seat cushion 340 can be formed from a foam material (such as molded polyurethane foam) or a non-foam material, or a combination thereof. In an alternative example, the seat assembly 320 can be provided without any cushion 340, such that the trim assembly is supported directly on the support member 322, for example, as a panel or substrate.

[0270] In one non-limiting example, the non-foam components or members of the seat cushion 340 are formed from a twisted mesh material (also known as an entangled three-dimensional filament structure). The twisted mesh material is made of a polymer mesh having a plurality of integrated polymer strands. The twisted mesh material can be made of, for example, a linear low density polyethylene (LLDPE) material, although other polymers and materials that are effective in providing the desired properties and functionality are also contemplated. The twisted mesh material can be formed using extruded filaments of linear low density polyethylene (LLDPE) that are randomly entangled, bent, looped, or otherwise positioned and positioned, and directly bonded to each other to provide a porous mesh structure.

[0271] refer to Figure 5-Figure 6 , shows a decorative component 400 according to various examples of the present disclosure. The decorative component 400 can be formed of multiple layers of material as described below. The decorative component 400 can be used as a decorative component 332 and a decorative component 332. Figure 4 The vehicle seat assembly 320 may be used with the vehicle seat assembly 320, or may be used with another seat or another vehicle or other application as described above.

[0272] Trim assembly 400 includes a perforated trim cover 402. Trim cover 402 may provide an A-surface for trim assembly 400, or a seating surface visible to a seat occupant. Perforated trim cover 402 may be formed from one or more panels 404 of leather, artificial leather, vinyl, woven fabric, knitted fabric, or other materials. Perforations in panels 404 of trim cover 402 allow air to flow through trim cover 402. The perforations may be provided as small holes or apertures formed through the trim cover. A knit or woven pattern in a fabric trim cover may act as perforations and provide airflow through the fabric layer.

[0273] The panels 404 of the decorative cover layer 402 are connected to each other via a joint 406. The joint 406 can be provided by sewing, welding, bonding, laminating, or another process to connect two adjacent decorative panels 404 and form the decorative cover layer. In the example shown, the decorative panels 404 are connected to each other via a seam formed by sewing to provide the joint 406. A margin 408 is provided in the decorative cover layer 402, which is the area between the edge and the joint area or seam line on the two panels connected together.

[0274] The trim assembly 400 has a barrier layer 410 connected to the trim cover layer 402. The barrier layer 410 is impermeable to air. In one example, the barrier layer 410 is formed from a continuous plastic layer (e.g., a thermoplastic polyurethane sheet or film). A vent port 412 can be connected to or formed in the barrier layer 410, for example, using one or more of the techniques described above with respect to the joint, and can be connected via a hose or tube to the vent port 412 described above with respect to the joint. Figure 4 Air system 350 is described.

[0275] One or more porous spacer material layers 420 are positioned between the trim cover layer 402 and the barrier layer 410. Each of the spacer material layers 420 is formed of an air-permeable material or includes perforations or other features to allow air to pass through and across the layer. In the illustrated example, a first spacer material layer 422 and a second spacer material layer 424 are provided. In other examples, three or more spacer material layers 420 are provided. The spacer material layers 420 can be formed of the same material or different materials.

[0276] In the example shown, the first spacer layer 422 is formed from a reticulated foam layer (e.g., urethane or other foam material) and may also be referred to as a soft touch material that provides a cushioned feel to the seat occupant. In one non-limiting example, the reticulated foam has a range of 25-45 pores per inch, although other ranges of pores per inch are also contemplated. The second spacer layer 424 is formed from a spacer fabric, such as a knitted or reticulated spacer fabric. The spacer fabric can be a knitted or otherwise formed fabric layer that forms a reticulated structure to allow air to pass through and provide a secure support surface. In other examples, the first spacer material layer 422 and the second spacer material layer 424 can be formed from other materials that allow air to flow through them.

[0277] A first spacer layer 422 contacts the decorative cover layer 402, and a second spacer layer 424 is positioned between the first spacer layer 422 and the barrier layer 410. The first spacer layer 422 has a groove 426 or slot formed therein. As used herein, a groove 426 may refer to an open channel or recess formed in the spacer layer 420 and intersecting one of the surfaces. In one example, the groove 426 has a bottom plate 428. As shown, the groove 426 may be formed on a surface that engages or contacts the B surface of the decorative cover layer 402. The margin 408 between two adjacent panels of the decorative cover layer is received within the groove, and the connecting portion 406 may also be received within the groove 426.

[0278] In another example, a perforated heating pad or mat (not shown) can be positioned between the trim cover layer 402 and the barrier layer 410 and layered with the spacer layer 420. The heating pad can be selectively operated to provide heat from the trim assembly 400 to the seat occupant.

[0279] like Figure 4 As shown, a trim cover layer 402 is attached to a barrier layer 410 around the perimeter of the trim assembly, and a spacer material layer 420 is surrounded by the trim cover layer and the barrier layer. The trim cover layer 420 can be sewn, bonded, welded, laminated, or otherwise attached to the barrier layer around the perimeter. Additional trim panels can be attached to the trim assembly, for example, near the perimeter to cover other portions of the seat or its surroundings, as shown below with reference to FIG. 3- Figure 5 In addition, additional trim panels may be provided as described with respect to trim assembly 400 or may be provided without a barrier layer or other layer. Additional tie-downs may be provided around or adjacent the perimeter of trim assembly 400 for attaching the trim assembly to seat 320.

[0280] The trim assembly 400 has a tie film 430 connected to the trim cover layer 402, which can be used as a reinforcement layer or material 430. Figure 9 In the figure, for illustrative purposes, film 430 is shown as partially transparent beneath spacer layer 420. In one example, tie film 430 is formed from a non-woven fabric. A porous spacer material layer, such as first spacer layer 422, is positioned between trim cover layer 402 and at least a portion of tie film 430. As shown, tie film 430 can be laminated between first spacer material layer 422 and second spacer material layer 424, with tie film 430 separated from trim cover layer 402 by first porous spacer material layer 422. Tie film 430 can contact first spacer layer 422 opposite groove 426.

[0281] The tie film 430 is connected to the trim cover layer 402 and to the joint 406 and / or the margin 408 of the first and second panels 404, 404. In the example shown, the margin 408 is sewn to the tie film 430 via a seam 432 through the first spacer material layer 422 (e.g., through the bottom panel 428 of the groove 426 in the first spacer material layer).

[0282] The stitching tension in the seam 432 connecting the allowance 408 to the tie film 430, along with the depth of the groove 426 and the thickness of the layer 422, helps define the shape of the trim cover layer 402 and the appearance of the trim assembly 400 because it creates the tie effect or visual appearance of the joint 406 or seam between the panels 404 of the trim assembly.

[0283] In various examples, the first spacer material layer 422 and / or the tie film 430 are each connected to the second spacer material layer 424. For example, the first spacer material layer 422 and the tie film 430 are each connected to the second spacer material layer 424 via bonding and / or lamination.

[0284] Trim assembly 400 can be formed or assembled before being attached to cushion 340 or seat assembly 320. In another example, trim cover assembly 400 can be assembled in a first facility or production line and then shipped or moved to the location or assembly line for vehicle seat assembly 320. Because trim assembly 400 can include components for features such as ventilation and / or heating preassembled within assembly 400, seat 320 can be assembled more easily and in fewer steps.

[0285] refer to Figure 7-Figure 9 , shows a decoration component 500 according to various examples of the present disclosure. The decoration component 500 can be formed of multiple layers of materials as described below. The decoration component 500 can be used as a decoration component 332 and a decoration component 332. Figure 4 The vehicle seat assembly 320 may be used with the vehicle seat assembly 320, or may be used with another seat or another vehicle or other application as described above. Figure 2 - Elements identical or similar to those described in FIG. 3 are given the same reference numerals, and a description of these elements can be found above according to various examples.

[0286] The trim assembly 500 has a perforated trim cover layer 402 as described above and formed from one or more panels 404. In one example, two panels 404 are connected via a joint 406 having a margin 408. In other examples, a single panel 404 may be provided.

[0287] The trim assembly 500 has a barrier layer 410 connected to the trim cover layer 402. The barrier layer 410 has a vent port 412 and can be connected to the above described vent port via a hose or tube. Figure 4 Air system 350 is described.

[0288] One or more porous and breathable spacer material layers 420 are positioned between the trim cover layer 402 and the barrier layer 410. In the example shown, a first spacer material layer 422 and a second spacer material layer 424 are provided. In other examples, three or more spacer material layers 420 are provided. In the non-limiting example shown, the first spacer layer 422 is formed from a reticulated foam layer, and the second spacer layer 424 is formed from a spacer fabric, such as a knitted or reticulated spacer fabric.

[0289] The first spacer layer 422 can be provided with a first portion and a second portion. The second spacer layer can also be provided with a first portion and a second portion. The first portion of the layer forms a first stack 502, and the second portion of the layer forms a second stack 504. The first stack 502 and the second stack 504 can be positioned adjacent to each other in a non-overlapping manner. In other examples, additional stacks of spacer layers can also be provided. The margin 408 between the panels 404 of the decorative cover layer can be positioned between adjacent stacks, for example, in the gap 506 between adjacent stacks.

[0290] like Figure 7-Figure 9 As shown, the decorative cover layer 402 is connected to the barrier layer 410 around the perimeter of the decorative assembly, and the spacer material layer 420 is surrounded by the decorative cover layer and the barrier layer. The decorative cover layer 420 can be sewn, bonded, welded, laminated or otherwise connected to the barrier layer around the perimeter. An additional decorative panel 510 can be connected to the decorative assembly 500, for example near the perimeter to cover other portions of the seat or its surroundings. In addition, the additional decorative panel can be provided as described with respect to the decorative assemblies 400, 500, or can be provided without the barrier layer or other layers shown. Additional fasteners can be provided around or adjacent the perimeter of the decorative assembly 400, for example, along a seam or other joint 512, or at another location along the perimeter, for connecting the decorative assembly to the seat 320.

[0291] Trim assembly 500 has a tie-down membrane 520 attached to trim cover layer 402. In one example, tie-down membrane 520 is formed from a breathable or porous material, and in the illustrated example, is formed from a screen or coated mesh. In one non-limiting example, the coated mesh is a vinyl-covered fiberglass screen. In other examples, tie-down membrane 520 may be formed from a plastic material, such as a thermoplastic polyurethane sheet or film, and may be perforated or otherwise formed to provide airflow therethrough.

[0292] The tie film 520 is connected to the decorative cover layer 402. In one example, the tie film 520 is connected to the joint 406 and / or the margin 408 of the first panel 404 and the second panel 404. In another example, the tie film 520 is connected to the single panel 404, for example, by decorative stitching, bonding, and / or lamination in a central area of ​​the panel away from the edge or joint.

[0293] The tie film 520 extends outward from the B surface of the decorative cover layer 402 to a distal end 522. The tie film 520 extends between the first and second portions of each porous spacer material layer, or through the gap 506 between the stacks 502, 504 to the barrier layer. The tie film 520 is positioned between adjacent stacks 502, 504 of the spacer layer 420. Thus, the tie film 520 extends laterally through the spacer material layer 420 to the distal end 522. In one example, and as shown, the tie film 520 extends through the barrier layer 410 to the distal end 522, wherein the distal end is thus positioned outside of the barrier layer, and wherein the barrier layer is positioned between the distal end and the spacer layer. In other examples, the distal end 522 of the tie film may remain within the barrier layer.

[0294] The tie film 520 is connected to the barrier layer 410, for example, adjacent the distal end 522. The tie film 520 can be connected to the barrier layer 410 via any of the techniques described above with respect to the joint.

[0295] The distal end 522 of the tie-down membrane 520 may be used as a tie-down to the cushion and / or frame of the seat 320 , for example, using clips, loops, hook-and-loop fasteners, etc. The distal end of the tie-down membrane may further be provided with a bead or eyelet for use with these attachment features.

[0296] The distance between the attachment points of trim cover layer 402 and barrier layer 410 to tie film 520 helps define the shape of trim cover layer 402 and the appearance of trim assembly 500 because it creates a tie effect or visual appearance of the joints or seams between the panels of the trim assembly.

[0297] Figure 7 A method 600 for forming a trim cover assembly 332 is shown, and a method for assembling the trim cover assembly 332 and a seat assembly (such as the vehicle seat assembly 320) is also provided. In various examples, the steps may be performed in other orders, or may be performed sequentially or simultaneously. Furthermore, additional steps may be added, or steps may be omitted. According to various embodiments, the method 600 may be used to form the trim assembly 400 or the trim assembly 500.

[0298] At step 602 , ports 412 are inserted or formed in barrier layer 410 .

[0299] At step 604 , one or more porous spacer material layers 420 are positioned between the perforated trim cover layer 402 and the barrier layer 410 .

[0300] In one example, a first spacer material layer 422 and a second spacer material layer 424 are positioned between the perforated decorative cover layer 402 and the barrier layer 410. In a further step, a groove 426 may be formed in the first spacer layer 422 on the side that engages or faces the decorative cover layer 402. The decorative cover layer may be formed with a joint 406 between the two panels 404. In one example, the joint 406 is a seam, weld, or lamination, and there is a margin 408 formed by the two panels. The margin 408 is located in the groove 426 of the spacer layer.

[0301] In another example, the first portion and the second portion of each spacer material layer 420 are positioned between the perforated trim cover layer 402 and the barrier layer 410. The first portions of the spacer layers can be stacked with each other in a first stack 502, and the second portions of the spacer layers can be stacked with each other in a second stack 504 that is offset from and does not overlap the first stack.

[0302] At step 606 , the perforated trim cover layer 402 is coupled to the tie film 430 , 520 , with the spacer layer 422 positioned between the trim cover layer 402 and at least a portion of the tie film.

[0303] In one example, tie film 430 is laminated below first spacer material layer 422 and opposite groove 426. In another example, tie film 430 is positioned between first spacer material layer 422 and second spacer material layer 424. The trim cover panel margin 408 is sewn to tie film 430 through spacer material layer 422 along groove 426. The first spacer layer 422 and tie film 430 can then be connected to the second spacer layer 424, for example, by bonding, welding, lamination, or other techniques.

[0304] In another example, the tie-down film 520 is positioned such that it extends transversely to the trim cover layer 402 and extends between the first and second portions of each spacer material layer or between the stacks 502, 504 to a distal end 522. The tie-down film 520 is connected, for example, sewn or otherwise attached, to the trim cover layer 402 and may be connected via a joint 406 (such as a seam) between the two panels. Alternatively, the tie-down film 520 may be attached via a decorative stitching or seam, or via lamination, bonding, or welding. The tie-down film 520 is also connected to the barrier layer 410. In one example, the distal end 522 of the tie-down film extends outwardly from the barrier layer 410 such that the barrier layer is positioned between the distal end 522 and the spacer layer 420. The distal end 522 of the tie-down film may then additionally serve as a tie-down for a trim assembly to the frame and / or padding of a seat (such as seat 320).

[0305] At step 608, the perforated trim cover layer 402 is connected to the barrier layer 410 to assemble the trim assembly 400, 500. In one example, the trim cover layer 402 is sewn to the barrier layer 410. The spacer layer 420 is encapsulated by the trim cover layer and the barrier layer.

[0306] At step 610, the trim assembly 400, 500 is connected to the frame 322 of the seat assembly. In one example, the trim assembly 400, 500 can be directly connected to the frame 322 and / or the cushion 340. Various tie-downs, such as perimeter tie-downs for the trim assembly 332, can be used to connect the trim assembly 332 to the seat 320, and an additional trim panel 510 can be connected to the seat 320.

[0307] At step 612 , the trim assembly is connected to the air system 350 by connecting a fan and / or pump to the inlet port 412 in the barrier layer 410 .

[0308] At step 614, the trim assembly 332 of the seat 320 is ventilated by providing airflow from the air system 350 to the ports 412 of the barrier layer 410 from a fan and / or air pump of the air system 350. Figure 2 and Figure 5 4. As shown schematically in FIG. 4 , the barrier layer 410 is impermeable to air, and air can exit the trim assembly 332 only through the perforated trim cover layer 402. Air flows into the trim assembly 332 and upward through the second spacer layer 424 and the first spacer layer 422 because each layer is porous and breathable. For the trim assembly 400 with the tie-downs 430, the air generally flows around the tie-downs, although some air can flow through the tie-downs. For the trim assembly 500 with the tie-downs 520, the air can flow laterally within the trim assembly 500 and through the tie-downs 520, causing the air to flow into various portions of the spacer layers, through the stacks 502, 504, and into different areas of the trim assembly 500. Note that for either trim assembly, the structure of the porous spacer layer 420 causes the air to disperse and diffuse through the trim assemblies 400, 500 and to different areas of the trim cover layer 402. The air then flows through the perforated trim cover layer 402 and toward the seat occupant.

[0309] In other examples, elements such as a heating layer within trim assembly 332 may be operated to provide heat from the trim assembly to a seat occupant.

[0310] In one or more embodiments, an assembly (e.g., 400) includes a perforated decorative cover layer (e.g., 402), a tie-down membrane (e.g., 430) (e.g., a reinforcement layer) connected to the decorative cover layer (e.g., 402), a barrier layer (e.g., 410) (e.g., an impermeable layer, e.g., air-impermeable, e.g., a continuous plastic layer, such as a thermoplastic polyurethane sheet or film) connected to the decorative cover layer (e.g., 402), and a porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material, or a spacer fabric, such as a knitted or meshed spacer fabric) positioned between the decorative cover layer (e.g., 402) and the barrier layer (e.g., 410) (e.g., an impermeable layer, such as air-impermeable, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film).

[0311] In some embodiments, a layer of porous spacer material (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) is positioned between the decorative cover layer (e.g., 402) and at least a portion of the tie-down membrane (e.g., 430) (e.g., a reinforcement layer).

[0312] In various embodiments, the assembly (e.g., 400) further includes a ventilation port (e.g., 412) connected to a barrier layer (e.g., 410) (e.g., an impermeable layer (e.g., an airtight layer), such as a continuous plastic layer (e.g., a thermoplastic polyurethane sheet or film).

[0313] In one or more embodiments, a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) is surrounded by a decorative cover layer (e.g., 402) and a barrier layer (e.g., 410) (e.g., an impermeable layer, such as airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film).

[0314] In various embodiments, the assembly (e.g., 400) includes a second layer (e.g., 420) of porous spacer material (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric).

[0315] In some embodiments, a second layer of porous spacer material (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) is positioned between a first layer of porous spacer material (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer (e.g., a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) and a barrier layer (e.g., 410) (e.g., an impermeable layer, such as airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film).

[0316] In one or more embodiments, the first porous spacer material layer (eg, 420) comprises reticulated foam.

[0317] In various embodiments, the second porous spacer material layer (eg, 420 ) comprises a spacer fabric.

[0318] In some embodiments, the decorative cover layer (e.g., 402) is connected to a barrier layer (e.g., 410) (e.g., an impermeable layer, e.g., airtight, e.g., a continuous plastic layer, e.g., a thermoplastic polyurethane sheet or film) around the perimeter of the assembly (e.g., 400).

[0319] In one or more embodiments, the assembly (eg, 400 ) further includes one or more decorative panels (eg, 404 ) connected to the assembly (eg, 400 ) adjacent its perimeter.

[0320] In one or more embodiments, the assembly (eg, 400) further includes one or more tie members connected to the assembly (eg, 400) adjacent its periphery.

[0321] In various embodiments, the assembly (e.g., 400) further includes a perforated heating gasket positioned between the decorative cover layer (e.g., 402) and a barrier layer (e.g., 410) (e.g., an impermeable layer, e.g., airtight, e.g., a continuous plastic layer, such as a thermoplastic polyurethane sheet or film).

[0322] In some embodiments, the perforated decorative cover layer (e.g., 402) includes a first panel (e.g., 404) connected to a second panel (e.g., 404) along a joint (e.g., 406) (e.g., a seam) and having a margin (e.g., 408) (e.g., an area between an edge and a joint area or stitching line on the two panels connected together).

[0323] In one or more embodiments, a joint (eg, 406 ) (eg, a seam) includes a seam (eg, 432 ).

[0324] In various embodiments, a tie-down membrane (e.g., 430) (e.g., a reinforcement layer) is connected to a joint (e.g., 406) (e.g., a seam) and / or a margin (e.g., 408) (e.g., an edge and an area between a joint area or stitching line on two panels connected together) of a first panel and a second panel (e.g., 404).

[0325] In some embodiments, a layer of porous spacer material (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) defines a groove (e.g., 426) and the margin (e.g., 408) (e.g., the area between the edge and the joint area or stitching on the two panels connected together) is received within the groove (e.g., 426).

[0326] In one or more embodiments, the margin (e.g., 408) (e.g., the area between the edge and the join area or stitching line on the two panels being joined together) is sewn to the tie-down membrane (e.g., 430) through a porous spacer material (e.g., 420) (e.g., a breathable layer or perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric).

[0327] In various embodiments, a tie membrane (eg, 430 ) (eg, a reinforcement layer) is connected to a decorative cover layer (eg, 402 ) in a central region of its panel (eg, 404 ) via decorative stitching, bonding, and / or lamination.

[0328] In some embodiments, the perforated trim covering (eg, 402 ) comprises leather, artificial leather, vinyl, and / or fabric.

[0329] In one or more embodiments, the barrier layer (eg, 410) (eg, an impermeable layer, eg, air-impermeable, eg, a continuous plastic layer, eg, a thermoplastic polyurethane sheet or film) comprises an impermeable layer.

[0330] In various embodiments, the barrier layer (eg, 410 ) comprises plastic.

[0331] In some embodiments, the tie-down membrane (e.g., 430) (e.g., a reinforcement layer) is laminated between a first porous spacer material layer and a second porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) such that the tie-down membrane (e.g., 430) (e.g., a reinforcement layer) is separated from the decorative cover layer by the first porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric).

[0332] In one or more embodiments, a first spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) and a tie-down membrane (e.g., 430) (e.g., a reinforcement layer) are each connected to a second spacer material layer, such as 420 (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric).

[0333] In various embodiments, a first spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) and a tie-down membrane (e.g., 430) (e.g., a reinforcement layer) are each connected to a second spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) via bonding and / or lamination.

[0334] In some embodiments, the tie membrane (eg, 430 ) (eg, the reinforcement layer) comprises a nonwoven fabric.

[0335] In one or more embodiments, the porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) includes a first portion and a second portion, and the tightening membrane (e.g., 430) (e.g., a reinforcement layer) extends between the first portion and the second portion of the porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) to the barrier layer (e.g., 410) (e.g., an impermeable layer, such as an airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film).

[0336] In various embodiments, a second layer of porous spacer material (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) includes a first portion and a second portion, and a tie-down membrane (e.g., 430) (e.g., a reinforcement layer) extends between the first portion and the second portion of the second layer of porous spacer material (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) to a barrier layer (e.g., 410) (e.g., an impermeable layer, such as an airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film).

[0337] In some embodiments, the tie-down membrane (e.g., 430) (e.g., a reinforcement layer) extends laterally through a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) and a barrier layer (e.g., 410) (e.g., an impermeable layer, such as airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film) to the distal end.

[0338] In one or more embodiments, a barrier layer (e.g., 410) (e.g., an impermeable layer, e.g., airtight, e.g., a continuous plastic layer, e.g., a thermoplastic polyurethane sheet or film) is positioned between the distal end of the tie-down membrane 430 (e.g., a reinforcement layer) and a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, e.g., urethane or other foam material or a spacer fabric, such as a knitted or reticulated spacer fabric) such that the distal end of the tie-down membrane (e.g., 430) (e.g., a reinforcement layer) is on the outside of the barrier layer (e.g., 410) (e.g., an impermeable layer, e.g., airtight, e.g., a continuous plastic layer, e.g., a thermoplastic polyurethane sheet or film).

[0339] In various embodiments, a barrier layer (e.g., 410) (e.g., an impermeable layer, e.g., airtight, e.g., a continuous plastic layer, e.g., a thermoplastic polyurethane sheet or film) is connected to a tie-down membrane (e.g., 430) (e.g., a reinforcement layer).

[0340] In some embodiments, the tie film (eg, 430) (eg, the reinforcement layer) is perforated.

[0341] In one or more embodiments, the tie-down membrane (eg, 430 ) (eg, reinforcement layer) comprises a mesh.

[0342] In one or more embodiments, a seat assembly (eg, 320 ) includes a support structure (eg, 322 ) (eg, a frame) and an assembly (eg, 400 ) supported by the support structure (eg, 322 ) (eg, the frame).

[0343] In various embodiments, the seat assembly (eg, 320 ) further includes a cushion member covered by the assembly (eg, 400 ).

[0344] In some embodiments, an assembly (eg, 400 ) is connected to a frame and / or cushion member (eg, 328 , 330 ).

[0345] In various embodiments, the seat assembly (e.g., 400) further includes an air pump (e.g., 352) and / or a fan (e.g., 352) connected to a barrier layer (e.g., 410) (e.g., an impermeable layer, e.g., airtight, e.g., a continuous plastic layer, such as a thermoplastic polyurethane sheet or film).

[0346] In one or more embodiments, a method (e.g., 460) includes positioning (i.e., step 461) one or more layers of porous spacer material (e.g., 420) (e.g., a breathable layer or perforated layer or a layer having other characteristics that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) between a perforated decorative cover layer (e.g., 402) and a barrier layer (e.g., 410) (e.g., an impermeable layer, such as an airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film), with a tie film (e.g., 430) positioned between the decorative cover layer (e.g., 402) and the tie film (e.g., 430). and a spacer layer (e.g., 420) (e.g., a breathable layer or perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material, or a spacer fabric, such as a knitted or mesh spacer fabric) between at least a portion of the perforated decorative cover layer (e.g., 402) and at least a portion of the reinforcement layer), connecting (i.e., step 466) the perforated decorative cover layer (e.g., 402) to the tie membrane (e.g., 430) (e.g., the reinforcement layer), and connecting (i.e., step 468) the perforated decorative cover layer (e.g., 402) to the barrier layer (e.g., 410) (e.g., an impermeable layer, such as air-impermeable, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film) to assemble the decorative assembly.

[0347] In various embodiments, the step 461 of positioning one or more spacer layers (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) between the perforated decorative cover layer (e.g., 402) and the barrier layer (e.g., 410) (e.g., an impermeable layer, such as an airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film) further comprises positioning a first spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) between the perforated decorative cover layer (e.g., 402) and the barrier layer (e.g., 410) (e.g., an impermeable layer, such as an airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film) A layer of foam, such as urethane or other foam material or spacer fabric, such as a knitted or mesh spacer fabric) and a second layer of spacer material, such as 420 (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) are positioned between the perforated decorative cover layer, such as 402, and the barrier layer, such as 420 (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric).

[0348] In some embodiments, the method (e.g., 460) further includes forming (i.e., step 462) a groove (e.g., 426) in a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric), and positioning (i.e., step 463) an allowance (e.g., 408) of a joint 406 (e.g., a seam) between two panels (e.g., 404) of a decorative cover layer (e.g., 402) (e.g., an edge and an area between a joint area or a stitching line on two panels joined together) into the groove (e.g., 426).

[0349] In one or more embodiments, the method (e.g., 460) further includes layering a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) between the tie-down membrane (e.g., 430) (e.g., a reinforcement layer) and the decorative cover layer 402 (i.e., step 464), and sewing (e.g., step 466) the excess, such as 408 (e.g., the area between the edge and the joining area or stitching line on the two panels connected together) through the spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) along the groove (e.g., 426) to the tie-down membrane 430 (e.g., the reinforcement layer).

[0350] In various embodiments, the step 461 of positioning one or more porous spacer material layers, such as 420 (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) between the perforated decorative cover layer (e.g., 402) and the barrier layer (e.g., 410) (e.g., an impermeable layer, such as an airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film) further comprises positioning the spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and across the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) between the perforated decorative cover layer (e.g., 402) and the barrier layer (e.g., 410) (e.g., an impermeable layer, such as an airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film) The first and second portions of the layer of spacer material 420 (e.g., a breathable layer or perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric) are positioned (i.e., step 465) so that the tie-down membrane (e.g., 430) (e.g., a reinforcement layer) extends transversely to the trim cover layer 402 and extends to the distal end (e.g., 522) between the first and second portions of the spacer material layer 420 (e.g., a breathable layer or perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric).

[0351] In some embodiments, method such as 460 further includes connecting (i.e., step 467) the distal end (e.g., 522) to a barrier layer (e.g., 410) (e.g., an impermeable layer, such as airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film).

[0352] In one or more embodiments, the method (eg, 460 ) further includes connecting (ie, step 469 ) a trim assembly (eg, 500 ) to the frame of the seat assembly 320 .

[0353] In various embodiments, method such as 460 also includes positioning (ie, step 470) an inlet port such as 412 in a barrier layer such as 410 (eg, an impermeable layer, such as airtight, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film).

[0354] In some embodiments, the method, eg, 460, further includes connecting (ie, step 472) a fan and / or pump (eg, 352) to the inlet port (eg, 412).

[0355] In one or more embodiments, the method (e.g., 460) further includes passing air through a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a layer having other features that allow air to pass through and through the layer, such as a reticulated foam, such as urethane or other foam material or a spacer fabric, such as a knitted or mesh spacer fabric), and through the perforated decorative cover layer (e.g., 402) into the inlet port (e.g., 412) (i.e., step 474) to ventilate the decorative assembly (e.g., 400).

[0356] In various embodiments, the method 460 further includes, for example, enabling airflow across (ie, step 474 ) the tie membrane (eg, 430 ) (eg, the reinforcement layer).

[0357] Figure 11 A vehicle seat assembly 720 is shown according to some embodiments. The vehicle seat assembly 720 is provided with a seat bottom 722 adapted to be mounted to the vehicle floor. The vehicle seat assembly 720 can be positioned in any row of a vehicle. The vehicle seat assembly 720 includes a seat back 724 extending vertically from the seat bottom 722. The vehicle seat assembly 720 also includes a head restraint 726 extending above the seat back 724. The vehicle seat assembly 720 can be used in any type of vehicle, including land vehicles, watercraft, aircraft, and the like. The vehicle seat assembly 720 can be any seat assembly, such as an office chair, furniture, and the like.

[0358] The vehicle seat assembly 720 is provided with a plurality of adjacent trim cover sections 728, 729 over a seat bottom 722, a seat back 724, and a head restraint 726 to conceal the frame, cushioning, and functional components. The seat bottom 722 is provided with a seat pad 730. The seat pad 730 may be composed of a stranded thermoplastic mesh or foam.

[0359] Figure 12 A trim cover assembly 731 is shown, according to some embodiments. The trim cover assembly 731 is provided with a first fluid impermeable layer 732 and a second fluid impermeable layer 742 sized to be placed on the seat cushion 730. The first fluid impermeable layer 732 can be composed of a cushioning material such as foam. The first fluid impermeable layer 732 can also be composed of any air-impermeable material or an impermeable polymer material such as polyethylene. According to one embodiment, the first fluid impermeable layer 732 can be sewn to a plurality of adjacent trim cover sections 728, 729. According to some embodiments, the first fluid impermeable layer 732 can be glued or welded to the plurality of adjacent trim cover sections 728, 729.

[0360] In addition, a plurality of adjacent decorative cover segments 728 are provided with seams 736 extending through the first impermeable layer 732, thereby defining a first zone 738 and a second zone 740. The second fluid impermeable layer 742 can be formed from an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene, etc. According to some embodiments, the first fluid impermeable layer 732 is provided with a plurality of vents 734 formed therethrough. Although a plurality of vents 734 are illustrated and described, any number of vents 734 may be utilized. The vents 734 direct airflow through the decorative cover assembly 731. If the plurality of adjacent decorative cover segments 738, 729 are impermeable and have holes formed therethrough, the plurality of vents 734 is optional. In addition, the first fluid impermeable layer 732 is thermally insulative.

[0361] The second fluid-impermeable layer 742 cooperates with the first fluid-impermeable layer 732 to provide a fluid chamber 744 therebetween. The second fluid-impermeable layer 742 is provided with a first portion 746 and a second portion 748. The first portion 746 extends through the first region 738, and the second portion 748 extends through the second region 740. The first portion 746 of the second fluid-impermeable layer 742 is provided with a first flap 766 extending between the first region 738 and the second region 740 and sewn into the seam 736. The second portion 748 of the second fluid-impermeable layer 742 is also provided with a second flap 768 extending in a direction opposite to the first flap 766 for connection to the seat pad 730. The second fluid-impermeable layer 742 is perforated, for example, along the first flap 766 to allow air to pass through the first region 738 and the second region 740.

[0362] Continue to refer Figure 12 The trim cover assembly 731 is further provided with a first fluid-permeable layer 754, 755 and a second fluid-permeable layer 756, 757. The fluid-permeable layers 754, 755, 756, 757 are formed from a resilient and porous material, such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material, or the like. The first fluid-permeable layers 754, 755 are displaced along the first fluid-impermeable layer 732. The first fluid-permeable layers 754, 755 extend through the first zone 38 and the second zone 740 and are separated at the seam 736 as first fluid-permeable layer portions 754, 755, each of which is located within one of the zones 738, 740. According to some embodiments, the first fluid-permeable layers 754, 755 are sewn to the seam 736. According to some embodiments, the first fluid-permeable layers 754, 755 are laminated and may not be sewn to the seam 736.

[0363] Second fluid-permeable layers 756, 757 are spacer fabrics sized to fit within fluid chamber 44 and spaced apart from first fluid-permeable layers 754, 755. Second fluid-permeable layers 756, 757 extend through first and second zones 738, 740 and are separated at seam 736 into second fluid-permeable layer portions 756, 757, each within one of zones 738, 740. Second fluid-permeable layers 756, 757 also displace along perforated second fluid-impermeable layer 742, thereby allowing air to flow through first and second zones 738, 740. Without permeable layers 754, 755, 756, 757, the impermeable layers 732, 742 could be compressed when weight from an occupant is applied, potentially cutting off airflow when fan 752 is in use. Permeable layers 754, 755, 756, 757 can be omitted when trim cover assembly 731 utilizes a compressor instead of fan 752.

[0364] The decorative cover assembly 731 is also provided with a heat transfer layer 758, which is displaced along the first fluid-impermeable layer 732 and spaced apart from the second fluid-impermeable layer 742. In some embodiments, the heat transfer layer 758 can be displaced along the decorative cover sections 728, 729, or alternatively, between the second fluid-permeable layers 756, 757 and the fan 752. In some embodiments, the heat transfer layer 758 can be displaced between the first fluid-permeable layers 754, 755 and the first fluid-impermeable layer 732. The heat transfer layer 758 is provided with a conductive heater pad. The decorative cover assembly 731 also includes outer decorative cover sections 728, 729 disposed above the first and second fluid-impermeable layers 732, 742. The decorative cover sections 728, 729 are perforated to allow fluid to pass through the outer decorative cover 728. The decorative cover sections 728, 729 are also provided with orifices 764 along the seam 736 to allow air to pass through the first and second zones 738, 740. Furthermore, the trim cover sections 728, 729 are sewn to the first fluid impermeable layer 732 without adhesive. According to some embodiments, the trim layer sections 728, 729 are glued to the first fluid impermeable layer 732.

[0365] refer to Figure 12, the decorative cover assembly 731 is provided with a fluid actuator 750, such as a fan 752. According to some embodiments, the fluid actuator 750 is directly welded to the second fluid impermeable layer 742 to seal the connection around the fluid actuator 750. According to some embodiments, the fan 752 is connected to the second fluid impermeable layer 742 by a retaining ring. The fan 752 is mounted between the decorative cover 728 and the seat cushion 730. The seat cushion 730 includes a receptacle sized to receive the fan 752. Conventional fans are mounted below the vehicle seat cushion and outside the decorative cover assembly. Mounting the fan 752 above the seat cushion 730 allows the fan 752 to be displaced within the decorative cover assembly 731.

[0366] Prior art seat assemblies with heating and cooling features typically position the fan beneath the cushions. The fluid ducts are then assembled through the cushions and trim cover of the conventional seat assembly. Fluid-impermeable layers 732, 742, permeable layers 754, 755, 756, 757, heat transfer layer 758, and fluid actuator 750 are all preassembled within trim cover assembly 731, allowing trim cover assembly 731 to be installed as a single unit to the seat frame. This reduces manufacturing costs and time compared to prior art designs.

[0367] The trim cover assembly 731 can be used with a breathable, non-foam seat cushion 730 formed from a thermoplastic mesh. The second fluid-impermeable layer 742 provides a barrier between the fluid chamber 744 and the seat cushion 730. When used with the foam cushion 730, the second fluid-impermeable layer 742 can be omitted if the cushion 730 is not breathable. In this case, the fluid actuator 750 can be welded directly to the first fluid-impermeable layer 732 to deliver fluid through the plurality of vents 734 in the fluid-impermeable layer 732. Alternatively, the fluid actuator 750 can be separate from the trim cover 728.

[0368] Figure 13A second fluid-impermeable layer 742 is shown, according to some embodiments. The second fluid-impermeable layer 742 includes a first portion 746 and a second portion 748. The first portion 746 extends through the first region 738 of the trim cover assembly 731. The second portion 748 extends through the second region 740 of the trim cover assembly 731. The first portion 746 also includes a first flap 766 extending between the first region 738 and the second region 740. In one embodiment, the first flap 766 is perforated to allow air to flow between the first region 738 and the second region 740. In some embodiments, the first flap 766 may be segmented to allow air to flow between the first region 738 and the second region 740. The second portion 748 also includes a second flap 768 that extends in a direction opposite to the first flap 766 and is connected to the seat cushion 730. The first portion 746 and the second portion 748 may be sewn, welded, adhered, or otherwise fastened together.

[0369] Figure 14 A second fluid-impermeable layer 742 is shown as a continuous sheet according to some embodiments. The second fluid-impermeable layer 742 extends through the first region 738 and the second region 740. The second fluid-impermeable layer 742 is provided with a first flap 760 and a second flap 762. The first flap 760 extends between the first region 738 and the second region 740. In addition, the first flap 760 is perforated to allow air to pass through the first region 738 and the second region 740. The second flap 762 extends in a direction opposite to the first flap 760 and can be attached to the seat cushion 730. The first flap 760 and the second flap 762 can be sewn, welded, adhered, or otherwise fastened to the second fluid-impermeable layer 742.

[0370] In one or more embodiments, an assembly (e.g., 731) includes a first fluid-impermeable layer, e.g., 732 (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) sized to be placed on a seat cushion (e.g., 730, such as foam or thermoplastic mesh strands), multiple adjacent trim cover segments (e.g., 728, 729) for concealing a frame, cushioning, and other functional components sewn to the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), and seams (e.g., 736) extending through the multiple adjacent trim cover segments (e.g., 728, 729) for concealing the frame, cushioning, and other functional components and the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material, such as polyethylene).

[0371] In various embodiments, the first fluid-impermeable layer (eg, 732) (eg, any air-impermeable material or impermeable polymeric material, such as polyethylene) further comprises a plurality of vents (eg, 734) formed therethrough.

[0372] In some embodiments, a seam (e.g., 736) extends through a first impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to define a first region (e.g., 738) and a second region (e.g., 740) of the trim cover segment (e.g., 728).

[0373] In one or more embodiments, the component (e.g., 731) also includes a second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) that cooperates with the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to provide a fluid chamber (e.g., 744) therebetween.

[0374] In various embodiments, the second fluid-impermeable layer (e.g., 742) (e.g., any breathable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) also includes a first portion (e.g., 746) extending through the first zone (e.g., 738) and the second zone (e.g., 740).

[0375] In some embodiments, the second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) also includes a second portion (e.g., 748) that extends in an opposite direction from the first portion (e.g., 746) to connect to the seat pad (e.g., 730).

[0376] In one or more embodiments, the second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) is perforated to allow air to pass through the first zone (e.g., 738) and the second zone (e.g., 740).

[0377] In various embodiments, the component, such as 731, also includes a fluid actuator, such as 750 (e.g., a fan), which is attached to a second fluid-impermeable layer, such as 742 (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to transport fluid (e.g., air) through the fluid chamber, such as 744, and out of the first fluid-impermeable layer, such as 732 (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene).

[0378] In some embodiments, the fluid actuator (e.g., 750) (e.g., a fan) also includes a fan attached to one of the first zone (e.g., 738) or the second zone (e.g., 740) to provide fluid communication through the first zone (e.g., 738) and the second zone (e.g., 740).

[0379] In one or more embodiments, a fluid actuator (e.g., 750) (e.g., a fan) delivers air through a first portion (e.g., 746) of a second fluid-impermeable layer (e.g., 740) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), a fluid chamber (e.g., 744), and a first fluid-impermeable layer (e.g., 733) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) such that air is transferred from a first zone (e.g., 738) through a second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to a second zone (e.g., 740).

[0380] In various embodiments, the component (e.g., 731) also includes a first fluid permeable layer (e.g., 754, 755) (e.g., elastic and porous material, such as porous foam, extruded thermoplastic resin mesh, knitted three-dimensional spacer material) displaced along a first fluid impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene).

[0381] In some embodiments, a first fluid-permeable layer (e.g., 754, 755) (e.g., an elastic and porous material, such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material) extends through the first zone (e.g., 738) and the second zone (e.g., 740), and the first fluid-permeable layer (e.g., 754, 755) (e.g., an elastic and porous material, such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material) is sewn to the seam (e.g., 736).

[0382] In one or more embodiments, the component (e.g., 731) further includes a second fluid permeable layer (e.g., 756, 757) (e.g., an elastic and porous material, such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material), which is sized to be received within the fluid chamber (e.g., 744) and separated from the first fluid permeable layer (e.g., 754, 755) (e.g., an elastic and porous material, such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material).

[0383] In various embodiments, the fluid impermeable layer (eg, 732 / 742 ) is insulative.

[0384] In some embodiments, a plurality of adjacent trim cover segments (eg, 728 , 729 ) are perforated to allow fluid (eg, air) to pass through the trim cover segments (eg, 728 , 729 ).

[0385] In one or more embodiments, a second fluid-impermeable layer, such as 742 (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) of the component (e.g., 731) extends through the first zone (e.g., 738) and the second zone (e.g., 740), and the second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) also includes a first perforated portion (e.g., 746) extending to the seam (e.g., 736) of the trim cover segment (e.g., 728, 729) and a second portion (e.g., 748) connected to the seat pad (e.g., 730) (foam or non-foam thermoplastic filament web).

[0386] In various embodiments, a seat assembly (e.g., 720) includes a seat bottom (e.g., 722) and a seat back (e.g., 724) extending from the seat bottom (e.g., 722) in an upright position, a seat cushion (e.g., 730) attached to the seat bottom (e.g., 722) or the seat back (e.g., 724), and a trim cover assembly (e.g., 731) mounted over the seat cushion (e.g., 730).

[0387] In some embodiments, the seat pad (eg, 730 ) is fluid permeable.

[0388] In one or more embodiments, a method (e.g., 770) includes attaching (i.e., step 772) a plurality of adjacent trim cover segments (e.g., 728, 729) to a first fluid-impermeable layer 732 (e.g., any breathable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), and sewing (i.e., step 774) a seam (e.g., 736) through the adjacent trim cover segments (e.g., 728, 729) and the first fluid-impermeable layer (e.g., 732) (e.g., any breathable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to create a first zone (e.g., 738) and a second zone (e.g., 740).

[0389] In various embodiments, the method (e.g., 770) also includes attaching (e.g., sewing, welding, adhering, or otherwise fastening) a second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) with a perforated first portion (e.g., 746) extending through the first region (e.g., 738) and the second region (e.g., 740) (i.e., step 776).

[0390] In some embodiments, the method (e.g., 770) further includes attaching (i.e., step 778) a fluid actuator (e.g., 750) (e.g., a fan) to a second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene).

[0391] In one or more embodiments, the method (e.g., 770) also includes installing (i.e., step 780) a first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), a second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) and a trim cover segment (e.g., 728, 729) on a preassembled seat assembly (e.g., 720) having a cushion (e.g., 730) (e.g., a foam or mesh of polymer strands) and a frame (e.g., a rigid structure such as steel or aluminum for supporting subassemblies of the seat).

[0392] In various embodiments, an assembly, such as 731, includes a first fluid-impermeable layer, such as 732 (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), sized to be received by a seat cushion, such as 730 (e.g., a foam or non-foam web of polymer strands), wherein the first fluid-impermeable layer, such as 732 (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), is provided with at least one vent formed therethrough, and a plurality of adjacent trim cover sections, such as 728, 729, are sewn to the first fluid-impermeable layer by seams, such as 736. The first fluid-impermeable layer (e.g., 732) includes a seam (e.g., 736) extending through the trim cover segments (e.g., 728, 729) and the first fluid-impermeable layer (e.g., 732) to create a first zone (e.g., 738) and a second zone (e.g., 740), and a perforated second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) is mated (e.g., sewn, welded, adhered, or otherwise fastened) to the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to create a first zone (e.g., 738) and a second zone (e.g., 740). and a second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or an impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) having a first portion, such as 746, extending vertically through the first region (e.g., 738) and the second region (e.g., 740), and a second portion (e.g., 748) connected to the seat cushion (e.g., 730), the first fluid-permeable layer (e.g., 754, 755) being sized to be received by the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or an impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) and the second fluid-permeable layer (e.g., 754, 755) being sized to be received by the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or an impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene). ) (e.g., elastic and porous material, such as porous foam, extruded thermoplastic resin mesh, knitted three-dimensional spacer material), a fluid actuator (e.g., 750) (e.g., a fan) directly attached to a first portion (e.g., 746) of a second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), a second fluid-permeable layer (e.g., 756, 757) (e.g., elastic and porous material,For example, a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material), and a heat transfer layer such as 758 (for example, a conductive heater pad) along a second fluid permeable layer such as 756, 757 (for example, an elastic and porous material, such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material). The heat transfer layer such as 758 is provided with a conductive heater pad. The second fluid permeable layer (for example, 756, 757) (for example, an elastic and porous material, such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material) is separated from the first fluid permeable layer (for example, 754, 757) (for example, an elastic and porous material, such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material).

[0393] Figure 15 A vehicle seat assembly 810 is shown according to some embodiments. The vehicle seat assembly 810 is provided with a seat bottom 812 adapted to be mounted to the vehicle floor. The vehicle seat assembly 810 can be positioned in any row of a vehicle. The vehicle seat assembly 810 includes a seat back 814 extending vertically from the seat bottom 812. The vehicle seat assembly 810 also includes a head restraint 816 extending above the seat back 814. The vehicle seat assembly 810 can be used in any type of vehicle, including land vehicles, watercraft, aircraft, and the like. The vehicle seat assembly 810 can be any seat assembly, such as an office chair, furniture, and the like.

[0394] Vehicle seat assembly 810 is provided with a trim cover 818 over seat bottom 812, seat back 814 and head restraint 816 to conceal the frame, cushioning and functional components. Seat bottom 812 is provided with seat pad 820. Seat pad 820 may be formed of a stranded thermoplastic mesh or foam.

[0395] Figure 16 A trim cover assembly 822 is shown according to some embodiments. The trim cover assembly 822 is provided with a first fluid impermeable layer 824 and a second fluid impermeable layer 826, which are sized to be placed on the seat cushion 820. The first fluid impermeable layer 824 can be composed of a cushioning material such as foam. The second fluid impermeable layer 826 can be formed of an impermeable polymer material (e.g., a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene, etc.). The first fluid impermeable layer 824 is provided with a plurality of vents 836 formed therethrough. Although a plurality of vents 836 are shown and described, any number of vents 836 can be utilized. The vents 836 direct airflow through the trim cover assembly 822. In addition, the first fluid impermeable layer 824 is thermally insulating.

[0396] The second fluid-impermeable layer 826 cooperates with the first fluid-impermeable layer 824 to provide a fluid chamber 825 therebetween. The trim cover assembly 822 is also provided with a first fluid-permeable layer 828 and a second fluid-permeable layer 830. The fluid-permeable layers 828, 830 are formed of an elastic and porous material (e.g., a porous foam or an extruded thermoplastic resin mesh). The first fluid-permeable layer 828 is sized to be received within the fluid chamber 825 between the first fluid-impermeable layer 824 and the second fluid-impermeable layer 826. The second fluid-permeable layer 830 is displaced along the first fluid-impermeable layer 824 and is spaced apart from the first fluid-permeable layer 828. The first fluid-permeable layer 828 and the second fluid-permeable layer 830 ensure that the first fluid-impermeable layer 824 and the second fluid-impermeable layer 826 are not compressed together by the weight of the occupant. Without permeable layers 828, 830, impermeable layers 824, 826 may be compressed when weight from an occupant is applied, which may cut off airflow when using fan 832. When trim assembly 822 utilizes a compressor instead of fan 832, permeable layers 828, 830 may be omitted.

[0397] The decorative cover assembly 822 is also provided with a heat transfer layer 834 that is displaced along the first fluid-impermeable layer 824 and spaced apart from the second fluid-impermeable layer 826. In some embodiments, the heat transfer layer 834 can be displaced along the decorative layer 818, or alternatively, between the second fluid-permeable layer 830 and the fan 832. The heat transfer layer 834 is provided with a conductive heater pad. The decorative cover assembly 822 is also provided with an outer decorative layer 818 that is disposed above the first fluid-impermeable layer 824 and the second fluid-impermeable layer 826. The decorative layer 818 is perforated to allow fluid to pass through the outer decorative layer 818. In addition, according to some embodiments, the decorative layer 818 is sewn to the first fluid-impermeable layer 824 using stitches 838 without an adhesive. According to some embodiments, the decorative layer 818 is glued to the first fluid-impermeable layer 824.

[0398] Continue to refer Figure 16 , the decorative cover assembly 822 is provided with a fluid actuator 832, such as a fan 832. According to some embodiments, the fluid actuator 832 is directly welded to the second fluid impermeable layer 826 to seal the connection around the fan 832. According to some embodiments, the fan 832 is connected to the second fluid impermeable layer 826 by a retaining ring. The fan 832 is mounted between the decorative cover 818 and the seat cushion 820. The seat cushion 820 includes a receptacle sized to receive the fan 832. Conventional fans are mounted below the vehicle seat cushion and outside the decorative cover assembly. Mounting the fan 832 above the seat cushion 820 allows the fan 832 to be displaced within the decorative cover assembly 822.

[0399] Prior art seat assemblies with heating and cooling features typically position the fan beneath the seat cushion. The fluid conduit is then assembled through the cushion and trim cover of the conventional seat assembly. Fluid-impermeable layers 824, 826, permeable layers 828, 830, heat transfer layer 834, and fluid actuator 832 are all pre-assembled within trim cover assembly 822, allowing trim cover assembly 822 to be installed as a single unit to the seat frame. This reduces manufacturing costs and time compared to prior art designs.

[0400] The trim cover assembly 822 can be used with a breathable, non-foam seat cushion 820 formed from a thermoplastic mesh. A second fluid-impermeable layer 826 provides a barrier between the fluid chamber 825 and the seat cushion 820. When used with the foam cushion 820, the second fluid-impermeable layer 826 can be omitted if the cushion 820 is not breathable. In this case, the fluid actuator 832 can be welded directly to the first fluid-impermeable layer 824 to deliver fluid through the vents 836 in the fluid-impermeable layer 824. Alternatively, the fluid actuator 832 can be separate from the trim cover 818.

[0401] Figure 17 The outer decorative layer 818, the first fluid-impermeable layer 824, and the second fluid-impermeable layer 826 are shown with stitching 838 along the perimeter. The stitching 838 seals the layers 818, 824, 826 so that air cannot escape the fluid chamber 825. Alternatively, the layers 818, 824, 826 can be attached together with adhesive or welded instead of utilizing stitching 838.

[0402] In one or more embodiments, a component (e.g., 822) includes: a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) that is sized to be placed on a seat cushion (e.g., 820) (e.g., a non-woven web of foam or polymer filaments) and having at least one vent (e.g., 836) formed therethrough; and a fluid actuator (e.g., 832), such as a fan attached to the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) to convey a fluid (e.g., air) through the vent (e.g., 836) of the first fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0403] In various embodiments, the component (e.g., 822) further includes a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), which is coupled (e.g., sewn, welded, adhered, or otherwise fastened) to the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) to provide a fluid chamber (e.g., 825) therebetween.

[0404] In some embodiments, a fluid actuator (e.g., 832) (such as a fan) is directly attached to a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) to pass fluid (e.g., air) through a fluid chamber (e.g., 825) and then out a vent (e.g., 836) of a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0405] In one or more embodiments, the component (e.g., 822) further includes a first fluid permeable layer (e.g., 828) (e.g., a resilient and porous material such as a porous foam or an extruded thermoplastic resin web) that is sized to be received within the fluid chamber (e.g., 825).

[0406] In various embodiments, component, such as 822, further comprises a second fluid permeable layer (e.g., 830) (e.g., an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh), which is displaced along the first fluid impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and is separated from the first fluid permeable layer (e.g., 828) (e.g., an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh).

[0407] In some embodiments, the fluid actuator (e.g., 832) (e.g., a fan) is directly attached to a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0408] In one or more embodiments, the fluid actuator (e.g., 832) (e.g., a fan) is welded to a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0409] In various embodiments, the component (e.g., 822) also includes a heat transfer layer 834 (e.g., a conductive heater pad) that is displaced along a first fluid-impermeable layer 824 (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and is separated from a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0410] In some embodiments, the heat transfer layer (eg, 834 ) further includes a conductive heater pad.

[0411] In one or more embodiments, the component (e.g., 822) further includes an outer decorative layer (e.g., 818) disposed over a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0412] In various embodiments, the outer decorative layer (eg, 818 ) is perforated to allow fluid (eg, air) to pass through the outer decorative layer (eg, 818 ), such as through the perforations.

[0413] In some embodiments, the outer decorative layer (e.g., 818) is stitched to the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as thermoplastic polyurethane (TPU) film, polyvinyl chloride (PVC) film, polyethylene) without adhesive.

[0414] In one or more embodiments, the fluid actuator (eg, 832 ) further includes a fan.

[0415] In various embodiments, the first fluid impermeable layer (eg, 824) (eg, an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) is thermally insulating.

[0416] In some embodiments, a plurality of vents (eg, 836) are formed through a first fluid impermeable layer (eg, 824) (eg, an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0417] In one or more embodiments, a seat assembly (e.g., 810) such as for a vehicle includes a seat bottom (e.g., 812), a seat back (e.g., 814) extending from the seat bottom (e.g., 812) in an upright position, a seat cushion (e.g., 820) attached to the seat bottom (e.g., 812) or the seat back (e.g., 814), and a trim cover assembly (e.g., 822) mounted over the seat cushion (e.g., 820).

[0418] In various embodiments, the seat pad (eg, 820 ) is fluid permeable.

[0419] In one or more embodiments, a method (e.g., 840) includes attaching (i.e., step 842) a fluid actuator (e.g., 832) (e.g., a fan) to a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), attaching (i.e., step 844) an outer decorative layer (e.g., 818) to the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), and installing (i.e., step 844) the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and the outer decorative layer 818 on a preassembled seat assembly 810 having a seat pad 820 and a frame.

[0420] In various embodiments, the method (eg, 840 ) further includes attaching (ie, step 845 ) a second fluid impermeable layer that cooperates with the first fluid impermeable layer to provide a fluid chamber between the first and second fluid impermeable layers.

[0421] In one or more embodiments, the component (e.g., 822) includes: a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) that is sized to be received by a seat cushion (e.g., 820) (e.g., foam or non-foam, such as a non-woven web of polymer filaments), wherein the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) is provided with at least one vent (e.g., 836) formed therethrough; a second fluid-impermeable Layer, e.g., 826 (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), which is mated (e.g., sewn, welded, bonded, or otherwise fastened) to a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) to provide a fluid chamber (e.g., 825) therebetween, the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) being sized to receive the first fluid-impermeable layer. a permeable layer (e.g., 828) (e.g., an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh); a fluid actuator (e.g., 832) (e.g., a fan) directly attached to a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene); a second fluid-permeable layer (e.g., 830) (e.g., an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh) attached along the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene); C) film, polyethylene) displacement; a heat transfer layer (e.g., 834), such as a conductive heater pad, along a second fluid permeable layer (e.g., 830) (e.g., an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh); and a perforated outer decorative layer 818, which is disposed above the first fluid impermeable layer (e.g., 824) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and the second impermeable layer 826 (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) to allow fluid to pass through the outer decorative layer 818. The heat transfer layer (e.g., 834) is provided with a conductive heater pad.The second fluid permeable layer (e.g., 830) (e.g., an elastic and porous material such as a porous foam or an extruded thermoplastic resin mesh) is separated from the first fluid permeable layer (e.g., 828) (e.g., an elastic and porous material such as a porous foam or an extruded thermoplastic resin mesh).

[0422] Figure 18 A vehicle seat assembly 910 is shown according to some embodiments. The vehicle seat assembly 910 is provided with a seat bottom 912 adapted to be mounted to the vehicle floor. The vehicle seat assembly 910 can be positioned in any row of a vehicle. The vehicle seat assembly 910 includes a seat back 914 extending vertically from the seat bottom 912. The vehicle seat assembly 910 also includes a head restraint 916 extending above the seat back 914. The vehicle seat assembly 910 can be used in any type of vehicle, including land vehicles, watercraft, aircraft, and the like. The vehicle seat assembly 910 can be any seat assembly, such as an office chair, furniture, and the like.

[0423] Vehicle seat assembly 910 is provided with a trim cover 918 over a seat bottom 912, a seat back 914, and a head restraint 916 to conceal the frame, cushioning components, and functional components. Seat bottom 912 is provided with a seat cushion 920. Seat cushion 920 may be constructed from a twisted thermoplastic mesh or foam. Vehicle seat assembly 910 is also provided with a controller and pump 944. Controller and pump 944 may be located in a module beneath seat cushion 920 and may be a multi-function controller that also controls other functions in the vehicle.

[0424] Figure 19 A trim cover assembly 922 is shown, according to some embodiments. The trim cover assembly 922 is provided with a first trim cover layer 924 and a second fluid-impermeable layer 928, the second fluid-impermeable layer being sized to be placed over the seat cushion 920. The first trim cover layer 924 is referred to as the first fluid-impermeable layer 924. The first fluid-impermeable layer 924 can be comprised of a cushioning material such as foam. The second fluid-impermeable layer 928 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, the first fluid-impermeable layer 924 is provided with a plurality of vents 926 formed therethrough. Although a plurality of vents 926 are illustrated and described, any number of vents 926 may be utilized. The vents 926 direct airflow through the trim cover assembly 922. According to some embodiments, if the trim cover 918 has a plurality of apertures formed therethrough, the first fluid-impermeable layer 924 and the vents 926 may be optional. Additionally, the first fluid-impermeable layer 924 is thermally insulating.

[0425] The second fluid-impermeable layer 928 cooperates with the first fluid-impermeable layer 924 to provide a fluid chamber 930 therebetween. The trim cover assembly 922 is also provided with an inflatable bladder assembly 932. According to some embodiments, the inflatable bladder assembly 932 is supported on the first fluid-impermeable layer 924 and positioned within the fluid chamber 930. According to some embodiments, the inflatable bladder assembly 932 can be displaced outside of the fluid chamber 930, such as between the second fluid-impermeable layer 928 and the seat cushion 920.

[0426] Controller 944 is in electrical communication with pump 944, which in turn is in fluid communication with inflatable bladder assembly 932 to inflate assembly 932. Controller 944 is configured to receive input indicative of a manual adjustment and adjust inflatable bladder assembly 932 to apply pressure to the occupant.

[0427] The trim cover assembly 922 is also provided with a first fluid-permeable layer 934 and a second fluid-permeable layer 936. The fluid-permeable layers 934, 936 are formed of a resilient and porous material, such as a porous foam or an extruded thermoplastic resin mesh. The first fluid-permeable layer 934 is sized to be received within the fluid chamber 930 and displaced over the inflatable bladder assembly 932. The first fluid-permeable layer and the inflatable bladder assembly 932 are positioned between the first fluid-impermeable layer 924 and the second fluid-impermeable layer 928. Although a plurality of inflatable bladder assemblies 932 are shown, any number of bladder assemblies 932 may be present.

[0428] Second fluid-permeable layer 936 is displaced along and spaced apart from first fluid-impermeable layer 924. First and second fluid-permeable layers 934, 936 ensure that first and second fluid-impermeable layers 924, 928 are not compressed together by the weight of an occupant. Without permeable layers 934, 936, impermeable layers 924, 928 could be compressed when the weight of an occupant is applied, which could cut off airflow when fan 942 is used. Permeable layers 934, 936 can be omitted when trim assembly 922 utilizes a compressor instead of fan 942.

[0429] The decorative cover assembly 922 is also provided with a heat transfer layer 938, which is positioned along the first fluid-impermeable layer 924 and spaced apart from the second fluid-impermeable layer 928. In some embodiments, the heat transfer layer 938 can be positioned along the decorative layer 918, or alternatively, between the second fluid-impermeable layer 928 and the fan 942. In some embodiments, the heat transfer layer 938 can be positioned between the first fluid-impermeable layer 924 and the first fluid-permeable layer 934. The heat transfer layer 938 is provided with a conductive heater pad. The decorative cover assembly 922 is also provided with an outer decorative layer 918, which is positioned above the first fluid-impermeable layer 924 and the second fluid-impermeable layer 928. The decorative layer 918 is perforated to allow fluid to pass through the outer decorative layer 918. In addition, according to some embodiments, the decorative layer 918 is sewn to the first fluid-impermeable layer 924 without adhesive. According to some embodiments, the decorative layer 918 is glued to the first fluid-impermeable layer 924.

[0430] Continue to refer Figure 19 , the decorative cover assembly 922 is provided with a fluid actuator 940, such as a fan 942. The fluid actuator 940 is directly welded to the second fluid impermeable layer 928 to seal the connection around the fan 942. According to some embodiments, the fan 942 is connected to the second fluid impermeable layer 928 by a retaining ring. The fan 942 is mounted between the decorative cover 918 and the seat cushion 920. The seat cushion 920 includes a receptacle sized to receive the fan 942. Conventional fans are mounted below the vehicle seat cushion and outside the decorative cover assembly. Mounting the fan 942 above the seat cushion 920 allows the fan 942 to be displaced within the decorative cover assembly 922.

[0431] Prior art seat assemblies with heating and cooling features typically position the fan and massage bladder assembly beneath the cushions. The fluid conduits are then assembled through the cushions and trim cover of the conventional seat assembly. Fluid-impermeable layers 924, 928, permeable layers 934, 936, heat transfer layer 938, air bladder assembly 932, and fluid actuator 940 are all preassembled within trim cover assembly 922, allowing it to be installed as a single unit to the seat frame. This preassembly reduces manufacturing costs and time compared to prior art designs.

[0432] The trim cover assembly 922 can be used with a breathable, non-foam seat cushion 920 formed from a thermoplastic mesh. A second fluid-impermeable layer 928 provides a barrier between the fluid chamber 930 and the seat cushion 920. When used with a foam cushion 920, the second fluid-impermeable layer 928 can be omitted if the cushion 920 is air-impermeable. In this case, the fluid actuator 940 can be welded directly to the first fluid-impermeable layer 924 to deliver fluid through the vent 926 of the fluid-impermeable layer 924. Alternatively, the fluid actuator 940 can be separate from the trim cover.

[0433] In one or more embodiments, an assembly, such as 922, includes a first trim cover layer, such as 924, sized to be placed on a seat cushion, such as 920, and at least one inflatable bladder assembly, such as 932, supported on the first trim cover layer, such as 924, to apply pressure to an occupant.

[0434] In various embodiments, the first trim cover layer (eg, 924 ) is fluid impermeable.

[0435] In some embodiments, the component (e.g., 922) further includes a first fluid-impermeable layer (e.g., 924) (e.g., a cushioning material or an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) that includes at least one vent (e.g., 926) formed therethrough.

[0436] In one or more embodiments, the component (e.g., 922) also includes a second fluid-impermeable layer (e.g., 928) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) that is mated (e.g., sewn, welded, adhered, or otherwise fastened) to the first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) to provide a fluid chamber (e.g., 930) therebetween.

[0437] In various embodiments, the assembly (e.g., 922) also includes a second fluid actuator (e.g., 940), such as a fan, which is directly attached to the second fluid-impermeable layer (e.g., 928) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0438] In some embodiments, a second fluid actuator, such as 940 (e.g., a fan), is welded to a second fluid-impermeable layer (e.g., 928) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0439] In one or more embodiments, the second fluid actuator (eg, 940 ) further includes a fan.

[0440] In various embodiments, at least one inflatable bladder assembly (eg, 932) is positioned within a fluid chamber (eg, 930).

[0441] In some embodiments, the assembly (e.g., 922) further includes a first fluid-permeable layer (e.g., 934) (e.g., a resilient and porous material, such as a porous foam or an extruded thermoplastic resin mesh) that is sized to be received within the fluid chamber (e.g., 930), wherein the first fluid-permeable layer (e.g., 934) (e.g., a resilient and porous material, such as a porous foam or an extruded thermoplastic resin mesh) is displaced over the inflatable bladder assembly (e.g., 932).

[0442] In one or more embodiments, the component (e.g., 922) further includes a second fluid-permeable layer (e.g., 936) (e.g., an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh) that is displaced along and spaced apart from the first fluid-impermeable layer (e.g.,) 924 (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0443] In various embodiments, the component (e.g., 922) also includes a heat transfer layer (e.g., 938) (e.g., a conductive heater pad) that is displaced along the first fluid-impermeable layer and separated from a second fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0444] In some embodiments, the heat transfer layer (eg, 938 ) further includes a conductive heater pad.

[0445] In one or more embodiments, the component (e.g., 922) further includes an outer decorative layer (e.g., 918) disposed over a first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and a second fluid-impermeable layer (e.g., 926) (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), wherein the outer decorative layer (e.g., 918) is perforated to allow fluid to pass through the outer decorative layer (e.g., 918).

[0446] In one or more embodiments, the outer decorative layer (e.g., 918) is stitched to a first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, polyvinyl chloride (PVC) film, polyethylene) without an adhesive.

[0447] In various embodiments, the assembly (e.g., 922) further includes a controller (e.g., 944) that is electrically connected to the at least one inflatable bladder assembly (e.g., 932), the controller (e.g., 944) being configured to receive input indicating a manual adjustment and adjust the at least one inflatable bladder assembly (e.g., 932) to apply pressure to the occupant.

[0448] In various embodiments, the first fluid impermeable layer (eg, 924) (eg, an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) is thermally insulating.

[0449] In some embodiments, a plurality of vents (eg, 926) are formed through a first fluid impermeable layer (eg, 924) (eg, an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0450] In one or more embodiments, the at least one inflatable bladder assembly (eg, 932 ) further includes a plurality of inflatable bladder assemblies (eg, 932 ) housed within the fluid chamber (eg, 930 ).

[0451] In various embodiments, a seat assembly (e.g., 910) includes a seat bottom (e.g., 912), a seat back (e.g., 914) extending from the seat bottom (e.g., 912) in an upright position, a seat cushion (e.g., 920) attached to the seat bottom (e.g., 912) or the seat back (e.g., 914), and an assembly (e.g., 922) mounted above the seat cushion (e.g., 920).

[0452] In some embodiments, the seat pad (eg, 920 ) is fluid permeable.

[0453] In one or more embodiments, a method (e.g., 950) includes installing (i.e., 952) a first trim cover layer (e.g., 918) sized to be placed over a seat cushion (e.g., 920), and installing (i.e., 954) at least one inflatable bladder assembly (e.g., 932) supported on the first trim cover layer 918 to apply pressure to an occupant.

[0454] In various embodiments, the assembly (e.g., 922) includes a thermally insulating first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) sized to be received by a seat cushion (e.g., 920), wherein the first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) is provided with at least one vent (e.g., 926) formed therethrough; a second fluid-impermeable layer (e.g., 928) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film , polyvinyl chloride (PVC) film, polyethylene), which is matched (e.g., sewn, welded, bonded or otherwise fastened) with a first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material such as thermoplastic polyurethane (TPU) film, polyvinyl chloride (PVC) film, polyethylene) to provide a fluid chamber (e.g., 930) therebetween; a fluid actuator such as 940 (e.g., a fan), which is directly attached to the second impermeable layer (e.g., 928) (e.g., an impermeable polymer material such as thermoplastic polyurethane (TPU) film, polyvinyl chloride (PVC) film, polyethylene); at least one inflatable bladder assembly (e.g., 932) positioned within the fluid chamber (e.g., 930) ) and supported on a first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) to apply pressure to the occupant; a first fluid-permeable layer such as 934 (e.g., an elastic and porous material such as a porous foam or an extruded thermoplastic resin mesh) that is displaced on the inflatable bladder assembly (e.g., 932); a second fluid-permeable layer such as 936 (e.g., an elastic and porous material such as a porous foam or an extruded thermoplastic resin mesh) that is displaced along the first fluid-impermeable layer such as 924 (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) to apply pressure to the occupant; C) film, polyethylene) displacement; a heat transfer layer such as 938 (e.g., a conductive heater pad) along a second fluid permeable layer such as 936 (e.g., an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh); and a perforated outer decorative layer (e.g., 918) disposed above a first fluid impermeable layer such as 924 (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and a second impermeable layer such as 926 (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) to allow fluid to pass through the outer decorative layer (e.g., 918).A second fluid-permeable layer (e.g., 936) (e.g., a resilient and porous material such as a porous foam or an extruded thermoplastic resin mesh) is spaced apart from the first fluid-permeable layer (e.g., 934) (e.g., a resilient and porous material such as a porous foam or an extruded thermoplastic resin mesh). A heat transfer layer (e.g., 938) is provided with a conductive heater pad.

[0455] Figure 20 A seat assembly 1020 is shown according to some embodiments. The seat assembly 1020 is described as a vehicle seat assembly 1020. The seat assembly 1020 can be used in any vehicle, such as a land vehicle, an aircraft, or a watercraft. Although a vehicle seat assembly 1020 is disclosed, any seat assembly 1020 can be implemented, such as an office chair.

[0456] Seat assembly 1020 includes a seat bottom assembly 1022 adapted to be mounted to a vehicle floor. Seat bottom assembly 1022 is sized to receive and support the pelvis and thighs of an occupant seated thereon. A seat back assembly 1024 extends from seat bottom assembly 1022 in an upright orientation. Seat back assembly 1024 is sized to receive and support the back of the seated occupant. A head restraint assembly 1026 extends above seat back assembly 1024 to support the head of the seated occupant.

[0457] The seat back assembly 1024 includes a seat support member of cushioning material, such as a cushion 1028, to provide compliant support to the occupant. The cushion 1028 is formed of a cushioning material (e.g., polyurethane foam, etc.) that has sufficient structure to support the occupant, but is also compliant to provide comfort to the occupant. The cushion 1028 includes a central area 1030 that is sized to support the occupant's lumbar and thoracic regions. A pair of bolsters 1032 each extend laterally outward from the central area 1030 in a fore-aft direction and extend forward from the central area 1030 to provide lateral support to the occupant's lumbar and thoracic regions. The cushion 1028 also includes a shoulder area 1034 that extends above the central area 1030 and slightly forward to accommodate and support the occupant's shoulders. On the front surface of the pad 1028, the center region 1030, the pillow 1032, and the shoulder region 1034 collectively provide a support surface 1036 for contacting and supporting an occupant.

[0458] Now refer to Figure 20 and Figure 21, seat assembly 1020 includes a localized pressure assembly, such as massage assembly 1038, for applying a localized pressure effect, such as a massage effect, to a seated occupant. To apply the massage effect to various areas or zones within seat assembly 1020, massage assembly 1038 includes a plurality of localized pressure devices, such as massage device 1040, each of which is located in one of a plurality of zones along a central region 1030 of cushion 1028. Although massage device 1040 is positioned in central region 1030, massage device 1040 may be used in any area of ​​seat assembly 1020. Although massage devices are illustrated and described, any localized pressure device may be used, such as a tactile device, a lumbar adjustment device, a bolster adjustment device, a shoulder adjustment device, and the like.

[0459] The massage device 1040 is positioned on the rear surface 1042 of the seat cushion 1028, as shown in FIG. Figure 21 The rear surface 1042 of the seat cushion 1028 is spaced apart from the support surface 1036 and is sized to be mounted to the frame or other structural support of the seat assembly 1020. The seat cushion 1028 may also be concave on the rear surface 1042 to partially conceal and enclose the massage device 1040 and other functional or structural components of the seat assembly 1020.

[0460] For the depicted embodiment, the massage device 1040 is an inflatable air bladder 1040. To this end, the seat assembly 1020 includes a pump and valve assembly 1044 that fluidly cooperates with each air bladder 1040 to inflate and deflate the air bladder 1040. The seat assembly 1020 or vehicle includes a controller 1046 that communicates with the pump and valve 1044 to control the operation of the pump and valve 1044.

[0461] The prior art provides seat assemblies with massage assemblies. These prior art massage assemblies typically include a massage device positioned on a support surface of a seat cushion. Front-surface placement of the massage device allows for direct massage effects to the occupant. However, positioning the massage device on the support surface typically requires assembling the massage assembly through the seat cushion. For example, the massage device is pulled through an orifice in the seat cushion using pneumatic tubing or wiring extending through the cushion to the rear surface of the seat cushion for connection to a pneumatic air or power source. Positioning the massage device on the support surface increases the complexity, manufacturing time, and cost of prior art massage assemblies.

[0462] Placing the massage device 1040 on the rear surface 1042 of the seat cushion 1028 is typically avoided in the prior art. Prior art seat cushions inherently inhibit a massaging effect because actuation of the massage device compresses the seat cushion foam before providing detectable pressure to the occupant. Furthermore, the massaging effect from the rear surface of the seat cushion is typically distributed across the entire support surface of the seat cushion. Displacing the support surface of prior art seat cushions typically requires displacement of the entire support surface, resulting in a "tent" effect on the seat cushion.

[0463] To effectively provide an effective massage effect from the rear surface 1042 of the seat cushion 1028, a plurality of movable or hinged portions 1048 are formed in the seat cushion 1028. Due to weakened areas 1050 formed between the movable portions 1048 and the seat cushion 1028, the movable portions 1048 can translate relative to the remainder of the seat cushion 1028. The weakened areas 1050 partially separate the movable portions 1048 from the central region 1030, allowing for translation while maintaining their connection to the seat cushion 1028. The movable portions 1048 can be formed of a different material than the seat cushion 1028 to suit the applicable function. For example, the seat cushion 1028 can be formed of a foam such as polyurethane, while the movable portions 1048 may include compressed fibers or other materials that provide elasticity for the hinged device. The additional material in the movable portions 1048 can be insert-molded into the foam of the movable portions 1048.

[0464] Seat assembly 1020 includes a trim cover 1060 over seat cushion 1028 to conceal cushion 1028 and massage assembly 1038. According to various embodiments, a comfort layer, spacer fabric, reticulated foam, dense material, or any suitable material may be provided between trim cover 1060 and seat cushion 1028.

[0465] exist Figure 22-24 One of the movable portions 1048 is shown in more detail in FIG. Figure 23 and Figure 24 Seat cushion 1028 is shown mounted to seat frame 1058. Seat frame 1058 can be formed from stamped steel, a polymer substrate, or any suitable material. Massage device 1040 is positioned between the movable portion and seat frame 1058. Massage device 1040 can be adhered to the rear surface of movable portion 1048 via an adhesive. Seat frame 1058 provides sufficient elasticity to provide a reaction force to actuator 1040, so that the massage effect is effectively distributed to movable portion 1048 with concentrated energy and displacement.

[0466] Figure 22-24The overall shape of the movable portion 1048 is shown to be defined by a weakened area 1050. The movable portion 1048 is sized to correspond to the shape of an actuator, such as a massage bladder 1040. The weakened area 1050 includes a pair of slots 1052 formed through the seat support surface 1036. The slots 1052 collectively extend around most of the perimeter of the movable portion 1048. The slots 1052 also define a pair of tethers 1054 between the movable portion 1048 and the remainder of the seat support surface 1036 of the seat cushion 1028. The tethers 1054 are sized to connect the movable portion 1048 relative to the seat support surface 1036 for translation relative to the seat support surface 1036. Although two tethers 1054 are shown, any number and orientation of tethers 1054 may be employed.

[0467] The weakened area 1050 also includes a recess 1056 formed in the rear surface 1042 of the seat pad 1028. The recess 1056 is formed to a blind depth, such as Figure 24 1048 and the center region 1030. Recesses 1056 extend around the perimeter of the movable portion 1048 and intersect the slots 1052. According to some embodiments, a weakened area 1050 can be provided with recesses 1056 formed around the perimeter of the movable portion 1048 without the slots 1052, such that the tether 1054 extends as a web around the perimeter of the movable portion 1048. The weakened area 1050 can be formed in the seat pad 1028 by any forming operation of the seat pad 1028, such as a molding operation.

[0468] According to some embodiments, the tether 1054 can be sized to sever after initial operation of the massage device 1040. For example, the tether 1054 can be sized to maintain the position and orientation of the movable portion 1048 until the movable portion 1048 adheres to the massage device 1040. Then, after several cycles of the massage device 1040, the tether 1054 can be torn to allow tetherless translation of the movable portion 1048, thereby further improving travel performance.

[0469] like Figure 25 As shown, each movable portion 1048 is individually translatable in the fore-aft direction of vehicle seat assembly 1020. Movable portions 1048 enhance the massaging effect by effectively distributing pressure and energy from massage device 1040 to movable portions 1048 and the occupant with increased intensity compared to the prior art.

[0470] Now refer to Figure 20-25The massage assembly 1038 simplifies the massage assembly manufacturing process while minimizing the total number of components. The massage assembly 1038 also minimizes energy loss by allowing the massage points 1048 of the foam to articulate fore and aft relative to the seated occupant. The massage device 1040 and related components (such as tubing and connectors) are mounted on the rear surface 1042 of the seat cushion 1028 without being connected through the foam of the seat cushion 1028. By placing the massage device 1040 on the rear surface 1042, the massage assembly 1038 can be pre-assembled by mounting it on the frame 1058.

[0471] Figure 26 A seat pad 1062 is shown in accordance with some embodiments. The seat pad 1062 is similar to the previous embodiments. The seat pad 1062 also includes a reinforcement portion 1064 on the front surface of each movable portion 1048. The reinforcement portion 1064 can encompass the entire movable portion 1048. Depending on the displacement specifications of a particular application, the reinforcement portion 1064 can even include the tether 1054. The reinforcement portion 1064 can be formed from a stiffer foam than the rest of the seat pad 1028 to provide a firmer, and therefore harder, surface, thereby increasing the efficiency of transferring energy from the massage device 1040 to the occupant during massage actuation by mitigating the damping and dissipation of the massage effect.

[0472] The reinforcement portion 1064 can be formed from a higher density or durometer foam that is molded separately from the rest of the seat pad 1028. The reinforcement portion 1064 can be molded separately as a unitary body and then insert molded with the softer foam used for the rest of the seat pad 1028. Alternatively, the reinforcement portion 1064 and the seat pad 1028 can be molded together in a common mold in a multi-step process.

[0473] A vehicle seat assembly (e.g., 1020) is provided that includes a support member (e.g., a panel, base, or frame) to support a cushion (e.g., 1028) including a cushioning material (e.g., polyurethane foam). The support member defines a support surface (e.g., 1036) sized to support an occupant and includes a weakened area (e.g., 1050, such as a pair of slots 1052 formed through support surface 1036). The weakened portion (e.g., 1050) provides a movable portion (e.g., 1048), which may be formed of a material different from the cushioning material (e.g., movable portion 1048 is formed of compressed fibers while the cushioning material is polyurethane foam), that translates relative to the seat support surface (e.g., 1036). In various embodiments, the translation results from a localized pressure effect, such as a massaging effect, such as from pressurized bladders applied to the rear surface of the movable portion (e.g., 1048) from a localized pressure device (e.g., massage device 1040). The localized pressure device (e.g., massage device 1040) is disposed on the rear surface of the support of the cushioning material. In one or more embodiments, the rear surface (e.g., 1042) of the cushion (e.g., 1028) is spaced apart from the seat support surface (e.g., 1036).

[0474] In variations, a weakened area (e.g., 1050, such as a pair of slots 1052 formed through support surface 1036) extends around the perimeter of the movable section (e.g., 1048), such as extending around a majority of the perimeter. In various embodiments, the weakened area (e.g., 1050) is defined as a recess (e.g., 1056) formed in the support member to partially separate the movable portion (e.g., 1048) from the support surface (e.g., 1036). In some embodiments, the recess (e.g., 1056) is formed through the support member. In one or more embodiments, the recess (e.g., 1056) is formed as a blind depth, with a tether (e.g., 1054) in the weakened area (e.g., 1050). In various embodiments, the weakened area (e.g., 1050) is defined as a plurality of recesses formed in the support member to partially separate the movable portion (e.g., 1048) from the remainder of the support member.

[0475] In one or more embodiments, the support member includes at least one tether (e.g., 1054) connecting the movable portion (e.g., 1048) and the seat support surface (e.g., 1036). In one variation, the seat support surface (e.g., 1036) has a first thickness, and the tether has a second thickness that is less than the first thickness. In some embodiments, the at least one tether (e.g., 1054) is sized to tear during initial operation to allow tetherless translation of the movable portion (e.g., 1048).

[0476] In one or more embodiments, the movable portion (e.g., 1048) is reinforced relative to the seat support surface (e.g., 1036), for example, by being formed of compressed fibers rather than polyurethane foam or of a higher stiffness, higher density, or harder foam, to disperse the effects of localized pressure applied to the reinforced portion (e.g., 1064) from a localized pressure device (e.g., a massage device such as a fluid bladder, e.g., an air bladder). For example, the support member is formed with a first stiffness, and the movable portion (e.g., 1048) is formed with a second stiffness greater than the first stiffness.

[0477] A localized pressure assembly (e.g., massage assembly 1038) is provided for applying a localized pressure effect, such as a massage effect, to a seated occupant. The localized pressure assembly (e.g., massage assembly 1038) includes a localized pressure device (e.g., massage device 1040) and a support member as described herein, including a weakened area (e.g., 1050), a movable portion (e.g., 1048), a tether (e.g., 1054), and / or a reinforced portion (e.g., 1064).

[0478] In various embodiments, the localized pressure device (eg, massage device 1040) includes an inflatable bladder.

[0479] A seat assembly (e.g., 1020) is described. The seat assembly (e.g., 1020) includes a seat frame (e.g., 1058, such as a rigid material (e.g., metal, plastic, wood, or a combination thereof), a localized pressure device (e.g., massage device 1040) disposed on the seat frame (e.g., 1058), and a support member (e.g., as described herein, including weakened area 1050, movable portion 1048, tether 1054, and / or reinforcement portion 1064) mounted to the seat frame (e.g., 1058), wherein the localized pressure device (e.g., massage device 1040) is aligned with the movable portion 1048.

[0480] A support member (e.g., panel, base, or frame) including a cushion (e.g., 1028) of a cushioning material (e.g., polyurethane foam) is provided. The support member provides a seat support surface (e.g., 1036) that is sized to support an occupant with a reinforcement portion (e.g., 1064 (e.g., compressed fibers or foam having greater stiffness, hardness, and / or density)) within the seat support surface (e.g., 1036) to disperse the effects of localized pressure (e.g., a massage effect) applied to the reinforcement portion (e.g., 1064) from a localized pressure device (e.g., massage device 1040).

[0481] In one or more embodiments, the support member is formed with a first stiffness, and the reinforcing portion (eg, 1064) is formed with a second stiffness greater than the first stiffness.

[0482] A localized pressure assembly (eg, massaging assembly 1038 ) is provided that includes a localized pressure device (eg, massaging device 1040 ) and a support member as described herein.

[0483] A seat assembly is also provided that includes a seat frame (e.g., 1058 (e.g., a rigid material such as metal, plastic, wood, or a combination thereof)), a localized pressure device (e.g., a massage device 1040) disposed on the seat frame (e.g., 1058), and a support member mounted on the seat frame (e.g., 1058) as described herein, wherein the localized pressure device (e.g., the massage device 1040) is aligned with a reinforcement portion (e.g., 1064).

[0484] In one or more embodiments, a seat support member of a cushioning material (e.g., polyurethane foam) is provided. The seat support member includes a seat support surface (e.g., 1036) sized to support an occupant. The seat support surface (e.g., 1036) further includes a plurality of recesses formed through the seat support surface (e.g., 1036) and extending partially around the periphery of a movable portion (e.g., 1048 (e.g., compressed fiber or foam with higher stiffness, hardness, and / or density)). The plurality of recesses allow for translation of a localized pressure effect (e.g., a massage effect) applied to the movable portion (e.g., 1048) by a localized pressure device (e.g., massage device 1040). The support member is formed with a first stiffness, and the movable portion (e.g., 1048) is formed with a second stiffness greater than the first stiffness. In one refinement, the seat support surface (e.g., 1036) has a first thickness. In some embodiments, the seat support member of cushioning material includes at least one tether connecting the movable portion and the seat support surface, the tether having a second thickness less than the first thickness. The supporting member is formed with a first rigidity, and the movable portion is formed with a second rigidity greater than the first rigidity.

[0485] Figure 27 A seating system 1120 is shown according to some embodiments. Seating system 1120 is a vehicle seating system 1120 for a land vehicle, a boat, an aircraft, or the like. Seating system 1120 may also be a seating system 1120 for a comfort chair, an office chair, or the like. In a vehicle environment, seating system 1120 may be a front row seating system 1120 or a subsequent middle or rear row seating system 1120.

[0486] Seating system 1120 includes a seat bottom 1122 sized to support the pelvis and thighs of an occupant. Seat bottom 1122 is adapted to be mounted to the vehicle floor. A seat back 1124 extends from seat bottom 1122 in an upright orientation. Seat back 1124 is sized to receive and support the occupant's back. Seat back 1124 can be supported by seat bottom 1122 or an underlying support surface. A head restraint 1126 is also provided on seat back 1124 to support the occupant's head.

[0487] Seating system 1120 provides contact surfaces 1128, 1130 for receiving and comfortably supporting an occupant. Seating system 1120 includes at least one actuator assembly 1132 disposed within seating system 1120 within contact surfaces 1128, 1130. Although one actuator assembly 1132 is illustrated and described, any number or location of actuator assemblies 1132 may be employed. Actuator assemblies 1132 may be used to impart haptic effects to the occupant, such as vibrations for conveying a warning, vibrations for imparting a massage, pressure for imparting a pressurized massage effect, support for the occupant, and the like.

[0488] In the depicted embodiment, the actuator assembly 1132 is a fluid bladder 1132, such as an air bladder 1132. The fluid bladder 1132 is used to provide a pressurized massage effect to the occupant. The fluid bladder 1132 can also be located in the side bolsters 1134 of the seat back 1124 to provide adjustable support to the occupant.

[0489] The seating system 1120 includes a valve assembly 1136 in fluid communication with the fluid bladder 1132. A pump 1138, such as a compressor, is in fluid communication with the valve assembly 1136 to provide a source of pressurized fluid, such as compressed air, to the valve assembly 1136. Any number of pumps 1138 and motorized valves 1136 may be employed. Alternatively, multiple pumps 1138 may be employed without any motorized valves 1136.

[0490] Controller 1140 is in electrical communication with pump 1138 to operate pump 1138 to generate a source of pressurized air. Controller 1140 is also in electrical communication with valve assembly 1136 to control valve assembly 1136 and regulate the flow of pressurized air to valve assembly 1136. Valve assembly 1136 is housed within seat back 1124 or seat bottom 1122 of seating system 1120. Controller 1140 is housed within the vehicle and, according to some embodiments, within seat back 1124 or seat bottom 1122.

[0491] System 1120 also includes an interface 1142 in electrical communication with controller 1140. Interface 1142 receives a manual selection of a massage effect. Interface 1142 transmits the massage request to controller 1140. Interface 1142 may be a mechanical selector switch or multiple switches. Interface 1142 may also be another human-machine interface, such as a graphical user interface, for the occupant to select a massage effect. Interface 1142 may be integrated into seat system 1120 or located elsewhere within the vehicle. Interface 1142 may be integrated with controller 1140.

[0492] The controller 1140 is programmed so that the massage component 1132 is initially deactivated. Thus, the massage component 1132 is initially inoperable without activation. The massage component 1132 may be activated as a service, incentive, subscription, promotion, or any other marketing or retail effort. For example, the massage component 1132 hardware may be installed in the seating system 1120 but not operational until activated.

[0493] The activation code can be provided in a software application accessible by a personal digital assistant (PDA) 1144, such as a smartphone. The PDA 1144 can be any controller configured to receive the activation code and transmit the code to the controller 1140. The PDA 1144 wirelessly communicates with a receiver 1146 in the vehicle or seat system 1120, which in turn communicates with the controller 1140. For example, an occupant can install an application on the PDA 1144 that is configured with the activation code. The occupant can subscribe to a service or otherwise access the activation code, which is transmitted to the controller 1140 to activate or otherwise unlock the operation of the massage assembly 1132. The interface 42 can also be provided with the activation code in the software application in the PDA 1144.

[0494] Alternatively, the massage operation can be a vehicle kit option. For example, a manufacturer, dealer, or other retailer can activate the massage operation based on the vehicle kit purchased.

[0495] Figure 28 A massage assembly 1148 is shown, which can be installed in seating system 1120 as massage assembly 1132. Massage assembly 1148 includes a pair of lumbar bladders 1150 positioned in the lumbar region of seating surface 1130 to apply a pressurized massage effect to the occupant. A valve assembly 1152 is in fluid communication with lumbar bladders 1150 and pump 1154 to deliver pressurized air from pump 1154 through valve assembly 1152 to lumbar bladders 1150. According to some embodiments, massage assembly 1148 provides one massage effect: inflation and deflation of lumbar bladders 1150. Alternatively, massage assembly 1148 can provide multiple massage effects through additional valves or additional massage programs.

[0496] Figure 29 An example method for operating the massage assembly 1148 in the seat system 1120 is shown. At block 1156, the controller determines whether a massage is authorized, such as upon receiving an activation code from the PDA 1144. If a massage operation is not authorized, block 1156 is repeated. If a massage is authorized, block 1158 determines whether a massage operation has been requested through selection at the interface 42. If a massage effect has not been requested, block 1158 is repeated. If a massage effect is requested, the massage operation is performed at block 1160.

[0497] Figure 30 A massage assembly 1162 is shown, according to some embodiments. The massage assembly 1162 is shown mounted to a suspension 1164, which supports the massage assembly 1162 for mounting to a seat frame. The massage assembly 1162 includes a plurality of inflatable bladders, including a lumbar bladder 1166, an array of incrementally spaced bladders 1168, a cervical bladder 1170, and a pair of side bolster bladders 1172. Each of these bladders 1166, 1168, 1170, 1172 can be individually inflated to support the occupant. Each of the bladders 1166, 1168, 1170, 1172 can also be individually inflatable or grouped to provide more than one massage effect.

[0498] With various massage options, the massage assembly 1162 can provide more than one massage effect by operating various combinations and / or various patterns of airbags 1166, 1168, 1170, 1172. By providing multiple massage effects, various subscription or trim level options can be provided to the end user to obtain various authorization codes.

[0499] Figure 31 A method for operating a massage assembly that provides at least two massage effects, such as massage assembly 1162, is shown. At block 1174, the controller determines whether a first massage is authorized. If not, the determination is repeated at block 1174. Once the first massage is authorized, the controller determines whether a second massage effect is authorized at block 1176. If the second massage effect is not authorized, the controller determines whether the first massage effect is requested at block 1178. If not, block 1176 is repeated. If the first massage effect is requested at block 1178, the first massage operation is performed at block 1180. Block 1176 is then repeated.

[0500] At step 1176, if the second massage is authorized, block 1182 determines whether the first massage effect is requested. If the first massage effect is requested, the first massage operation is performed at step 1184. Next, block 1182 is repeated. If the first massage effect is not requested at block 1182, step 1186 is executed to determine whether the second massage effect is requested. If the second massage effect is requested at block 1186, the second massage operation is performed at step 1188.

[0501] In one or more embodiments, an assembly (e.g., 1132 / 1134) (e.g., including a pair of lumbar bladders 1150) is described. The assembly (e.g., 1132 / 1134) includes a massage actuator (e.g., 1148) (e.g., a fluid bladder 1150, such as, but not limited to, a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154) operable to provide a massage effect (e.g., a pressurized massage effect or a vibration massage effect) to the seat assembly, and a controller (e.g., 1140) in communication with the massage actuator (e.g., 1148) (e.g., a fluid bladder 1150, such as, but not limited to, a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154). In various embodiments, the controller (e.g., 1140) is provided as one or more controllers or control modules for various components and systems. Controller (for example, 1140) and control system 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 may include any number of microprocessors, integrated circuits, memory devices (for example, 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 may be configured to execute a computer program contained in a non-transitory computer-readable medium, which is programmed to perform any number of functions disclosed herein. In various embodiments, the controller (e.g., 1140) is programmed to receive input indicating authorization, such as an authorization code to operate massage actuators (e.g., 1148) (e.g., fluid bladders 1150 such as air bladders including but not limited to lumbar bladders, bolster bladders, and / or shoulder bladders, valve assemblies 1136 / 1152, and pumps 1138 / 1154), receive input indicating a massage request (e.g., manual selection of a massage effect such as on an interface), and output signals to operate massage actuators (e.g., 1148) (e.g., fluid bladders 1150 such as air bladders including but not limited to lumbar bladders, bolster bladders, and / or shoulder bladders, valve assemblies 1136 / 1152, and pumps 1138 / 1154) in response to the authorization (e.g., the authorization code) and the massage request (e.g., manual selection of a massage effect such as on an interface).

[0502] In one refinement, the massage actuators (e.g., 1148) (e.g., fluid bladders 1150 such as air bladders including but not limited to lumbar bladders, bolster bladders, and / or shoulder bladders, valve assemblies 1136 / 1152, and / or pumps 1138 / 1154) are operable to provide at least two massage effects (e.g., a pressure tactile effect and a vibration tactile effect) and the controller 1140 is programmed to receive instructions to operate the massage actuators (e.g., 1148) (e.g., fluid bladders 1150 such as air bladders including but not limited to lumbar bladders, bolster bladders, and / or shoulder bladders, valve assemblies 1136 / 1152, and / or pumps 1138 / 1154) to provide a first massage effect (e.g., a pressure tactile effect and a vibration tactile effect). The apparatus may receive input of an authorization (e.g., an authorization code) for a first massage effect (e.g., a pressure massage), receive input indicating a request (e.g., a manual selection on an interface) for a first massage effect (e.g., a pressure or vibration massage), and output a first massage effect signal in response to the first massage effect authorization (e.g., the authorization code) and the first massage effect request (e.g., the manual selection on the interface) to operate a massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including but not limited to a lumbar bladder, a pillow bladder, and / or a shoulder bladder, the valve assembly 1136 / 1152, and / or the pump 1138 / 1154) to provide the first massage effect (e.g., a pressure or vibration massage).

[0503] In some embodiments, the controller (e.g., 1140) is programmed to receive input indicating authorization (e.g., an authorization code) for a second massage effect to operate the massage actuators (e.g., 1148) (e.g., fluid bladders 1150 such as, but not limited to, air bladders of the lumbar bladders, bolster bladders, and / or shoulder bladders, valve assemblies 1136 / 1152, and / or pumps 1138 / 1154), receive input indicating a request (e.g., a manual selection on an interface) for a second massage effect (e.g., a pressure or vibration massage), and output a second massage effect signal in response to the second massage effect authorization (e.g., the authorization code) and the second massage effect request (e.g., the manual selection on the interface) to operate the massage actuators (e.g., 1148) (e.g., fluid bladders 1150 such as, but not limited to, air bladders of the lumbar bladders, bolster bladders, and / or shoulder bladders, valve assemblies 1136 / 1152, and / or pumps 1138 / 1154) to provide the second massage effect (e.g., a pressure or vibration massage).

[0504] In some embodiments, the massage actuator (e.g., 1148) includes at least one air bladder. In various embodiments, the massage actuator (e.g., 1148) includes a valve assembly (e.g., 1136 / 1152) in fluid communication with a pump (e.g., 1138 / 1154) and at least one air bladder assembly (e.g., 1150). In one refinement, the valve assembly (e.g., 1136 / 1152) is in electrical communication with a controller (e.g., 1140) to deliver pressurized air from the pump (e.g., 1138 / 1154) to the at least one air bladder assembly (e.g., 1150) in response to a signal from the controller (e.g., 1140).

[0505] A seat assembly (e.g., 1120) is described that includes a seat bottom (e.g., 1122), a seat back (e.g., 1124) extending upright from the seat bottom (e.g., 1122), and an assembly as described herein (e.g., 1148 / 1162) that includes a massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including but not limited to a lumbar bladder, a pillow bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154) positioned in the seat bottom (e.g., 1122) or the seat back (e.g., 1124).

[0506] The system (e.g., 1120) includes the components described herein (e.g., 1148) and an interface (e.g., 1142) that is electrically connected to a controller (e.g., 1140) to output input indicating a massage request (e.g., manual selection of a massage effect) to the controller (e.g., 1140).

[0507] In some embodiments, the system (eg, 1120 ) includes a second controller in communication with the controller to output input indicative of authorization.

[0508] A method is also provided that includes installing (i.e., step 1190) a massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including but not limited to a lumbar bladder, a pillow bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154) in a seat assembly (e.g., 1120) to provide a massage effect (e.g., a pressurized or vibratory massage) and deactivating (i.e., step 1196) the massage actuator 1148 to prevent operation of the massage actuator 1148. In various embodiments, the method further includes connecting (i.e., step 1192) the massage actuator (e.g., 1148) to a controller (e.g., 1140), the controller (e.g., 1140) being programmed to control operation of the massage actuator (e.g., 1148), programming (i.e., step 1194) the controller (e.g., 1140) to deactivate operation of the massage actuator (e.g., 1148), retailing (i.e., step 1197) an activation code for activating the massage actuator (e.g., 1148), inputting (i.e., step 1198) the activation code to activate the massage actuator (e.g., 1148 and / or activating the massage actuator, such as by retailing a software application with the activation code), inputting (i.e., step 1199) and / or inputting a massage request (e.g., manually selecting a massage effect) to the massage actuator 1148 to impart a massage effect (e.g., pressure or vibration massage) from the activated massage actuator 1148. In various embodiments, a massage actuator (e.g., 1148) is activated using a wireless device (e.g., 1144). In one refinement, the method includes activating the massage actuator (e.g., 1148) using a first activation code to perform a first massage effect. In some embodiments, the method may further include activating the massage actuator (e.g., 1148) using a second activation code to perform a second massage effect. In one or more embodiments, the method includes installing at least one air bag assembly (e.g., 1150) and at least one valve assembly (e.g., 1153) in a seat assembly (e.g., 1120).

[0509] A seat assembly (e.g., 1120) is also provided, comprising a seat bottom (e.g., 1122), a seat back (e.g., 1134) extending upright from the seat bottom (e.g., 1122), a massage assembly, and a controller (e.g., 1140) in communication with a massage actuator. The massage assembly includes a massage actuator (e.g., 1148) positioned in the seat bottom (e.g., 1122) or the seat back (e.g., 1124) operable to provide a massage effect (e.g., a pressure or vibration massage). The controller (e.g., 1140) is programmed to receive input indicating authorization to operate the massage actuator (e.g., an authorization code), receive input indicating a massage request (e.g., a manual selection of a massage effect), and output a signal to operate the massage actuator (e.g., 1148) in response to the authorization (e.g., the authorization code) and the massage request (e.g., the manual selection of a massage effect). In various embodiments, the massage actuator (e.g., 1148) is operable to provide at least two massage effects (e.g., a pressure and a vibration massage effect). In some embodiments, the controller is programmed to receive input indicating authorization (e.g., an authorization code) to operate a massage actuator (e.g., 1148) for a first massage effect (e.g., pressure or vibration massage), receive input indicating a request (e.g., manually selected massage effect) for the first massage effect (e.g., pressure or vibration massage), and in response to the first massage effect authorization (e.g., the authorization code) and the first massage effect request (e.g., manually selected massage effect), output a first massage effect signal to operate the massage actuator (e.g., 1148) to provide the first massage effect (e.g., pressure or vibration massage). The massage actuator (e.g., 1148) receives an input indicating authorization (e.g., an authorization code) for operating a massage actuator (e.g., 1148) for a second massage effect (e.g., pressure or vibration), receives an input indicating a request (e.g., manually selecting a massage effect) for the second massage effect (e.g., pressure or vibration massage effect), and in response to the second massage effect authorization (e.g., authorization code) and the second massage effect request (e.g., manually selecting a massage effect), outputs a second massage effect signal to operate the massage actuator (e.g., 1148) to provide the second massage effect (e.g., pressure or vibration massage effect).

[0510] refer to Figure 32-Figure 33, discloses a massage bladder 1200 having a circular portion 1210. In one refinement, the bladder 1200 includes a first sheet 1220 that cooperates with a second sheet 1230 to define a bladder chamber having a circular shape, which can be filled with a fluid. In one refinement, the first sheet 1220 and the second sheet 1230 can be coupled, for example, by adhesives, heat riveting and / or ultrasonic welding, hot plate welding, hot die forging, cold pressing, etc. For example, heat riveting can form a localized bond between the two sheets 1220, 1230 that forms a seal. In one refinement, the sheets 1220, 1230 can be secured by heat riveting along the perimeter of the circular portion and / or the fluid channel to form a continuous heat riveted line. When a fluid, such as airflow, passes through at a pressure above a threshold, the seal allows the channel to expand.

[0511] In variations, the chamber is a sphere, a hemisphere, a sphere, a cylinder, or an ellipsoid. In one or more embodiments, a rounded / curved shape can be molded into the first sheet 1220 and / or the second sheet 1230 so that the first sheet 1220 and / or the second sheet 1230 are not flat under ambient conditions. For example, the first sheet 120 can be flat and the second sheet 1230 has half of a rounded shape (e.g., a hemisphere) molded into it, as in Figure 32-Figure 33 The bladder 1200 also includes a fluid channel 1240 for allowing fluid to enter and exit the chamber.

[0512] Sheets 1202, 1204 are made of a material that is generally impermeable to fluids such as air. In one variation, the sheet is an organic polymer material (i.e., plastic), such as polyethylene, polypropylene, polyvinyl chloride, polyurethane, acrylic acid, polycarbonate, or a combination thereof. The sheet can be thermoplastic or thermosetting. For example, the sheet can be thermoplastic polyurethane. In a refinement, the shape and size of sheets 1202, 1204 can be any suitable size for being assembled in a seat such as a vehicle seat. In a variation, the shape and size can be suitable for providing a massage effect to the human body (such as a person's back and / or neck). In another refinement, the shape and size of the first sheet and the second sheet are substantially similar or identical. In one or more embodiments, the thickness of the plastic sheet is less than 5 mm, or more preferably less than 1 mm, or even more preferably less than 0.5 mm. In a variation, the thickness is 0.01 to 5 mm, or more preferably 0.1 to 1 mm, or even more preferably 0.2 to 0.5 mm.

[0513] In one or more embodiments, the circular portion protrudes sharply from the plane XX defined by the sheet, e.g. Figure 33As shown. In a variation, the circular portion of the sheet defines a cavity that is at least 30% circular, or more preferably at least 50%, or even more preferably at least 60% circular. For example, the circular portion defines a cavity that is at least 30% of a sphere, or more preferably at least 50% of a sphere, or even more preferably at least 60% of a sphere. In one refinement, the cavity has a hemispherical shape (i.e., 50% of a sphere).

[0514] In some other embodiments, Figure 36 As shown, capsule 1600 includes a first sheet 1620 and a second sheet 1630, each having a circular shape 1610 (e.g., a hemisphere) molded therein. In a variation, the circular shapes molded therein are aligned so that the cavity they form has a different shape than the shape molded into either sheet. The molded portions of the aligned sheets provide a cavity that is at least 60% circular, or more preferably at least 75% circular, or even more preferably at least 90% circular. For example, first sheet 1620 and second sheet 1630 each have a hemisphere molded therein that, when aligned together, define a spherical cavity. In one refinement, the radius of the hemisphere or sphere is 5 to 35 mm, or more preferably 10 to 30 mm, or even more preferably 15 to 25 mm. For example, the radius is 21.335 mm.

[0515] Flatter structures, such as traditional accordion or bellows shaped bladders, are less efficient and more expensive. These bladders are typically formed from multiple flat (unmolded) sheets. For example, Figure 34-Figure 35 The conventional bladder 1400 shown requires at least four sheets to fit together to define the chamber - which requires additional material and processing. In other words, the bladder 1200 described herein has a greater volume to surface area ratio, so it uses less material. In addition, a flatter shape has a larger contact area, so that the occupant feels or experiences less pressure, while a rounded or more pointed shape (i.e., a shape with a sharper apex) has a smaller contact area around the apex, which applies more pressure, thereby producing a greater acupressure effect or massage, such as Figures 37-42 shown.

[0516] Figures 37-42 This graph shows the body pressure distribution when maximum pressure is applied. This graph is created by placing a pressure-sensitive cushion between the occupant and the airbag assembly and measuring the pressure during airbag inflation and deflation. A group of occupants is tested to obtain pressure data, such as the average maximum applied pressure. Red areas indicate the highest pressure, and blue areas indicate the lowest pressure. Figure 37 、 Figure 39 and Figure 41 A device having a capsule as described herein (such as Figure 32-Figure 33 those depicted in the) massage components, while Figure 38 、 Figure 40 and Figure 42 A conventional accordion-style capsule (such as Figures 34-35 As shown, the conventional bladders are less focused and apply lower pressure to the occupant. Figure 37 and Figure 38 depicts the average maximum pressure exerted on the 5th percentile occupant, Figure 39 and 40 depicts the average maximum pressure exerted on the 50th percentile occupant, and Figure 41 and 42 The average maximum pressure exerted on the 95th percentile occupant is depicted.In one or more embodiments, the bladder may exert a pressure of at least 1.8 PSI, or more preferably at least 2.0 PSI, or even more preferably at least 2.5 PSI on the occupant.

[0517] Table 1 (below) provides the average maximum pressure based on body pressure distribution test data.

[0518] Table 1

[0519]

[0520] The average maximum pressure exerted on an occupant using a massage assembly having the bladders disclosed herein is significantly greater than an assembly using conventional bladders. The more concentrated bladders described herein also provide a greater massage effect with a smaller chamber volume that fills and drains more quickly. Figure 36 Similar results were obtained for the capsule depicted in .

[0521] refer to Figure 43 , discloses a method for Figure 45 Massage assembly 1500 of seat 1700 is shown. In one refinement, seat 1700 includes seat back 1702 and / or seat bottom 1704. Massage assembly 1500 is disposed in seat back 1702 and / or seat bottom 1704. In addition to massage assembly 1500, the seat includes a seat frame 1706 and cushion 1708 for supporting assembly 1500. In one refinement, seat 1700 also includes a trim cover 1710 disposed over cushion 1708. In one variation, seat 600 is a seat for a vehicle such as an automobile, motorcycle, watercraft, aircraft, and / or locomotive.

[0522] The massage assembly 1500 includes a plurality of bladders 1510 and a plurality of fluid channels 1512 as described herein, wherein the first ends of the channels terminate at the chambers of the plurality of bladders 1510. The second ends of the channels 1512 can cooperate with a flow inducing device such as a compressor or pump so that they can receive fluid from the compressor or pump. In one refinement, the second ends of the channels 1512 can cooperate with a valve assembly 1514 to coordinate the massage effect. In other words, the valve assembly can be disposed between the fluid channels and the flow inducing device. In a variation, the first sheet 1502 and the second sheet cooperate to form the plurality of bladders and / or channels. For example, in Figure 44 15, the first sheet 1502 and the second sheet 1504 cooperate to form a channel 1506, and the first sheet 1502 has a port 1508 that can be connected to the bladder. Alternatively, the first sheet can have a molded circular shape instead of the port 1508. In another variation, each bladder can be connected to a valve assembly that provides selective fluid communication between the flow inducing device and the chamber via a tube forming a fluid channel 1512, such as Figure 32-Figure 33 In variations, the plurality of capsules is 2 to 20 capsules, or more preferably 4 to 16 capsules, or even more preferably 6 to 12 capsules.

[0523] In one or more embodiments, the massage assembly 1500 is disposed on a carrier plate 1800, such as Figure 47 The carrier plate 1800 is supported by the frame 1706, for example Figure 48 Frame 1706 of seat back 1702 is shown. In one refinement, carrier plate 1800 is generally flat and rigid. For example, carrier plate 1800 is a hard plastic, such as polyethylene, polycarbonate, polyurethane, polyvinyl chloride, or a combination thereof. In a variation, carrier plate 700 has a thickness of at least 0.5 mm, or more preferably at least 2 mm, or even more preferably at least 2.5 mm. In a refinement, carrier plate 700 has a thickness of 0.5 to 20 mm, or more preferably 1 to 10 mm, or even more preferably 2 to 3.5 mm. In one or more embodiments, carrier plate 1800 includes a plurality of fasteners / retainers for securing various other components, such as flow inducing devices, valve assemblies, inflatable subassemblies, electronic devices, or a combination thereof, to carrier plate 1800. In a variation, carrier plate 1800 includes a suspension system to secure it to seat assembly 1300, such as to a frame.

[0524] In one or more embodiments, the massage assembly 1500 can be positioned in a seat such that the circular portion defines a contact area with the occupant when the occupant is seated. It should be understood that direct contact is not required to define the contact area, and one or more layers, such as a trim cover, padding, and / or foam layer, can be positioned between the occupant and the bladder. In one refinement, the contact area can encompass the apex of the circular portion. In other words, when inflated, the circular portion can protrude into the occupant.

[0525] Also disclosed is a method 1900 of making a bladder having a rounded portion, such as Figure 49 The method 1900 includes providing a first sheet and a second sheet (i.e., step 1910), forming a circular portion into the first sheet and / or the second sheet (i.e., step 1920), positioning the first sheet and the second sheet together so that they cooperate to define a chamber (i.e., step 1930), and assembling the air bag in the seat so that the apex of the circular portion can protrude into a seated occupant during operation (i.e., step 1940). For example, Figure 48 An embodiment of a mold for shaping a first sheet and / or a second sheet is depicted. The mold has a circular shape so that it is molded into the sheet applied thereto. In one refinement, the mold and / or the sheet are heated to soften the sheet and assist in shaping. For example, the sheet is heated to at least 500°F, or more preferably at least 650°F, or even more preferably at least 750°F. In a variation, the circular portions of the first and second sheets are aligned to define a chamber. In yet another refinement, the first and second sheets are adhesively bonded together, heat-riveted and / or ultrasonically welded, or otherwise fitted around the circular portion to create a seal. In some embodiments, the sheets are adhesively bonded together, heat-riveted and / or ultrasonically welded to define a fluid passage to the chamber. In other embodiments, a tube can be sealed to the bladder so that fluid can enter and exit the bladder's chamber via the tube.

[0526] A bladder (e.g., 1200 / 1600, such as a fluid bladder (e.g., a pneumatic bladder)) is provided. The bladder (e.g., 1200 / 1600) includes a first sheet (e.g., 1220 / 1620) and a second sheet (e.g., 1230 / 1630) mated together (e.g., sheets 1220 / 1620, 1230 / 1630 are heat-riveted, fused, bonded, welded, heat-welded, ultrasonically welded, hot-plate welded, hot-forged, cold-pressed, adhered with an adhesive, laser welded, glued, high-frequency welded, sewn, or chemically welded) to define a circular chamber. In some embodiments, the bladder (e.g., 1200 / 1600) further includes a fluid channel (e.g., 1240) having a terminating end at the chamber such that a fluid (e.g., water or air) is delivered to the chamber through the fluid channel (e.g., 1240). The first sheet and / or the second sheet (e.g., 1220 / 1620, 1230 / 1630) have a circular portion (e.g., 1210 / 1610) molded therein. In an improvement, the sheet (e.g., 1220 / 1620, 1230 / 1630) is formed of an elastic material. In one or more embodiments, the polymer material is a thermoplastic. For example, the sheet (e.g., 1220 / 1620, 1230 / 1630) is a fabric, plastic, polyethylene, polypropylene compound, polyethylene, polyvinyl chloride, polyurethane, acrylic, polycarbonate, felt and / or In one or more embodiments, the circular portion (e.g., 1210 / 1610) and the circular chamber are spherical (e.g., hemispherical). For example, the chamber can be a sphere or a hemisphere. In variations, the circular portion (e.g., 1210 / 1610) is a hemisphere. In various embodiments, the circular chamber is a sphere.

[0527] A seat assembly is also provided that includes a frame supporting a massage assembly that includes a bladder (eg, 1200 / 1600). For example, a subassembly for massaging an occupant may be supported by the frame.

[0528] The subassembly includes a plurality of bladders and a fluid actuator such as a pump (e.g., a compressor). Each bladder (e.g., 1200 / 1600) includes a fluid channel (e.g., 1240) leading to a circular chamber defined by a first sheet (e.g., 1220 / 1620) and a second sheet (e.g., 1230 / 1630) mating (e.g., sheets 1220 / 1620, 1230 / 1630 are heat-riveted, fused, bonded, welded, heat-welded, ultrasonically welded, hot-plate welded, hot-forged, cold-pressed, adhered by adhesive, laser-welded, glued, high-frequency welded, sewn, or chemically welded). In various embodiments, the first sheet and / or the second sheet (e.g., 1220 / 1620, 1230 / 1630) each define a molded circular portion (e.g., 1210 / 1610). The fluid actuator moves fluid through one or more fluid channels (e.g., 1240) to one or more chambers. In an improvement, the circular portion (e.g., 1210 / 1610) of each bladder (e.g., 1200 / 1600) comprises a hemisphere. In a variation, the circular chamber is spherical.

[0529] In various embodiments, at least one circular portion (e.g., 1210 / 1610) is configured to protrude into a seat occupant. In one or more embodiments, a contact area with the occupant is defined around the apex of the at least one circular portion (e.g., 1210 / 1610) such that the bladder (e.g., 1200 / 1600) applies a pressure of at least 2 PSI to the occupant and / or applies a pressure of at least 2.5 PSI to the occupant.

[0530] refer to Figure 50 , a seat assembly 2000 such as for a vehicle is provided. For example, the seat assembly 2000 is for a motorcycle, an automobile, a boat, an aircraft, or a train. In one or more embodiments, the seat assembly includes a trim cover 2002 disposed above a cushion assembly 2004 and a seat frame 2006. Figure 51-53 and Figure 5 As shown, seat assembly 2000 also includes a fluid system 2100, such as for massaging and / or adjusting the seat.

[0531] In various embodiments, the fluid system 2100 is disposed in, on, and / or adjacent to the cushion assembly 2004. In variations, the cushion assembly 2004 includes a plurality of cushions. For example, the cushion assembly 2004 includes a seat bottom and a seat back, each having a center or middle cushion that can be sandwiched between pillows. In one refinement, the fluid system 2100 is disposed in, on, and / or adjacent to one or more cushions. For example, as Figure 51-55As shown, fluid system 2100 is disposed in the seat back of cushion assembly 2004. In one refinement, the cushion of cushion assembly 2004 is foam and / or a plurality of polymer strands.

[0532] In one or more embodiments, the fluid system 2100 includes a fluid displacement device, such as a pump, blower, compressor, and / or fan. During operation, the fluid displacement device moves a fluid or causes a fluid to flow. In a variation, the fluid system 2100 includes a first plurality of fluid bladders 2102 arranged along a first direction and / or dimension and a second plurality of fluid bladders 2104 arranged along a second direction and / or dimension, for example, X1 and Y1, respectively. Figure 53 As shown. For example, the first direction and / or dimension is defined by the transverse axis and the second direction and / or dimension is defined by the longitudinal axis. In one refinement, X1 and Y1 are different, non-parallel, intersecting and / or substantially orthogonal or perpendicular (e.g., defining an angle of 15 to 165 degrees, or more preferably 45 to 135 degrees, or even more preferably 60 to 120 degrees, or still even more preferably 90 degrees). When the first plurality of bladders and the second plurality of bladders are arranged in this manner, they employ greater range and capacity for individuals of different sizes, supports, massage programs and / or configurations. In various embodiments, the bladders or each plurality of bladders includes 4 to 20 bladders, or more preferably 6 to 16 bladders, or even more preferably 8 to 12 bladders.

[0533] In yet other embodiments, the third plurality of bladders 2106 and the fourth plurality of bladders 2108 are arranged along a third direction and / or dimension (e.g., X2) and a fourth direction and / or dimension (e.g., Y2). In one refinement, X2 is parallel or substantially parallel to X1 (e.g., within 20% of parallel, or more preferably within 10% of parallel, or even more preferably within 5% of parallel). A greater number of bladders provides greater customization for the size, shape, and comfort of different occupants. In another variation, the bladders are arranged in at least a 4 x 4 grid pattern, or more preferably at least a 4 x 6 grid pattern, or even more preferably at least a 6 x 6 grid pattern, corresponding to multiple groups of bladders along different dimensions, directions, and / or axes. In one refinement, the fluid system 2100 includes at least 16 bladders, or more preferably at least 20 bladders, or even more preferably at least 24 bladders.

[0534] In some embodiments, multiple bladders, such as the first / second / third / fourth plurality of bladders 2102 / 2104 / 2106 / 2108, are disposed in specific areas of the cushion assembly and may correspond to areas of the occupant (e.g., back, lower back, upper back, mid-back, bottom, thigh, left side, right side, center portion, etc.). For example, the first plurality of bladders 2102 (or the third plurality of bladders 2106) are disposed, for example, at the lower area 2110 (or upper area 2112) of the seat back, which corresponds to the lower back (or upper back) of the occupant. In yet another example, the second plurality of bladders 2104 (or the fourth plurality of bladders 2108) are disposed on a first side or half 2114 (or second side or half 2116) of the seat assembly 2000. It should be understood that as Figure 52-53 As shown, multiple groups or bladders may be positioned in the same area (eg, lower back, upper back, left side, right side).

[0535] In one or more embodiments, the dimensions on which the plurality of bladders are disposed correspond to occupant dimensions, such as the width and / or height of the occupant (e.g., lower back dimension, shoulder dimension, neck dimension, thigh dimension, etc.). In a refinement, the dimensions are greater than the 10th percentile of the occupant dimensions, or more preferably greater than the average occupant dimensions, or even more preferably the 75th percentile or greater of the occupant dimensions, still more preferably the 85th percentile or greater of the occupant dimensions, or still more preferably the 90th percentile or greater of the occupant dimensions.

[0536] For example, the dimension corresponds to shoulder width, such that the plurality of bladders extend along a dimension corresponding to a shoulder width greater than the 10th percentile occupant, or more preferably greater than the average shoulder width of an occupant, or even more preferably the shoulder width of the 75th percentile occupant or greater, or more preferably the shoulder width of the 85th percentile occupant or greater, or more preferably the shoulder width of the 90th percentile occupant or greater.

[0537] In yet another variation, different groups of bladders in the plurality of bladders are arranged to accommodate different occupant groups. For example, a first group of bladders (e.g., the innermost row of bladders including 2108) corresponds to an occupant group having a smaller dimension than average (e.g., shoulder width), a second group of bladders (e.g., the innermost row and the second innermost row of bladders including 2108 and 2104) corresponds to a second occupant group having approximately average dimensions (e.g., shoulder width), and a third group of bladders (e.g., the rows of all bladders) corresponds to a third occupant group having a larger dimension than average (e.g., shoulder width).

[0538] In one or more embodiments, the first plurality of bladders are arranged along a dimension, direction, or axis corresponding to the width, height, or length of the seat bottom or seat back, and the second plurality of bladders are arranged along a different dimension, direction, or axis corresponding to the width, height, or length of the seat bottom or seat back.

[0539] In still other embodiments, the seat assembly 2000 includes a controller 2200 that cooperates with and communicates with the fluid system 2100, such as Figure 56 As shown. In a variation, the controller 2200 includes a memory 2202 and a processor 2204. For example, the memory 2202 stores computer executable code or instructions that are executed by the processor 2204 to perform various functions described herein. In one refinement, the controller 2200 cooperates with and communicates with the fluid displacement device 2118 and / or the valve assembly 2120 so that the fluid (e.g., air or water) displaced by the fluid displacement device 2118 (e.g., a compressor or pump) passes through the valve assembly 2120 to fill / inflate or release / drain one or more of the bladders 2122. In one or more embodiments, as Figure 58 As shown, an actuator such as valve actuator 2400 cooperates with multiple valves 2402 that open and close together. For example, actuator head 2404 opens and closes first valve 2406, second valve 2408, and third valve 2410. In various embodiments, valve actuator 2400, for example, Figure 53 The invention is used together with a fluid system such that the first valve 2406 serves the large dimension (e.g., the outside), the second valve 2408 serves the middle dimension, and the third valve 2410 serves the small dimension (e.g., the inside). Using such a valve actuator reduces costs while still providing effective customization for the occupant.

[0540] In a variation, system 2100 further includes one or more sensors 2124, such as pressure sensors, to detect the pressure associated with one or more of the bladders 2122. In one refinement, the pressure is measured directly by the pressure sensor. In other embodiments, a proxy variable is used to detect the pressure. A sensor may additionally or alternatively be located in or near each bladder to detect the pressure associated with that bladder. For example, a sensor may be located in a position configured to detect the pressure associated with a group or multiple bladders. For example, a sensor may be located in a channel (e.g., a supply channel and / or a drain channel) associated with the first plurality of bladders and each corresponding plurality of bladders. In one refinement, various bladders or groups of bladders may be filled / inflated, and fluid released through the drain channel, allowing sensors in the drain channel to determine the pressure associated with the multiple bladders or groups of bladders. In short, sensors are located within and / or adjacent to the bladders to determine the pressure associated with the corresponding bladder or group of bladders. For example, an onboard air pressure sensor, such as an air pressure sensor, may be used. In another example, a sensor measures the tension or pressure of the sheet. In yet another example, a membrane and / or button sensor may be used. In some embodiments, a combination of sensors may be used.

[0541] In one or more embodiments, controller 2200 cooperates with and communicates with one or more sensors 2124. In one refinement, controller 2200 performs a scan to determine the size and / or dimensions of the occupant. In a variation, the scan is performed by filling / inflating one or more bladders, emptying / draining one or more bladders, and detecting a (first) pressure associated with the one or more bladders. In various embodiments, the (first) pressure indicates the size or dimensions of the occupant. For example, if the occupant's dimensions exceed a threshold pressure, this indicates that the occupant is proximate to one or more bladders.

[0542] In another or the same embodiment, if a (first) pressure is greater than a (second) pressure associated with one or more other bladders, it indicates that the occupant is adjacent to one or more bladders. For example, if the first pressure associated with the inner group of bladders is 2.00 PSI when the occupant is seated, any pressure less than a threshold amount relative to the inner group of bladders may indicate that the occupant is not adjacent to that group of bladders. In other words, a pressure drop of at least 10%, or more preferably at least 25%, or even more preferably at least 50%, indicates that the occupant is not adjacent to the bladder group. For example, a second pressure associated with an outer group of bladders having a pressure greater than 1.0 PSI, or more preferably greater than 1.5 PSI, or even more preferably greater than 1.8 PSI may indicate that the occupant is adjacent to the outer group of bladders, i.e., the occupant's dimensions extend at least to that outer group of bladders. However, if the second pressure associated with the outer group of bladders is 1.8 PSI or less, or more preferably 1.5 PSI or less, or even more preferably 1.0 PSI or less, then the occupant is not adjacent to the outer group of bladders, i.e., the occupant's dimensions do not extend to the occupant's outer group of bladders. In one or more embodiments, the pressure associated with each group or bladder is detected to determine the size or dimensions of the occupant. In some embodiments, the scan works inward by first determining the pressure associated with the outer groups or bladders. The scan proceeds inward until the size or dimensions of the occupant are determined. In one refinement, the scan determines the pressure associated with a particular bladder or group (such as the innermost group) before working inward to establish a threshold pressure or reference pressure.

[0543] In the above examples, a first (inner) group and a second (outer) group are described for illustrative purposes. However, it should be understood that many groups are included in the scan, and different groups can overlap or share bladders. For example, the inner and outer groups can refer to the inner and outer rows along the back, but the scan can also include a lower group and an upper group of the back that include portions of the inner and outer groups to determine dimensions across the occupant's back in two different directions (e.g., width and height).

[0544] In various embodiments, the scan determines multiple dimensions of the occupant. For example, in at least one embodiment, the scan determines a first dimension of the occupant, such as corresponding to the occupant's shoulder width, and a second dimension, such as corresponding to the occupant's lower back width. Additionally or alternatively, the scan determines a height dimension of the occupant's back.

[0545] In one or more embodiments, controller 2200 interfaces and communicates with bladder 2122, sensor 2124, fluid displacement device 2118, valve assembly 2120, and / or a control unit 2210, such as a mobile phone, via a wired and / or wireless network 2206. For example, network 2206 includes the Internet 2208. In various embodiments, different networks, such as wired and wireless networks, are used to communicate with different components. In one refinement, control unit 2210 is used to control subcomponents, such as massage system 2100. For example, an occupant can initiate a scan from control unit 2210, turn a massage unit on or off, or select specific conditions, such as desired support and / or massage program. Additionally or alternatively, scanning can be initiated automatically once the occupant is seated and the vehicle is in motion.

[0546] In various embodiments, after determining or obtaining one or more (e.g., one, two, three, four, five, etc.) occupant dimensions, the controller 2200 uses the occupant dimensions to perform customized tasks, such as providing support and / or massage protocols. Figure 54 Given the occupant size in FIG, the system 2100 employs a massage using all 24 bladders, but may massage using only 16 bladders. Figure 55 In other words, controller 2200 employs a massage that does not utilize the outer rows of bladders (assuming the occupant dimensions do not extend beyond those bladders). In a refinement, this selectivity provides a more comfortable and customized massage. Energy is also not wasted on bladders that are not in contact with the occupant.

[0547] In yet other embodiments, the scan detects "hot spots," or one or more points where an occupant applies unusual or significant amounts of pressure. In various embodiments, the support or massage applied by controller 2200 is then directed or guided to that one or more points. For example, additional support is provided in other areas to alleviate pressure in the hot spots. In one or more embodiments, bladders are used to provide both support and a massage effect. In such embodiments, the amount of support, i.e., the pressure of the bladders, corresponds to the amount of pressure applied by the occupant on the bladder or bladder groups, as determined by the scan.

[0548] In one or more embodiments, the controller 2200 cooperates and communicates with the fluid channels 2128, 2129, the fluid displacement device 2118, the valve assembly 2120, and the one or more bladders 2122 so that the bladders can be individually filled / inflated or simulated, allowing one or more scans and different massage functions to be performed. For example, a scan may include filling various columns and rows of bladders to determine occupant dimensions, but after determining the occupant dimensions, the individual bladders may be filled to provide a massage effect, such as a massage effect, within the dimensions.

[0549] Various massage effects are known, including acupressure, Swedish massage, deep tissue massage, trigger point massage, and the like, as well as various techniques for simulating such massages. For example, acupressure massage effects are provided by filling / inflating bladders to a pressure that causes them to push into the occupant and then releasing the bladders to relieve the pressure. This can be repeated multiple times in different positions to simulate the application of pressure from a hand and / or finger to the occupant. Regardless, a massage effect refers to the application and relief of pressure by filling / inflating and releasing / draining one or more bladders. As described above, the massage effect is based on the dimensions of the occupant. For example, bladders that are outside or extend beyond the occupant's dimensions are excluded from the massage or support procedure. In other words, the pressure variations within the bladders are within the confines of the occupant's dimensions.

[0550] In various embodiments, the seat frame 2006 is any suitable material for supporting the subassemblies and the occupant. In variations, the seat frame 2006 comprises a rigid material, such as metal, plastic, wood, or a combination thereof. For example, a seat frame 2006 of steel and / or aluminum is used. The cushion assembly 2004 includes one or more cushions. In various embodiments, the trim cover 2002 is configured to be adjacent to the seated occupant, i.e., the trim cover 2002 includes an outermost layer defining an outermost surface. In variations, the trim cover 2002 is disposed over one or more subassemblies, such as Figure 51-55 In one refinement, the decorative cover 2002 comprises a fabric, textile fabric, artificial leather or leather surface. For example, the decorative cover 2002 comprises cotton, polyester, polyurethane, nylon or any other suitable material.

[0551] As described above, the system includes computer-executable code or instructions, which, in various embodiments, are stored on a non-transitory computer-readable medium on a local device or in the cloud via network 2206. The non-transitory computer-readable medium with the computer-readable instructions configured for execution by the processor provides various functions for operating the system and seat assembly 2000, such as actuating the fluid displacement device and determining the pressure associated with one or more bladders via a sensor. The pressure can be measured directly using a sensor, or a proxy parameter for determining pressure can be used. For example, force (over a known area) can be measured to determine pressure.

[0552] In one or more embodiments, the processor comprises one or more devices selected from a high-performance computing system, the high-performance computing system comprising a high-performance core, a microprocessor, a microcontroller, a digital signal processor, a microcomputer, a central processing unit, a field programmable gate array, a programmable logic device, a state machine, a logic circuit, an analog circuit, a digital circuit, or any other device that manipulates signals (analog or digital) based on computer-executable instructions residing in a memory. In a variant embodiment, the memory comprises a single memory device or multiple memory devices, including but not limited to random access memory (RAM), volatile memory, non-volatile memory, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, cache memory, or any other device capable of storing information. In a refinement, the non-volatile memory / storage device comprises one or more persistent data storage devices, such as a hard drive, an optical drive, a tape drive, a non-volatile solid-state device, cloud storage, or any other device capable of persistently storing information.

[0553] In one or more embodiments, the executable code / instructions may reside in a software module. In a refinement, the software module includes an operating system and an application program. In various embodiments, the software module is compiled or interpreted by a computer program created using various programming languages ​​and / or technologies, including but not limited to the following, alone or in combination: Java, C, C++, C#, Objective C, Fortran, Pascal, JavaScript, Python, Perl, and PL / SQL. The non-volatile memory may also include data that supports functions, features, calculations, and processes.

[0554] In some embodiments, the above system includes a computer-readable storage medium (which is non-transitory in nature), and in various refinements includes volatile or non-volatile, removable and non-removable tangible media implemented in any method or technology for storing information, such as computer-readable instructions, data structures, program modules or other data. In variants, the computer-readable storage medium also includes RAM, ROM, erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid-state memory technology, portable compact disk read-only memory (CD-ROM) or other optical storage, cassettes, magnetic tape, disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and can be read by a computer. In various embodiments, the computer-readable program instructions can be downloaded via a network to a computer, another type of programmable data processing device or another device form of computer-readable storage medium, or downloaded to an external computer or external storage device.

[0555] In one or more embodiments, computer-readable program instructions stored in a computer-readable medium may be used to direct a computer, other types of programmable data processing devices, or other equipment to operate in a specific manner so that the instructions stored in the computer-readable medium produce an article of manufacture including instructions for implementing the functions, actions, and / or operations described herein. The functions, actions, and / or operations described herein may be reordered, processed serially, and / or processed concurrently.

[0556] refer to Figure 57 , also disclosed is a method 2300 for scanning and / or applying massage. In one or more embodiments, method 2300 includes determining first pressure 410 and second pressure 420 associated with a first bladder and a second bladder, respectively, and determining a first occupant dimension based on the first pressure and / or second pressure 440. For example, a sensor detects or measures the pressure associated with the bladder. The first and second pressures are compared to each other or to a threshold pressure to determine the first occupant dimension. In one refinement, method 2300 includes determining a third pressure associated with a third bladder 430. In various embodiments, method 2300 includes determining a second occupant dimension based on the third pressure 450. In variations, the third pressure is compared to the first pressure and / or the second pressure or the threshold pressure to determine the second occupant dimension. The method also includes applying a massage or massage effect based on the first and / or second occupant dimensions. For example, the massage or massage effect utilizes bladders that extend within the occupant dimensions, but does not utilize bladders that extend beyond the occupant dimensions.

[0557] A seat massage assembly (e.g., 2000, such as in a vehicle seat, such as for a motorcycle, automobile, boat, aircraft, or train) is provided that includes a first plurality of bladders (e.g., 2102), such as fluid bladders (e.g., pneumatic bladders), arranged along a first direction X1, such as a horizontal direction (e.g., along the width of a seat back) or a vertical direction (e.g., along the height of a seat back), and a controller 2200 that cooperates with the first plurality of bladders (e.g., 2102). For example, the first plurality of bladders (e.g., 2102) may be a top row of bladders, a middle row of bladders 2106, a bottom row of bladders 2102, a left column of bladders 2104, a middle column of bladders 2108, or a right column of bladders. In some embodiments, the first plurality of bladders (e.g., 2114) may be an outer or inner row or column of bladders. In various embodiments, a controller (e.g., 2200) is configured to scan an occupant by filling one or more bladders (e.g., 2122 (e.g., each bladder individually or an outer bladder and an inner bladder, etc.) with a fluid (e.g., air or water) and determining associated pressures (e.g., such as pressure exerted by the occupant on the one or more bladders 2122 or pressure of a fluid flow (e.g., air flow) released from the one or more bladders 2122). The controller 2200 may be provided as one or more controllers or control modules for various components and systems. The controller 2200 and control system may include any number of controllers and may be integrated into a single controller or have various modules. Some or all of the controllers may be connected via a controller area network (CAN) or other system. It should be appreciated that any controller, circuit, or other electrical device disclosed herein may include any number of microcontrollers. Processors, 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 may be configured to execute a computer program contained in a non-transitory computer-readable medium, the computer program being programmed to perform any number of the functions disclosed herein. In a variation, the scan determines the size of the occupant, such as by determining occupant dimensions (e.g., shoulder width, waist width, shoulder height, back length, neck height, neck length, head height, thigh width, thigh length, etc.). In one refinement, the scan is configured to determine a first dimension of the occupant (see Figure 54-55) and optionally, a second dimension of the occupant. In one or more embodiments, the controller 2200 is configured to control the first plurality of bladders (e.g., 2114) to massage the occupant according to the first dimension (e.g., such as shoulder width, waist width, back length, shoulder height, neck length, neck height, head height, thigh width, or thigh length). In some embodiments, the scan includes filling each bladder (e.g., 2122) and determining a corresponding pressure (e.g., such as a pressure applied by the occupant on one or more bladders 2122 or a pressure of a fluid flow (e.g., air flow) released from one or more bladders 2122). In one or more embodiments, the scan includes filling a first group of bladders (e.g., lateral bladders, middle bladders, medial bladders, left bladders, right bladders, top bladders, bottom bladders, such as 2104) in a first plurality of bladders (e.g., 2114) and determining a first pressure corresponding to the first group of bladders (e.g., 2104), filling a second group of bladders (e.g., lateral bladders, middle bladders, medial bladders, left bladders, right bladders, top bladders, bottom bladders) in the first plurality of bladders that is different from the first group of bladders (e.g., 2104), and determining a second pressure corresponding to the second group (e.g., pressure applied by an occupant on one or more bladders 2122 or pressure of a fluid flow released from one or more bladders 2122). In variations, the assembly (e.g., 2000) further includes one or more sensors (e.g., 2124) corresponding to each bladder (e.g., 2122) in the first plurality of bladders (e.g., 2114) and / or one or more sensors (e.g., 2124) corresponding to different groups of bladders, such as one or more sensors disposed in a discharge path (e.g., 2128) of the first plurality of bladders to determine the pressure of the fluid (e.g., air) released from the first plurality of bladders 2114. Also disclosed is a seat assembly (e.g., 2000, such as for a vehicle) that includes a frame (e.g., 2006) (e.g., a rigid material such as metal, plastic, and / or wood) supporting the assembly (e.g., 2000).

[0558] Also provided is an assembly (e.g., seat massage assembly 2000, such as in a vehicle seat) that includes a first plurality of bladders (e.g., 2106) arranged along a first axis (e.g., X1) (e.g., horizontal, vertical, inner, outer, diagonal) and a second plurality of bladders (e.g., 2102) arranged along a second axis (e.g., X2) (e.g., horizontal, vertical, inner, outer, diagonal) different from the first axis (e.g., X1), and one or more sensors (e.g., 2124, such as pressure sensors) arranged to determine pressures associated with different groups of bladders. For example, the sensor (e.g., 2124) can be arranged in a main vent (e.g., 2129) that serves all bladders (e.g., 2122), or the sensor (e.g., 2124) can serve a vent (e.g., 2128) for each column or row of bladders. In various embodiments, the bladders (e.g., 2122) are configured to be individually filled, such as by a valve assembly (e.g., 2120), such as to scan an occupant and simultaneously, such as to provide a massage effect. A seat component, such as a seat back or seat bottom, is also provided, comprising a frame (e.g., 2006) (e.g., a rigid material such as metal, plastic, or wood) that supports the assembly. In various embodiments, a first plurality of bladders (e.g., 2106) are arranged at a first location (e.g., top, bottom, middle) along the width of the seat back, and a second plurality of bladders (e.g., 2102) are arranged at a second location (e.g., top, bottom, middle) along the width of the seat back that is different from the first location. In some embodiments, the first plurality of bladders (e.g., 2106) are arranged along the width of the seat back, and the second plurality of bladders (e.g., 2108) are arranged along the height of the seat back. In some embodiments, a first plurality of bladders (e.g., 2104) are arranged at a first portion (e.g., left, right, center) along the height of the seat back, and a second plurality of bladders (e.g., 2108) are arranged at a second location (e.g., left, right, center) along the height of the seat back that is different from the first location. In one or more embodiments, the assembly (e.g., 2000) includes a controller (e.g., 2200) that cooperates with the first plurality of bladders (e.g., 2106) to scan the occupant by filling one or more bladders (e.g., 2122) with fluid and determining an associated pressure, such as pressure applied by the occupant on the one or more bladders (e.g., 2122) or pressure of a fluid flow (e.g., air flow) released from the one or more bladders (e.g., 2122). In various embodiments, the scan is configured to determine one or more dimensions of the occupant.

[0559] A method 2300 for scanning and massaging an occupant is described. Method 2300 includes determining a first pressure associated with a first bladder (i.e., step 2310), determining a second pressure associated with a second bladder (i.e., step 2320), and determining a first occupant dimension based on the first and second pressures (i.e., step 2340). In various embodiments, the first and second pressures are determined by releasing fluid from the first and second bladders. In some embodiments, method 2300 further includes applying a massage effect to the occupant based on the first occupant dimension (i.e., step 2360). In variations, method 2300 further includes determining a third pressure associated with a third bladder (i.e., step 2330) and determining a second occupant dimension based on the third pressure and the first and / or second pressures (i.e., step 2350). In one or more embodiments, method 2300 further includes applying a massage effect based on the first and second dimensions (i.e., step 2360).

[0560] Figure 59 A seat assembly 2420 is shown according to some embodiments. The seat assembly 2420 may be a vehicle seat assembly for a land vehicle, a watercraft, an aircraft, etc. Although a vehicle seat assembly 2420 is shown and disclosed, any seat assembly 2420 may be employed, such as an office chair, a comfort chair, etc.

[0561] Seat assembly 2420 includes a seat bottom 2422 for supporting the pelvis and thighs of an occupant. Seat bottom 2422 is supported on an underlying support surface, such as a vehicle floor. A seat back 2424 extends from seat bottom 2422 in an upright position to support the occupant's back and shoulders. Seat back 2424 can be supported by seat bottom 2422 or the underlying support surface. A head restraint 2426 can also be provided on seat back 2424 to support the occupant's head.

[0562] Seat assembly 2420 provides contact surfaces 2428, 2430 for receiving and comfortably supporting an occupant. Seat assembly 2420 includes a plurality of actuators 2432, 2434 disposed within contact surfaces 2428, 2430 within seat assembly 2420. Although two actuators 2432, 2434 are shown and described, any number or location of actuators 2432, 2434 may be employed. Actuators 2432, 2434 may be used to impart haptic effects to the occupant, such as vibrations for conveying a warning, vibrations for imparting a massage, pressure for imparting a pressurized massage effect, and the like.

[0563] In the depicted embodiment, the actuators 2432 , 2434 are fluid bladders 2432 , 2434 , such as air bladders 2432 , 2434 , for applying a pressurized massaging effect to the occupant. Figure 60An actuator assembly 2436 for a seat assembly 2420 is shown, according to some embodiments. Actuator assembly 2436 is shown schematically and can be installed within seat assembly 2420. Actuator assembly 2436 includes a fluid pump 2438, such as a pneumatic pump 2438, to provide a source of pressurized air. Actuator assembly 2436 also includes a valve assembly 2440 in fluid communication with pump 2438. A first fluid line 2442 connects pump 2438 to valve assembly 2440 to deliver pressurized air from pump 2438 to valve assembly 2440.

[0564] The valve assembly 2440 includes a housing 2444 having a plurality of fluid chambers 2446, 2448. Each fluid chamber 2446, 2448 receives a valve subassembly 2450, 2452 for translation within the fluid chamber 2446, 2448. The actuator assembly 2436 also includes a controller 2454 that cooperates with the valve subassemblies 2450, 2452 to actuate each valve subassembly 2450, 2452. For example, the controller 2454 may include a plurality of solenoids to apply linear actuation to each valve subassembly when current is passed through the solenoids.

[0565] The prior art utilizes separate valve subassemblies to inflate and deflate air bags in seat assemblies. To minimize the number of valve subassemblies 2450, 2452 in valve assembly 2440, each valve subassembly 2450, 2452 is a two-way valve with three ports and two positions, referred to as a 3-2 valve. Each valve subassembly 2450, 2452 is operable to inflate and deflate one of the air bags 2432, 2434. By using two-way valves, half the number of valves is utilized, thereby reducing the cost, weight, and size of valve assembly 2440.

[0566] Each fluid chamber 2446, 2448 includes a first port 2456, 2458 at a distal end of the fluid chamber 2446, 2448 that is in fluid communication with the first fluid line 2442 to deliver pressurized air through the first port 2456, 2458 and into the fluid chamber 2446, 2448. The first valve subassembly 2450 is shown in a position actuated by the controller 2454, whereby the first valve subassembly 2450 is actuated away from the first port 2456. Each valve subassembly 2450, 2452 includes a compression spring 2460 within the respective fluid chamber 2446, 2448. Each valve subassembly 2450, 2452 also includes an inlet seal 2462 on the translatable valve body 2464. Actuation of the first valve subassembly 2450 translates the valve body 2464 away from the first port 2456, thereby compressing the spring 2460 to remove the inlet seal 2462 from the first port 2456 and allow pressurized air to pass through the first port 2456 and into the fluid chamber 2446. As shown with reference to the second valve subassembly 2452, the controller 2454 removes current from the solenoid for the second valve subassembly 2452, causing the spring 2460 to expand, thereby pressing the inlet seal 2462 against the first port 2458, thereby closing the first port 2458.

[0567] Second ports 2466, 2468 are provided in the housing 2444 into each fluid chamber 2446, 2448. Outlet fluid lines 2470, 2472 connect each of the second ports 2466, 2468 to one of the bladders 2432, 2434. In the actuated or inflated position of the first valve subassembly 2450, air enters the fluid chamber 2446 through the first port 2456, bypasses the valve body 2464, exits the second port 2466, and passes through the outlet line 2470 to inflate the bladder 2432.

[0568] Each valve subassembly 2450, 2452 includes a second seal 2474 and a third seal 2476 on the valve body 2464, spaced sequentially from the first seal 2462. The housing 2444 also includes third ports 2478, 2480 formed through the housing and into each fluid chamber 2446, 2448 to serve as exhaust ports. In the charge position of the first valve subassembly 2450, the third port 2478 is sealed and isolated between the second seal 2474 and the third seal 2476. In the discharge position of the second valve subassembly 2452, the first port 2458 is sealed to isolate the fluid chamber 2448 from pressurized air. In the discharge position, the spring 2460 extends the valve body 2464, causing the second seal 2474 and the third seal 2476 to move beyond the second port 2468. In the vent position, second port 2468 and third port 2480 are in fluid communication so that pressurized air in air bag 2434 can decompress and pass through second fluid line 2472, through second port 2468, through fluid chamber 2448, and out exhaust port 2480 to atmosphere. Compression of the seated occupant against air bag 2434 can further assist in deflation of air bag 2434.

[0569] Figure 61 A valve assembly 2482, also referred to as a control module, is shown according to some embodiments. The valve assembly 2482 includes a housing 2484 for enclosing a plurality of fluid chambers 2486. A plurality of valve subassemblies 2488 are provided, each valve subassembly 2488 being located in one of the fluid chambers 2486.

[0570] Figure 62 and Figure 63 One of the valve subassemblies 2488 is depicted removed from the housing 2444. Each valve subassembly 2488 has an elongated valve body 2490. To minimize the weight and cost of the valve body 2490, the valve body 2490 is formed from a structurally resilient yet lightweight material, such as a polymeric material, such as polypropylene. According to some embodiments, the valve body 2490 may be reinforced with fiberglass or the like. The valve body 2490 is sized to translate within the fluid chamber 2486.

[0571] Reference again Figure 61 , housing 2484 includes a primary inlet port 2492. Primary inlet port 2492 is connected to pump 2438 to receive pressurized air. Housing 2484 includes a pressure chamber 2494 in fluid communication with primary inlet port 2492. Pressure chamber 2494 provides a reservoir for pressurized air storage to a plurality of valve subassemblies 2488. A plurality of first valve ports 2496 provide fluid communication from pressure chamber 2494 to each fluid chamber 2486.

[0572] Reference again Figure 62 and Figure 63 , the valve subassembly 2488 includes a first seal 2498 and a second seal 2500 mounted to opposite and spaced apart distal ends of the valve body 2490. Referring again to Figure 61 , the valve body 2490 extends to the vent position. In the vent position, the first seals 2498 each engage one of the first ports 2496 to seal the first port 2496 and disconnect each fluid chamber 2486 from the pressure chamber 2494.

[0573] Figure 62 and Figure 63 The valve subassembly 2488 is shown to include an integral compression spring 2502. The spring 2502 extends from a distal end of the valve body 2490 adjacent the first seal 2498 and partially extends toward the other distal end. As a compression spring 2502, the spring 2502 is sinusoidal, having an alternating curvature. A beam 2504 extends from the spring 2502, generally parallel to the valve body 2490. The beam 2504 can be integrally formed with the spring 2502 and the valve body 2490. The thickness of the beam 2504 (in Figure 63 2502) is greater than the thickness of the spring 2502 to control the deformation of the spring 2502. Similarly, the valve body 2490 also has a thickness greater than the spring 2502 to limit the deformation of the spring 2502.

[0574] The beam 2504 is designed to maintain a static position as the valve body 2490 translates within the fluid chamber 2486 and the spring 2502 is compressed and expanded. The beam 2504 includes a plurality of protrusions 2506, 2508 extending outwardly from the beam 2504. Figure 61 , the lateral protrusion 2506 is received in the slot 2510 in the housing 2484 to prevent axial translation of the beam 2504. During installation of the valve subassembly 2488 into the fluid chamber 2486, the first seal 2498 contacts the first port 2496, and then the spring 2502 is partially compressed to bias the first seal 2498 to close the first port 2496. The slot 2510 can be slightly tapered so that when the protrusion 2506 is installed into the slot 2510, the beam 2504 is gradually positioned toward the first port 2496 to slightly compress and preload the spring 2502. The protrusion 2508 is Figure 62 The beam 2504 extends toward the valve body 2490 and provides an alignment spacer between the valve body 2490 and the beam 2504 to maintain alignment of the valve body 2490 with the translation path toward and away from the first port 2496 .

[0575] like Figure 62 and Figure 63As shown, a pair of conductive terminals 2512, 2514 are mounted on the distal end of the beam 2504. The conductive terminals 2512, 2514 contact terminals (not shown) in a cover (also not shown) of the housing 2484. The conductive terminals 2512, 2514 are in electrical communication with the controller 2454. A linear actuator, such as a shape memory alloy (SMA) 2516, is connected to the two terminals 2512, 2514. The SMA 2516 extends from the terminals 2512, 2514, along the beam 2504, along the spring 2502, and around the distal end of the valve body 2490 adjacent the first seal 2498.

[0576] The SMA 2516 is formed of a material that actuates in response to an electrical current being passed through the SMA 2516. For example, the SMA 2516 may be formed of a nickel-titanium alloy that contracts when an electrical current is passed through the material. When an electrical current is passed through the SMA 2516, the length of the SMA 2516 decreases, thereby compressing the spring 2502 and moving the valve body 2490 away from the first port 2496.

[0577] Figure 64 A partially broken-away valve assembly 2482 is shown with one of the valve subassemblies 2488 cut away. Figure 64 All valve bodies 2490 are shown in the deflated position. The housing 2484 includes a plurality of second ports 2518, each second port 2518 connected to one of the fluid chambers 2486 and one of the plurality of bladders 2432, 2434. The second ports 2518 are parallel to the first ports 2496. The housing 2484 also includes a plurality of third ports 2520 disposed on the distal ends of the fluid chambers 2486 to vent each fluid chamber 2486 to the outside atmosphere. The third ports 2520 are axially aligned with the first ports 2496. Figure 64 In the deflated position, air can be deflated from the bladders 2432, 2434 through the second port 2518, into the fluid chamber 2486, and out the exhaust port 2520. As described above, in the deflated position, the first seal 2498 seals the first port 2496 to prevent pressurized air from entering the fluid chamber 2486.

[0578] Now refer to Figure 65, shows a cutaway valve subassembly 2488 in the inflated position. In this figure, controller 2454 conducts current through terminals 2512, 2514 and SMA 2516. The current passing through SMA 2516 causes the length of the SMA to decrease, thereby actuating valve body 2490 and compressing spring 2502. Valve body 2490 translates within fluid chamber 2486, causing second seal 2500 to engage and seal exhaust port 2520. In this inflated position, movement of valve body 2490 removes first seal 2498 from first port 2496. In this position, pressurized air enters first port 2496 from pressure chamber 2494, passes through fluid chamber 2486, and exits second port 2518 to one of bladders 2432, 2434, inflating bladder 2432, 2434.

[0579] Once the controller 2454 interrupts the current to the SMA 2516, the SMA 2516 extends, allowing the spring 2502 to expand. The expansion of the spring 2502 presses against the beam 2504 and the valve body 2490 to translate the valve body back to the Figure 64 In the absence of a signal to SMA 2516, airbags 2432 and 2434 are deflated. This situation is often referred to as constant deflation.

[0580] Figure 66 The assembled valve subassembly 2488 is shown. Figure 67 The valve subassembly 2488 is shown during an assembly step. Figure 67 , terminals 2512 , 2514 slide onto beam 2504 . Figure 68 Shown are the conductive components 2512, 2514, 2516 of the valve subassembly 2488. The SMA 2516 includes an intermediate ring 2522 spaced apart from the terminals 2512, 2514.

[0581] Figure 69 The assembly steps for attaching the SMA 2516 to the valve body 2490 are shown. Figure 67 When the intermediate ring 2522 of the SMA 2516 slides onto the beam 2504, it slides over the distal end of the valve body 2490. The valve body 2490 includes an inclined retainer 2524 and a retaining slot 2526 so that the ring 2522 slides over the retainer 2524 and into the slot 2526 to retain the SMA 2516 on the distal end of the valve body 2490.

[0582] Valve subassembly 2488 operates to inflate and deflate bladders 2432, 2434, thereby reducing the number of valves. Integrated spring 2502 further reduces component count. Only one signal is required to operate each valve subassembly 2488, simplifying controller 2454 programming and cost. Translating valve body 2490 also eliminates prior art flexible hinges, which typically require tighter and more expensive manufacturing tolerances.

[0583] An assembly (e.g., seat assembly 2420, actuator assembly 2436, valve assemblies 2440, 2482, valve subassemblies 2450, 2452, 2488) is described having a valve body (e.g., valve body 2464, 2490) sized to translate within a fluid chamber (e.g., fluid chamber 2446, 2448). The valve body can be elongated and formed from a lightweight and resilient material, such as a polymeric material such as polypropylene, reinforced with fiberglass, or formed from an aluminum alloy. The valve body can include a beam extending from the valve body and generally parallel to the valve body. The beam can be integrally formed with the spring. The beam can have a first thickness. The beam can include a plurality of transverse protrusions extending outward from the beam and received in a slot in the housing to prevent axial translation of the beam. The slot can be slightly tapered such that, when the protrusions are installed in the slot, the beam can gradually position toward the first port to slightly compress and preload the spring. The protrusion may extend toward the valve body and provide an alignment spacer between the valve body and the beam to maintain the valve body aligned with the translation path toward and away from the first port. The valve body may include a valve stem and a valve end. The valve body may seal against the inner surface of the bore at three axial locations. The fluid chamber may have a housing having a first port formed therein, a second port parallel to the first port, and a third port for venting to the outside atmosphere, the third port axially aligned with the first port and in fluid communication with the fluid chamber. The valve body may be positioned within the fluid chamber for translation to a fill position, whereby fluid from a pressurized fluid source enters the first port, passes through the fluid chamber, and exits the second port to inflate a fluid bladder (such as a lumbar bladder, a pillow bladder, or a shoulder bladder), while the third port is sealed from the fluid chamber, and the valve body may translate to a discharge position, whereby fluid from the fluid bladder enters the second port, passes through the fluid chamber, and exits the third port to discharge the fluid bladder, while the first port is sealed from the fluid chamber. The housing can be formed of a lightweight and structurally resilient material (such as a polymer material or a lightweight metal alloy) with gaskets, covers, fasteners, laser welds, friction welds, and / or adhesives. A pair of opposing seals (e.g., seals 2462, 2474, 2476, 2498, 2500) are positioned on the valve body (e.g., valve bodies 2464, 2490) to seal a pair of ports (e.g., ports 2456, 2458, 2466, 2468, 2478, 2480, 2492, 2496, 2518, 2520). The seals can be elastomeric and spaced apart and positioned on the distal end of the elongated valve body. A linear actuator (e.g., solenoid, shape memory alloy 2516) is mounted on the valve body (e.g., valve body 2464, 2490) to actuate the valve body (e.g., valve body 2464, 2490). The linear actuator may be a shape memory alloy having electrical terminals mounted on the distal end of the beam in electrical communication with the shape memory alloy.The shape memory alloy can extend from the terminal, along the beam, along the spring, and around the distal end of the valve body adjacent the first seal. The shape memory alloy can be formed from a material that actuates in response to an electrical current, such as a nickel-titanium alloy that contracts when an electrical current is passed through the material. The linear actuator can translate the valve body in response to the electrical current being conducted through the shape memory alloy, causing the length of the SMA to shorten, thereby compressing the spring and moving the valve body away from the first port.

[0584] In some embodiments, the linear actuator (e.g., solenoid, shape memory alloy 2516) further comprises a shape memory alloy (e.g., shape memory alloy 2516) to translate the valve body (e.g., valve body 2464, 2490) in response to an electrical current conducted through the shape memory alloy (e.g., shape memory alloy 2516). The shape memory alloy can be provided with an electrical terminal mounted on a distal end of the beam in electrical communication with the shape memory alloy. The shape memory alloy can extend from the terminal, along the beam, along the spring, and around the distal end of the valve body adjacent the first seal. The shape memory alloy can be formed of a material that actuates in response to an electrical current (e.g., nickel-titanium alloy), contracting when an electrical current is passed through the material, causing the length of the SMA to shorten, thereby compressing the spring and moving the valve body away from the first port.

[0585] In some embodiments, the valve body (e.g., valve bodies 2464, 2490) is elongated and each of a pair of opposing seals (e.g., seals 2462, 2474, 2476, 2498, 2500) is spaced apart and positioned at the distal end of the elongated valve body (e.g., valve bodies 2464, 2490).

[0586] In some embodiments, a housing (e.g., housing 2444, 2484) is provided with a fluid chamber (e.g., fluid chambers 2446, 2448) in which a first port (e.g., first port 2456, 2458, 2496), a second port (e.g., second port 2466, 2468, 2518), and a third port (e.g., third port 2478, 2480, 2520) are formed that are fluidically connected to the fluid chamber (e.g., fluid chamber 2446, 2448). The housing can be formed of a lightweight and structurally resilient material (such as a polymer material or a lightweight metal alloy) with a gasket, a cover, fasteners, laser welds, friction welds, and / or adhesives. The second port can be parallel to the first port. The third port can be axially aligned with the first port. The fluid chamber can be vented to the outside atmosphere. A valve body (eg, valve body 2464, 2490) is positioned within a fluid chamber (eg, fluid chamber 2446, 2448) for translation relative thereto.

[0587] In some embodiments, a valve body (e.g., valve bodies 2464, 2490) can translate to an inflate position, whereby fluid from a pressurized fluid source (e.g., pump 2438) enters a first port (e.g., first ports 2456, 2458, 2496), passes through a fluid chamber (e.g., fluid chambers 2446, 2448), and exits a second port (e.g., second ports 2466, 2468, 2518) to inflate a fluid bladder (e.g., fluid bladders 2432, 2434), while a third port (e.g., third ports 2478, 2480, 2520) is sealed from the fluid chamber (e.g., fluid chambers 2446, 2448). Fluid bladders, such as air bladders, such as lumbar bladders, pillow bladders, and / or shoulder bladders, can apply haptic effects to the occupant, such as vibration for conveying a warning, vibration for applying a massage, or pressure for applying a pressurized massage effect. The valve body (e.g., valve body 2464, 2490) can be translated to a discharge position, whereby fluid passes from the fluid bladder (e.g., fluid bladder 2432, 2434) into the second port (e.g., second ports 2466, 2468, 2518), through the fluid chamber (e.g., fluid chamber 2446, 2448) and out the third port (e.g., third ports 2478, 2480, 2520) to discharge the fluid bladder (e.g., fluid bladder 2432, 2434) while the first port (e.g., first port 2456, 2458, 2496) is sealed to the fluid chamber (e.g., fluid chamber 2446, 2448).

[0588] In some embodiments, actuators (e.g., fluid bladders 2432, 2434) are connected to second ports (e.g., second ports 2466, 2468, 2518). Actuators, such as fluid bladders, air bladders, lumbar bladders, pillow bladders, and / or shoulder bladders, can apply haptic effects to the occupant, such as vibrations for conveying a warning, vibrations for applying a massage, or pressure for applying a pressurized massage effect.

[0589] In some embodiments, a housing (e.g., housing 2444, 2484) has a plurality of fluid chambers (e.g., fluid chambers 2446, 2448) formed therein, each fluid chamber having a first port (e.g., first ports 2456, 2458, 2496), a second port (e.g., second ports 2466, 2468, 2518), and a third port (e.g., third ports 2478, 2480, 2520). The housing can be formed of a lightweight and structurally resilient material (such as a polymer material or a lightweight metal alloy) with gaskets, covers, fasteners, laser welds, friction welds, and / or adhesives. The second port can be parallel to the first port. The third port can be axially aligned with the first port. The fluid chambers can be vented to the outside atmosphere. A plurality of valve assemblies are provided (e.g., valve assemblies 2440, 2482, valve subassemblies 2450, 2452, 2488). The valve body (e.g., valve body 2464, 2490) of each valve assembly (e.g., valve assembly 2440, 2482, valve subassembly 2450, 2452, 2488) is oriented for translation within one of a plurality of fluid chambers (e.g., fluid chambers 2446, 2448).

[0590] An assembly (e.g., seat assembly 2420, actuator assembly 2436, valve assembly 2440, 2482, valve subassemblies 2450, 2452, 2488) having a valve body (e.g., valve body 2464, 2490) formed from a polymer material is described. The valve body can be elongated and can be formed from a lightweight and resilient material (e.g., polypropylene), can be reinforced with fiberglass, or can be formed from an aluminum alloy. The valve body can include a beam extending from the valve body and generally parallel to the valve body. The beam can be integrally formed with the spring. The beam can have a first thickness. The beam can include a plurality of transverse protrusions extending outward from the beam and received in a slot in the housing to prevent axial translation of the beam. The slot can be slightly tapered so that when the protrusions are installed in the slot, the beam can be gradually positioned toward the first port to slightly compress and preload the spring. The protrusions can extend toward the valve body and provide alignment spacers between the valve body and the beam to maintain alignment of the valve body with the translation path toward and away from the first port. The valve body can include a valve stem and a valve tip. The valve body can seal against the inner surface of the bore at three axial positions. The valve body (e.g., valve bodies 2464, 2490) is sized to translate within a fluid chamber (e.g., fluid chambers 2446, 2448). The fluid chamber can have a housing having a first port formed therein, a second port parallel to the first port, and a third port for venting to the outside atmosphere, the third port axially aligned with the first port and in fluid communication with the fluid chamber. The valve body can be positioned within the fluid chamber for translation to a fill position, whereby fluid from a pressurized fluid source enters the first port, passes through the fluid chamber, and exits the second port to inflate a fluid bladder (e.g., a lumbar bladder, a pillow bladder, or a shoulder bladder) while the third port is sealed from the fluid chamber, and the valve body can translate to a discharge position, whereby fluid from the fluid bladder enters the second port, passes through the fluid chamber, and exits the third port to discharge the fluid bladder while the first port is sealed from the fluid chamber. The housing can be formed of a lightweight and structurally resilient material (such as a polymer material or a lightweight metal alloy) with gaskets, covers, fasteners, laser welds, friction welds, and / or adhesives. A spring (e.g., spring 2460, 2502) is integrally formed with the valve body (e.g., valve body 2464, 2490) and extends from the valve body (e.g., valve body 2464, 2490) to bias the valve body (e.g., valve body 2464, 2490) in one direction. The spring can be a compression spring. The spring can be a sinusoidal curve with alternating curvature. The spring can have a second thickness that is reduced relative to the first thickness to limit deformation of the spring. A linear actuator (e.g., solenoid, shape memory alloy 2516) is mounted on the valve body (e.g., valve body 2464, 2490) to actuate the valve body (e.g., valve body 2464, 2490) to actuate the valve body (e.g., valve body 2464, 2490) and compress the spring (e.g., spring 2460, 2502).The linear actuator can be a shape memory alloy having an electrical terminal mounted on a distal end of a beam in electrical communication with the shape memory alloy. The shape memory alloy can extend from the terminal, along the beam, along the spring, and around the distal end of the valve body adjacent the first seal. The shape memory alloy can be formed from a material that actuates in response to an electrical current, such as a nickel-titanium alloy that contracts when an electrical current passes through the material. The linear actuator can translate the valve body in response to the electrical current conducted through the shape memory alloy, causing the length of the SMA to shorten, thereby compressing the spring and moving the valve body away from the first port. The linear actuator can translate the valve body in response to the electrical current conducted through the shape memory alloy, causing the length of the SMA to shorten, thereby compressing the spring and moving the valve body away from the first port.

[0591] In some embodiments, the linear actuator (e.g., solenoid, shape memory alloy 2516) further comprises a shape memory alloy (e.g., shape memory alloy 2516) to translate the valve body (e.g., valve body 2464, 2490) in response to an electrical current conducted through the shape memory alloy (e.g., shape memory alloy 2516). The shape memory alloy can be provided with an electrical terminal mounted on a distal end of the beam in electrical communication with the shape memory alloy. The shape memory alloy can extend from the terminal, along the beam, along the spring, and around the distal end of the valve body adjacent the first seal. The shape memory alloy can be formed of a material that is actuated in response to an electrical current, such as nickel-titanium alloy, which contracts when an electrical current is passed through the material, causing the length of the SMA to shorten, thereby compressing the spring and moving the valve body away from the first port.

[0592] In some embodiments, a beam (e.g., beam 2504) extends from a valve body (e.g., valve bodies 2464, 2490). The beam can be substantially parallel to the valve body. The beam can be integrally formed with the spring. The beam can have a first thickness. The beam can include a plurality of transverse protrusions extending outward from the beam and received in slots in the housing to prevent axial translation of the beam. The slots can be slightly tapered such that when the protrusions are installed in the slots, the beam gradually positions toward the first port to slightly compress and preload the spring. The protrusions can extend toward the valve body and provide alignment spacers between the valve body and the beam to maintain alignment of the valve body with the translation path toward and away from the first port.

[0593] In some embodiments, a beam (e.g., beam 2504) has a first thickness, and a spring (e.g., springs 2460, 2502) has a second thickness that is reduced relative to the first thickness. The reduced thickness can limit deformation of the spring.

[0594] In some embodiments, the spring (eg, springs 2460, 2502) further comprises a compression spring. The spring may be a sinusoidal curve having alternating curvatures.

[0595] In some embodiments, electrical terminals (e.g., terminals 2512, 2514) are mounted on a beam (e.g., beam 2504) in electrical communication with a shape memory alloy (e.g., shape memory alloy 2516). The shape memory alloy can extend from the terminals, along the beam, along the spring, and around the distal end of the valve body adjacent to the first seal. The shape memory alloy can be formed from a material that actuates in response to an electrical current, such as a nickel-titanium alloy that contracts when an electrical current passes through the material.

[0596] In some embodiments, a housing (e.g., housing 2444, 2484) is provided with a fluid chamber (e.g., fluid chambers 2446, 2448) in which a first port (e.g., first port 2456, 2458, 2496), a second port (e.g., second port 2466, 2468, 2518), and a third port (e.g., third port 2478, 2480, 2520) are formed that are fluidically connected to the fluid chamber (e.g., fluid chamber 2446, 2448). The housing can be formed of a lightweight and structurally resilient material (such as a polymer material or a lightweight metal alloy) with a gasket, a cover, fasteners, laser welds, friction welds, and / or adhesives. The second port can be parallel to the first port. The third port can be axially aligned with the first port. The fluid chamber can be vented to the outside atmosphere. A valve body (eg, valve body 2464, 2490) is positioned within a fluid chamber (eg, fluid chamber 2446, 2448) for translation relative thereto.

[0597] In some embodiments, a valve body (e.g., valve bodies 2464, 2490) can translate to an inflate position, whereby fluid from a pressurized fluid source (e.g., pump 2438) enters a first port (e.g., first ports 2456, 2458, 2496), passes through a fluid chamber (e.g., fluid chambers 2446, 2448), and exits a second port (e.g., second ports 2466, 2468, 2518) to inflate a fluid bladder (e.g., fluid bladders 2432, 2434), while a third port (e.g., third ports 2478, 2480, 2520) is sealed from the fluid chamber (e.g., fluid chambers 2446, 2448). Fluid bladders, such as air bladders, such as lumbar bladders, pillow bladders, and / or shoulder bladders, can apply haptic effects to the occupant, such as vibration for conveying a warning, vibration for applying a massage, or pressure for applying a pressurized massage effect. The valve body (e.g., valve body 2464, 2490) can be translated to a discharge position, whereby fluid passes from the fluid bladder (e.g., fluid bladder 2432, 2434) into the second port (e.g., second ports 2466, 2468, 2518), through the fluid chamber (e.g., fluid chamber 2446, 2448) and out the third port (e.g., third ports 2478, 2480, 2520) to discharge the fluid bladder (e.g., fluid bladder 2432, 2434) while the first port (e.g., first port 2456, 2458, 2496) is sealed to the fluid chamber (e.g., fluid chamber 2446, 2448).

[0598] In some embodiments, actuators (e.g., fluid bladders 2432, 2434) are connected to the second ports (e.g., second ports 2466, 2468, 2518). Actuators, such as fluid bladders, air bladders, lumbar bladders, pillow bladders, and / or shoulder bladders, can apply haptic effects to the occupant, such as vibrations for conveying a warning, vibrations for applying a massage, or pressure for applying a pressurized massage effect. A pressurized fluid source (e.g., pump 2438) is connected to the first ports (e.g., first ports 2456, 2458, 2496).

[0599] In some embodiments, a housing (e.g., housing 2444, 2484) has a plurality of fluid chambers (e.g., fluid chambers 2446, 2448) formed therein, each fluid chamber having a first port (e.g., first ports 2456, 2458, 2496), a second port (e.g., second ports 2466, 2468, 2518), and a third port (e.g., third ports 2478, 2480, 2520). The housing can be formed of a lightweight and structurally resilient material (such as a polymer material or a lightweight metal alloy) with gaskets, covers, fasteners, laser welds, friction welds, and / or adhesives. The second port can be parallel to the first port. The third port can be axially aligned with the first port. The fluid chambers can be vented to the outside atmosphere. A plurality of valve assemblies are provided (e.g., valve assemblies 2440, 2482, valve subassemblies 2450, 2452, 2488). The valve body (e.g., valve body 2464, 2490) of each valve assembly (e.g., valve assembly 2440, 2482, valve subassembly 2450, 2452, 2488) is oriented for translation within one of a plurality of fluid chambers (e.g., fluid chambers 2446, 2448).

[0600] An assembly (e.g., seat assembly 2420, actuator assembly 2436, valve assembly 2440, 2482, valve subassembly 2450, 2452, 2488) is described having a housing (e.g., housing 2444, 2484) that defines a fluid chamber (e.g., fluid chamber 2446, 2448) with a first port (e.g., first port 2456, 2458, 2496), a second port (e.g., second port 2466, 2468, 2518), and a third port (e.g., third port 2478, 2480, 2520) formed therein for fluid communication with the fluid chamber (e.g., fluid chamber 2446, 2448). The housing can be formed of a lightweight and structurally resilient material (e.g., a polymer material or a lightweight metal alloy) with a gasket, a cover, fasteners, laser welds, friction welds, and / or adhesives. The second port can be parallel to the first port. The third port can be axially aligned with the first port. The fluid chamber can be vented to the outside atmosphere. The first port (e.g., first ports 2456, 2458, 2496) or the third port (e.g., third ports 2478, 2480, 2520) is formed at the distal end of the fluid chamber (e.g., fluid chambers 2446, 2448). The valve (e.g., valve body 2464, 2490) is positioned in the fluid chamber (e.g., fluid chamber 2446, 2448) to translate to: a fill position, whereby fluid from a pressurized fluid source (e.g., pump 2438) enters the first port (e.g., first port 2456, 2458, 2496), passes through the fluid chamber (e.g., fluid chamber 2446, 2448) and exits the second port (e.g., second port 2466, 2468, 2518) to fill the fluid bladder (e.g., fluid bladder 2432, 2434), while the third port (e.g., third port 2478, 2480, 2520) is sealed to the fluid chamber (e.g., fluid chamber 2446, 2448). Fluid bladders, such as air bladders, such as lumbar bladders, pillow bladders, and / or shoulder bladders, can apply tactile effects to the occupant, such as vibration for conveying a warning, vibration for applying a massage, or pressure for applying a pressurized massage effect. The valve (e.g., valve body 2464, 2490) can also translate to a discharge position, whereby fluid from the fluid bladder (e.g., fluid bladder 2432, 2434) enters the second port (e.g., second ports 2466, 2468, 2518), passes through the fluid chamber (e.g., fluid chamber 2446, 2448), and exits the third port (e.g., third ports 2478, 2480, 2520) to discharge the fluid bladder (e.g., fluid bladder 2432, 2434), while the first port (e.g., first port 2456, 2458, 2496) is sealed from the fluid chamber (e.g., fluid chamber 2446, 2448).The valve body can be elongated and can be formed from a lightweight and resilient material (e.g., a polymer material such as polypropylene), can be reinforced with fiberglass, or can be formed from an aluminum alloy. The valve body can include a beam extending from the valve body and generally parallel to the valve body. The beam can be integrally formed with the spring. The beam can have a first thickness. The beam can include a plurality of transverse protrusions extending outward from the beam and received in a slot in the housing to prevent axial translation of the beam, the slot can be slightly tapered so that when the protrusions are installed in the slot, the beam can be gradually positioned toward the first port to slightly compress and preload the spring. The protrusions can extend toward the valve body and provide alignment spacers between the valve body and the beam to maintain alignment of the valve body with the translation path toward and away from the first port. The valve body can include a valve stem and a valve end. The valve body can seal against the inner surface of the bore at three axial locations.

[0601] Figure 70 A seating system 2620 is shown according to some embodiments. Seating system 2620 is a vehicle seating system 2620 for a land vehicle, a boat, an aircraft, or the like. Seating system 2620 may also be a seating system 2620 for a comfort chair, an office chair, or the like. In a vehicle environment, seating system 2620 may be a front row seating system 2620 or a subsequent middle or rear row seating system 2620.

[0602] Seating system 2620 includes a seat bottom 2622 sized to support the pelvis and thighs of an occupant. Seat bottom 2622 is adapted to be mounted to the vehicle floor. A seat back 2624 extends from seat bottom 2622 in an upright orientation. Seat back 2624 is sized to receive and support the occupant's back. Seat back 2624 can be supported by seat bottom 2622 or an underlying support surface. A head restraint 2626 is also provided on seat back 2624 to support the occupant's head.

[0603] Seating system 2620 provides contact surfaces 2628, 2630 for receiving and comfortably supporting an occupant. Seating system 2620 includes a plurality of actuators 2632, 2634 disposed within contact surfaces 2628, 2630 within seating system 2620. Although an arrangement of actuators 2632, 2634 is shown and described, any number or location of actuators 2632, 2634 may be employed. Actuators 2632, 2634 may be used to impart haptic effects to the occupant, such as vibrations for conveying an alert, vibrations for imparting a massage, pressure for imparting a pressurized massage effect, support for the occupant, and the like.

[0604] In the depicted embodiment, the actuators 2632, 2634 are fluid bladders 2632, 2634, such as air bladders 2632, 2634. The fluid bladders 2632 are used to apply a pressurized massage effect to the occupant. The fluid bladders 2634 are located in the side bolsters of the seat back 2624 to provide adjustable support to the occupant.

[0605] Seating system 2620 includes a gate valve assembly 2636 in fluid communication with fluid bladders 2632, 2634. Gate valve assembly 2636 is in fluid communication with a fill valve assembly 2638 and a logic valve assembly 2640. A pump 2642, such as a compressor, is in fluid communication with fill valve assembly 2638 and logic valve assembly 2640 to provide a source of pressurized fluid, such as compressed air, to fill valve assembly 2638 and logic valve assembly 2640. Any number of pumps 2642 and motorized valves 2638, 2640 may be employed. Alternatively, multiple pumps 2642 may be employed without any motorized valves 2638, 2640.

[0606] Controller 2644 is electrically connected to pump 2642 to operate pump 2642 to generate a source of pressurized air. Controller 2644 is also electrically connected to fill valve assembly 2638 and logic valve assembly 2640 to control fill valve assembly 2638 and logic valve assembly 2640 to regulate the flow of pressurized air to gate valve assembly 2636. Valve assemblies 2636, 2638, and 2640 are housed within seat back 2624 or seat bottom 2622 of seating system 2620. Controller 2644 is housed within the vehicle and, in some embodiments, within seat back 2624 or seat bottom 2622. Fill valve assembly 2638 and logic valve assembly 2640 can be manufactured as a single unit. In this case, controller 2644 can be preassembled and integrated into the single unit. If the fill valve assembly 2638 and the logic valve assembly 2640 are manufactured as two separate units, the controller 2644 may also be separated into two units, with each respective unit attached to a respective valve assembly 2638 , 2640 .

[0607] exist Figure 71 26. The gate valve assembly 2636 is shown in greater detail in FIG. The gate valve assembly 2636 includes a matrix of gate valve subassemblies 2646. Each gate valve subassembly 2646 is used to charge one of the fluid actuators 2632, 2634. The gate valve assembly 2636 utilizes a matrix or linear array of two by three gate valve subassemblies 2646. Although a two by three matrix is ​​illustrated and described, any arrangement and number of gate valve subassemblies 2646 may be utilized, such as two by three, one by four, four by four, six by nine, and the like.

[0608] The gate valve assembly 2636 utilizes gate valve subassemblies 2646 and pneumatic logic to charge and discharge a large number of fluid actuators while minimizing the number of electrically controlled valves 2638 and 2640. Electrically controlled valves 2638 and 2640 are typically expensive, bulky, and occupy volume within the seating system 2620. In contrast, the gate valve subassembly 2646 is mechanically controlled, less expensive, compact, and lighter. In the depicted example, five electrically operated valves are used to operate a two-by-three matrix of six gate valve subassemblies 2646 for actuating six fluid actuators 2632 and 2634, eliminating one electrically operated valve assembly. According to another example, nine electrically operated valves can be used in a three-by-six matrix of gate valve subassemblies 2646 for actuating eighteen fluid actuators 2632 and 2634, eliminating nine electrically operated valves.

[0609] The gate valve assembly 2636 includes a housing 2648. The housing 2648 is formed of a lightweight and structurally resilient material, such as a polymer material or a lightweight metal alloy. The housing 2648 includes a matrix of fluid chambers 2650, each of which contains a gate valve subassembly 2646. Figure 71 and Figure 72 , a pair of covers 2652, 2654 (shown in phantom) are attached to the housing 2648. Gaskets 2656, 2658 are disposed between the covers 2652, 2654 and the housing 2648. Fasteners 2660 attach the covers 2652, 2654 and the gaskets 2656, 2658 to the housing 2648. According to some embodiments, the covers 2652, 2654 can be laser welded, friction welded, glued, or otherwise attached directly to the housing 2648 to omit the gaskets 2656, 2658 and fasteners 2660.

[0610] Reference again Figure 71 , the matrix 2636 of gate valve subassemblies 2646 includes two subsets 2662, 2664 of gate valve subassemblies 2646, which are positioned in rows 2662, 2664 in the figure. The first row 2662 of gate valve subassemblies 2646 is configured to operate the fluid actuators 2634 under a constant filling condition, as will be explained in further detail below. The constant filling condition is used for bladders 2634 that maintain pressure, such as waist bladders, pillow bladders, shoulder bladders, etc. The second row 2664 of gate valve subassemblies 2646 is configured to operate the fluid actuators 2632 under a constant discharge condition, which will also be explained in further detail below. The constant discharge condition is used for bladders 2632 that fill and discharge quickly, such as massage bladders 2632.

[0611] Housing 2648 includes a plurality of filling connectors 2666, each providing filling pressure access to a subset or column 2668, 2670, 2672 of gate valve subassemblies 2646, each gate valve subassembly 2646 including one gate valve subassembly 2646 from a row 2662, 2664. Each of the three filling connectors 2666 is connected to a pressure chamber reservoir or bus 2674. Bus 2674 extends along the length of each column 2668, 2670, 2672 for fluid communication with each fluid chamber 2650 in the corresponding column 2668, 2670, 2672. Bus 2674 is also enclosed and sealed by cap 2652 and gasket 2656. Connector 2666 has a barb for connecting to a hose for receiving pressurized air from fill valve assembly 2638.

[0612] The housing 2648 also includes a plurality of control connectors 2676, each of which provides a control pressure inlet to one of the rows 2662, 2664 of the gate valve subassemblies 2646. Each of the two control connectors 2676 is connected to a bus 2678, such as Figure 72 A bus bar 2678 extends along the length of each row 2662, 2664 for fluid communication with each fluid chamber 2650 within the corresponding row 2662, 2664. The bus bar 2678 is enclosed and sealed by a cover 2654 and a gasket 2658. A control connector 2676 receives pressurized air from the logic valve assembly 2640.

[0613] Figure 71 and Figure 72 The housing 2648 is shown to include a plurality of port connectors 2680, each of which is fluidly connected to one of the fluid chambers 2650. Each port connector 2680 is also in fluid communication with one of the fluid actuators 2632, 2634 to deliver pressurized fluid from the fluid chamber 2650 to the fluid actuator 2632, 2634 to charge the fluid actuator 2632, 2634.

[0614] Reference again Figure 70 During operation of the gate valve subassembly 2646 of row 2662, the controller 2644 operates the pump 2642 to provide a source of pressurized air. The controller 2644 also operates the fill valve assembly 2638 to allow pressurized air to enter the connector 2666 ( Figure 71 ) enters bus 2674 of gate valve assembly 2636. Reference Figure 73 and Figure 74 , a lateral fluid line 2682 is provided for each given valve subassembly 2646, which branches from the corresponding bus 2674 toward the corresponding fluid chamber 2650. The fill inlet 2684 is at Figure 74 , which is formed to the fluid chamber 2650 via a transverse fluid line 2682.

[0615] Reference again Figure 73 and Figure 74 Each gate valve subassembly 2646 includes a valve body 2686 for translating within the fluid chamber 2650 toward and away from the fill inlet 2684. The valve body 2686 is formed from a lightweight, resilient material, such as a polymer or an aluminum alloy. The valve body 2686 includes a transverse extension 2688 at one distal end that supports a longitudinal extension 2690 that is offset from and shorter than the valve body 2686. An elastomeric valve seal 2692 is disposed on the longitudinal extension 2690. Figure 75 A cross section of the valve body 2686 is shown depicting a receptacle 2694 for receiving a compression spring 2696. The spring 2696 engages the inner surface of the fluid chamber 2650 to compress the valve seal 2692 agai...

Claims

1. A component or system comprising: a) a valve body, a pair of opposed seals, and a linear actuator, the valve body being sized to translate within a fluid chamber, the pair of opposed seals being positioned on the valve body to seal a pair of ports, and the linear actuator being mounted on the valve body to actuate the valve body; b) a valve body and a linear actuator, the valve body being formed of a polymer material and being sized to translate within a fluid chamber spring, the fluid chamber spring being integrally formed with the valve body and extending from the valve body to bias the valve body in one direction, the linear actuator being mounted on the valve body to actuate the valve body and compress the spring; c) a housing and a valve, the housing having a fluid chamber formed therein, the fluid chamber having a first port, a second port, and a third port in fluid communication with the fluid chamber, wherein the first port or the third port is formed at a distal end of the fluid chamber, the valve being oriented in the fluid chamber for translation into: a fill position in which fluid enters the first port from a pressurized fluid source, passes through the fluid chamber, and exits the second port to fill a fluid bladder while the third port is sealed from the fluid chamber, and a drain position in which fluid enters the second port from the fluid bladder, passes through the fluid chamber, and exits the third port to drain the fluid bladder while the first port is sealed from the fluid chamber; d) a housing having a matrix of fluid chambers, a plurality of gate valves, a plurality of charging pressure inlets, a plurality of control pressure inlets, a plurality of ports, and a controller, each gate valve being disposed in one of the matrix of fluid chambers, each charging pressure inlet being fluidly coupled with a subset of the fluid chambers and a first source of pressurized fluid, each control pressure inlet being fluidly coupled with one fluid chamber of each subset of the fluid chambers and a second source of pressurized fluid, each port being fluidly coupled with one fluid chamber in the matrix of fluid chambers to charge a fluid actuator when pressurized fluid is delivered through a corresponding charging pressure inlet and a corresponding control pressure inlet of the corresponding fluid chamber, and to discharge the fluid actuator when pressurized fluid is not delivered through at least one of the corresponding charging pressure inlet and the corresponding control pressure inlet of the corresponding fluid chamber, the controller being in communication with the first source of pressurized fluid and the second source of pressurized fluid such that a first subset of the plurality of gate valves operates in a normally charged position and a second subset of the plurality of gate valves operates in a normally discharged position; e) a piston body having a rectangular cross-section, and a seal oriented about the piston body to engage an inner wall of the fluid chamber; f) a first valve, a second valve, and a first actuator, the first valve having a first valve element, the second valve having a second valve element, the second valve being positioned adjacent to the first valve, the first actuator having an actuator member movable between a first actuator position and a second actuator position, the actuator member being coupled to each of the first valve element and the second valve element for movement therewith; g) a pump, a first rail connected to the pump via one or more control valves, a second rail connected to the pump via the one or more control valves, a series of first valves, a vent line, a series of first bladders, a series of paired second valves, a series of second bladders, a series of paired actuators, wherein the one or more control valves control fluid flow from the pump to one of the first rail and the second rail, each first valve having a first port with an associated first valve element and an associated second valve element, the first port of each of the first valves receiving pressurized fluid from the first rail via the first valve element, each first bladder fluidly coupled to the first port of one of the first valves, each second valve having a second port with an associated third valve element, the second port of each of the second valves receiving pressurized fluid from the second rail, each second bladder fluidly coupled to the second port of one of the second valves, one actuator in each pair of actuators coupled to the first valve element and the third valve element of one of the second valves in each pair for movement therewith, and the other actuator in each pair of actuators coupled to the second valve element and the third valve element of the other of the second valves in each pair for movement therewith; h) a first number of pneumatic massage actuators, an air pump, and a pneumatic valve network, the pneumatic valve network for distributing air from the air pump to any one of the pneumatic massage actuators, the one pneumatic massage actuator being selected based on a state of a second number of binary electrical signals, wherein no air from the air pump is directed to any one of the first number of pneumatic actuators except for the one selected pneumatic actuator, and wherein the first number exceeds the second number; i) a first number of pneumatic massage actuators, an air pump, a pneumatic valve network for distributing air from the air pump to respective subsets of the pneumatic massage actuators and only to the subsets, the subsets being selected based on states of a second number of binary electrical signals, wherein the first number exceeds the second number, each NOT-type valve exhausting a corresponding one of the pneumatic massage actuators in response to an input line of the corresponding pneumatic massage actuator being unpressurized; j) a first number of pneumatic massage actuators, an air pump, and a pneumatic valve network, the pneumatic valve network being operable to distribute air from the air pump to respective subsets of the pneumatic massage actuators and only to the subsets, the subsets being selected based on states of a second number of binary electrical signals, wherein the first number exceeds the second number, and the pneumatic valve network exhausting air from all pneumatic massage actuators not in the selected subset; k) a massage actuator adapted to be attached to a seat cushion, an air pump, and a valve, the valve comprising: a pressure port fluidly connected to the air pump, at least one outlet port fluidly connected to the massage actuator, a vent port, a valve core for sliding within a bore, at least one spring and a solenoid, the at least one spring biasing the valve core toward a neutral position in which the at least one outlet port is isolated from both the pressure port and the vent port, the solenoid moving the valve core to a first position in response to an electric current in a first direction and moving the valve core to a second position in response to an electric current in a second direction, the at least one outlet port being fluidly connected to the pressure port when the valve core is in the first position, and the at least one outlet port being fluidly connected to the vent port when the valve core is in the second position; l) a pressure port, at least one outlet port, a vent port, a valve spool for sliding within a borehole, at least one spring and a solenoid, wherein the at least one spring biases the valve spool toward a neutral position in which the at least one outlet port is isolated from both the pressure port and the vent port, the solenoid moving the valve spool to a first position in response to an electric current in a first direction and moving the valve spool to a second position in response to an electric current in a second direction, the at least one outlet port being fluidly connected to the pressure port when the valve spool is in the first position, and the at least one outlet port being fluidly connected to the vent port when the valve spool is in the second position; and / or m) A massage actuator, an air pump and a valve adapted to be attached to a seat cushion, the valve comprising: a pressure port fluidly connected to the air pump, at least one outlet port fluidly connected to the massage actuator, a vent port, a valve core for sliding in a bore, at least one spring and a solenoid, the at least one spring biasing the valve core toward a holding position in which the actuator is maintained in its current charge state, the solenoid moving the valve core to a charge position in response to an electric current in a first direction and moving the valve core to a discharge position in response to an electric current in a second direction, air being delivered from the air pump to the massage actuator when the valve core is in the charge position, and air being delivered from the massage actuator to the environment via the vent port when the valve core is in the discharge position.

2. The assembly according to claim 1, further comprising: The valve body is dimensioned to translate within the fluid chamber; the pair of opposed seals being positioned on the valve body to seal the pair of ports; and The linear actuator is mounted on the valve body to actuate the valve body.

3. The assembly according to claim 1 or 2, wherein: The linear actuator also includes a shape memory alloy to translate the valve body in response to an electric current conducted through the shape memory alloy.

4. An assembly according to any one of the preceding claims, wherein: The valve body is elongated; and Each of the pair of opposing seals is spaced apart and positioned on a distal end of the elongated valve body.

5. The assembly according to any one of the preceding claims, further comprising: a housing in which the fluid chamber is formed, the fluid chamber having a first port, a second port, and a third port in fluid communication with the fluid chamber; and Wherein the valve body is positioned in the fluid chamber for translation relative to the fluid chamber.

6. The assembly according to claim 5, wherein: the valve body being translatable to a filling position in which fluid from a pressurized fluid source enters the first port, passes through the fluid chamber and exits the second port to fill the fluid bladder while the third port is sealed from the fluid chamber; and Wherein, the valve body is translatable to a venting position in which fluid enters the second port from the fluid bladder, passes through the fluid chamber and exits the third port to vent the fluid bladder while the first port is sealed to the fluid chamber.

7. The assembly of claim 6, further comprising an actuator connected to the second port.

8. A component comprising: a housing having a plurality of fluid chambers formed therein, each fluid chamber having a first port, a second port, and a third port; and A plurality of valve assemblies, each valve assembly according to any one of the preceding claims, wherein the valve body of each valve assembly is oriented for translation within one of the plurality of fluid chambers.

9. The assembly of claim 1, further comprising: the valve body being formed of the polymer material and being sized to translate within the fluid chamber; The spring is formed integrally with the valve body and extends from the valve body to bias the valve body in one direction; and The linear actuator is mounted on the valve body to actuate the valve body and compress the spring.

10. The assembly according to claim 9, wherein: The linear actuator also includes a shape memory alloy to translate the valve body in response to an electric current conducted through the shape memory alloy.

11. The assembly of claim 10 further comprising a beam extending from the valve body.

12. The assembly according to claim 11, wherein The beam has a first thickness; and The spring has a second thickness that is reduced relative to the first thickness.

13. An assembly according to claim 11 or 12, wherein: The spring also includes a compression spring.

14. The assembly of any one of claims 11-13, further comprising an electrical terminal mounted on the beam in electrical communication with the shape memory alloy.

15. The assembly according to any one of claims 10 to 14, further comprising: a housing in which the fluid chamber is formed, the fluid chamber having a first port, a second port, and a third port in fluid communication with the fluid chamber; and Wherein the valve body is positioned in the fluid chamber for translation relative to the fluid chamber.

16. The assembly of claim 15, wherein: the valve body being translatable to a filling position in which fluid from a pressurized fluid source enters the first port, passes through the fluid chamber and exits the second port to fill the fluid bladder while the third port is sealed from the fluid chamber; and The valve body is translatable to a discharge position, in which fluid enters the second port from the fluid bladder, passes through the fluid chamber and exits the third port to discharge the fluid bladder, while the first port is sealed from the fluid chamber.

17. The assembly according to claim 15 or 16, further comprising: an actuator connected to the second port; and A source of pressurized fluid is connected to the first port.

18. An assembly comprising: a housing having a plurality of fluid chambers formed therein, each fluid chamber having a first port, a second port, and a third port in fluid communication with the fluid chamber; and A plurality of valve assemblies, each valve assembly according to any one of claims 9-14, wherein the valve body of each valve assembly is oriented for translation within one of the plurality of fluid chambers.

19. The assembly of claim 1, further comprising a valve assembly, the valve assembly comprising: the housing having the fluid chamber formed therein, the first port, the second port, and the third port being in fluid communication with the fluid chamber, wherein the first port or the third port is formed at a distal end of the fluid chamber; and The valve is oriented in the fluid chamber for translation to: an inflation position in which fluid from the pressurized fluid source enters the first port, passes through the fluid chamber, and exits the second port to inflate the fluid bladder while the third port is sealed from the fluid chamber, and A drain position in which fluid enters the second port from the fluid bladder, passes through the fluid chamber and exits the third port to drain the fluid bladder while the first port is sealed to the fluid chamber.

20. A seat assembly comprising: a seat bottom adapted to be secured to a vehicle floor; A seat back extending upright from the seat bottom ； An assembly as claimed in claim 7 or 17, wherein the actuator is provided on the seat bottom or the seat back.

21. The seat assembly of claim 20 further comprising the source of pressurized fluid connected to the first port.

22. The system of claim 1, further comprising: said housing having a matrix of said fluid chambers; the plurality of gate valves, each gate valve disposed in one of the matrix of fluid chambers; the plurality of filling pressure inlets, each filling pressure inlet being in fluid cooperation with a subset of the fluid chambers and the first source of pressurized fluid; the plurality of control pressure inlets, each control pressure inlet in fluid cooperation with one fluid chamber of each subset of the fluid chambers and the second source of pressurized fluid; the plurality of ports, each port fluidly cooperating with one of the matrix of fluid chambers to charge the fluid actuator when pressurized fluid is delivered through a corresponding charge pressure inlet and a corresponding control pressure inlet of the corresponding fluid chamber, and to discharge the fluid actuator when pressurized fluid is not delivered through at least one of the corresponding charge pressure inlet and the corresponding control pressure inlet of the corresponding fluid chamber; and The controller, which is in communication with the first and second pressurized fluid sources, causes the first subset of the plurality of gate valves to operate in the normally filling position and the second subset of the plurality of gate valves to operate in the normally draining position.

23. The system of claim 22, further comprising a plurality of charging pressure valves, each charging pressure valve being fluidly coupled to one of the plurality of charging pressure inlets and electrically connected to the controller to regulate flow of the first pressurized fluid source into each of the plurality of charging pressure inlets.

24. The system of claim 22, further comprising a plurality of control pressure valves, each control pressure valve fluidly cooperating with one of the plurality of control pressure inlets and electrically communicating with the controller to regulate flow of the second pressurized fluid source into each of the plurality of control pressure inlets.

25. The system of claim 24, further comprising a source of pressurized air in fluid communication with the plurality of charging pressure valves and the plurality of control pressure valves.

26. The system of any preceding claim, further comprising a plurality of vents, each vent being in fluid cooperation with one of the matrix of fluid chambers.

27. The system of claim 26, wherein: At least one of the first subset of the plurality of gate valves has a first condition in which the corresponding vent is closed and the corresponding port is closed, a second condition in which the corresponding vent is closed and the corresponding port is open, and a third condition in which the corresponding vent is open and the corresponding port is closed to contain pressurized fluid in the corresponding fluid actuator.

28. The system of claim 26 or 27, wherein: At least one of the second subset of the plurality of gate valves has a first condition in which the corresponding vent is open and the corresponding port is closed and a second condition in which the corresponding vent is closed and the corresponding port is open.

29. The system of any preceding claim, further comprising a plurality of balloons, each balloon being in fluid communication with one of the plurality of ports.

30. The system according to any one of the preceding claims, further comprising: Seat bottom; Seat backs; and A fluid actuator in the seat bottom or the seat back.

31. The assembly of claim 1, further comprising: The piston body has a rectangular cross-section; and The seal is oriented about the piston body to engage an inner wall of the fluid chamber.

32. The assembly of claim 31, wherein: The piston seal tapers to narrow away from the piston body.

33. An assembly according to claim 31 or 32, wherein The piston seal is spaced apart from a distal end of the piston body; and A protrusion is provided on the distal end to maintain a gap between the distal end and the fluid chamber.

34. The assembly of any one of claims 31-33, further comprising a housing having the fluid chamber, wherein the piston body and the piston seal are positioned in the fluid chamber.

35. The assembly of claim 34 further comprising an inlet in the housing into the fluid chamber for receiving pressurized fluid at the distal end of the piston body.

36. An assembly according to claim 34 or 35, further comprising a valve body extending from the piston body to be actuated by the piston body.

37. The assembly of claim 36 further comprising a valve seal on the valve body.

38. The assembly of claim 37, further comprising: forming a charge pressure inlet in the housing into the fluid chamber; and a port formed in the housing and opening into the fluid chamber; and Wherein the valve seal engages the port in a closed position of the port.

39. The assembly of claim 38, further comprising a biasing member cooperating with the housing and the valve body to bias the valve seal into engagement with the port.

40. The assembly of claim 38 or 39, further comprising a vent formed in the housing to vent the fluid chamber.

41. The assembly of claim 40, wherein: The valve seal engages the vent in an open position of the port to allow pressurized fluid to pass from the charging pressure inlet to the port.

42. The assembly of any one of claims 31-41, further comprising: Seat bottom; Seat backs; and A fluid actuator is in fluid communication with the fluid chamber in the seat bottom or the seat back.

43. The system of claim 1, further comprising: said housing having a matrix of said fluid chambers; The plurality of gate valves, each gate valve being disposed in one of the matrix of fluid chambers, each gate valve comprising: A piston body having a rectangular cross section, a seal oriented about the piston body to engage an inner wall of the fluid chamber, a valve body extending from the piston body, and a valve seal on the valve body; the plurality of filling pressure inlets, each filling pressure inlet being in fluid cooperation with a subset of the fluid chambers and the first source of pressurized fluid; a plurality of charging pressure valves, each charging pressure valve in fluid cooperation with one of the plurality of charging pressure inlets to regulate the flow of pressurized fluid into each of the plurality of charging pressure inlets; the plurality of control pressure inlets, each control pressure inlet fluidly cooperating with one fluid chamber of each subset of the fluid chambers to distribute pressure to a corresponding piston body to actuate a corresponding gate valve; a plurality of control pressure valves, each control pressure valve fluidly cooperating with one of the plurality of control pressure inlets to regulate the flow of pressurized fluid into each of the plurality of control pressure inlets; a plurality of ports, each port fluidly cooperating with one of the matrix of fluid chambers to charge a fluid actuator when pressurized fluid is delivered through a corresponding charge pressure inlet and a corresponding control pressure inlet of the corresponding fluid chamber, and to discharge the fluid actuator when pressurized fluid is not delivered through at least one of the corresponding charge pressure inlet and the corresponding control pressure inlet of the corresponding fluid chamber, wherein a corresponding valve seal engages the corresponding port in a closed position of the port; and A controller is in communication with the plurality of charging pressure valves and the plurality of control pressure valves to regulate operation of the plurality of charging pressure valves and the plurality of control pressure valves so that a first subset of the plurality of gate valves operates in a normal charging position and a second subset of the plurality of gate valves operates in a normal exhaust position.

44. The system of claim 1, comprising: The first valve has the first valve element; the second valve having the second valve element, the second valve being positioned adjacent to the first valve; and The first actuator has the actuator member movable between a first actuator position and a second actuator position, the actuator member being coupled to each of the first valve element and the second valve element for movement therewith.

45. The system of claim 44, wherein: When the actuator member is in the first actuator position, each of the first valve and the second valve is in a closed position, and when the actuator member is in the second actuator position, each of the first valve and the second valve is in an open position.

46. ​​The system of claim 45, further comprising a third valve having a third valve element; The first valve has a fourth valve element.

47. The system of claim 46, wherein: The system also includes a second actuator having a second actuator member coupled to each of the third valve element and the fourth valve element for movement therewith.

48. The system of any one of claims 44-47, wherein: The first actuator is a solenoid actuator or a shape memory alloy actuator.

49. The system of any one of claims 44-48, further comprising a connector plate connected to the actuator member and the first and second valve elements.

50. The system of any one of claims 44-49, further comprising a pump positioned upstream of the first valve and the second valve; and a control valve fluidly connecting the pump to the first valve and the second valve; Wherein the pump is fluidly coupled to the first valve when the control valve is in a first valve position, and wherein the pump is fluidly coupled to the second valve when the control valve is in a second valve position.

51. The system of claim 50, further comprising a first fluid rail providing pressurized fluid from the pump to the first valve via the control valve, and a second fluid rail providing pressurized fluid from the pump to the second valve via the control valve.

52. The system of claim 51 further comprising a first bladder in fluid communication with the first valve to receive pressurized fluid therefrom.

53. The system of claim 52, wherein: The first valve has a first port in fluid communication with the first bladder, wherein the first port fluidly couples the first fluid track to the first bladder via the first valve element, and wherein the first port fluidly couples the first bladder to atmosphere via a third valve element of the first valve.

54. The system of claim 53, further comprising a second bladder in fluid communication with the second port of the second valve to receive pressurized fluid therefrom.

55. The system of claim 54, further comprising a third valve having a fourth valve element, wherein the third valve is in fluid communication with the second fluid rail; a second actuator having a second actuator member coupled to each of the third valve element and the fourth valve element for movement therewith; and A third bladder is in fluid communication with the third valve to receive pressurized fluid therefrom.

56. The system of claim 54, wherein: The second fluid track is in fluid communication with the atmosphere when the second valve element is in a closed position, and wherein the second fluid track is in fluid communication with the second port and the second bladder when the second valve element is in an open position.

57. The system of claim 56, further comprising a vent valve fluidly connecting the second rail to atmosphere in a vent position.

58. The system of claim 57, further comprising a check valve fluidly connecting the first port of the first valve to the second fluid rail via the third valve element, wherein the check valve is positioned to close when pressure in the second fluid rail is greater than pressure in the first port and the third valve element is in an open position.

59. The system of claim 57, further comprising a third fluid rail that receives fluid from the first port of the first valve; and A check valve fluidly connects the third fluid rail to the second fluid rail, wherein the check valve is positioned to close when pressure in the second fluid rail is greater than pressure in the third fluid rail.

60. The system of claim 1, further comprising: the pump; the first rail connected to the pump via the one or more control valves; the second rail connected to the pump via the one or more control valves, wherein the one or more control valves control fluid flow from the pump to one of the first rail and the second rail; the series of first valves, each first valve having a first port with an associated first valve element and an associated second valve element, and the vent line, the first port of each of the first valves receiving pressurized fluid from the first rail via the first valve element; the series of first bladders, each first bladder fluidly coupled to a first port of one of the first valves; the series of pairs of second valves, each second valve having a second port with an associated third valve element, the second port of each of the second valves receiving pressurized fluid from the second rail; the series of second bladders, each second bladder fluidly coupled to a second port of one of the second valves; and The series of paired actuators, one actuator in each pair of actuators is coupled to the first valve element and the third valve element of one of the second valves in each pair to move together therewith, and the other actuator in each pair of actuators is coupled to the second valve element and the third valve element of the other of the second valves in each pair to move together therewith.

61. The system of claim 60, further comprising one or more check valves fluidly coupling the vent line of at least one of the first ports to the second rail, wherein the one or more check valves are positioned to close when pressure in the second rail is greater than pressure in the at least one of the first ports and the second valve element is in an open position.

62. The assembly of claim 1, further comprising: said first number of pneumatic massage actuators; the air pump; and The pneumatic valve network is used to distribute air from the air pump to any one of the pneumatic massage actuators, the one pneumatic massage actuator being selected based on the state of a second number of binary electrical signals, wherein: no air from the air pump is directed to any of the first number of pneumatic actuators except the one selected pneumatic actuator; and The first amount exceeds the second amount.

63. The assembly of claim 62, wherein: The second number exceeds 2 raised to a power of 1 less than the first number.

64. An assembly according to claim 62 or claim 63, wherein The second number is equal to 2 raised to the power of the first number.

65. An assembly according to any one of claims 62-65, wherein The pneumatic valve network comprises: at least a first number of AND-type valves; and The second number of signal valve assemblies, each signal valve assembly is used to guide air from the pressure source to the first signal pipeline when and only when the corresponding binary electrical signal is in the on state, and to guide air from the pressure source to the second signal pipeline when and only when the corresponding binary electrical signal is in the off state.

66. The assembly of claim 65, wherein: Each of the signal valve assemblies comprises: a single output signal valve to direct air from a pressure source to said first signal line if and only if a corresponding binary electrical signal is in an on state; and A NOT type valve is provided to direct air from the pressure source to the second signal line when and only when the first signal line is not pressurized.

67. An assembly according to claim 65 or claim 66, wherein The signal valve assemblies each utilize a single valve core in a single bore to direct air to either the first signal line or the second signal line.

68. The assembly of claim 67, wherein: The signal valve assemblies each further exhaust the first signal line when and only when the corresponding binary electrical signal is in an off state, and the signal valve assemblies each further exhaust the second signal line when and only when the corresponding binary electrical signal is in an on state.

69. The assembly of any one of claims 62-68, further comprising: The first number of NOT-type valves each exhaust the corresponding pneumatic massage actuator in response to an input line of the corresponding pneumatic massage actuator being depressurized.

70. The assembly of claim 1, further comprising: said first number of pneumatic massage actuators; the air pump; the pneumatic valve network for distributing air from the air pump to respective subsets of the pneumatic massage actuators and only to the subsets, the subsets being selected based on states of a second number of binary electrical signals, wherein the first number exceeds the second number; and The first number of NOT-type valves each exhaust the corresponding pneumatic massage actuator in response to an input line of the corresponding pneumatic massage actuator being depressurized.

71. The assembly of claim 70, wherein: The second number exceeds 2 raised to a power of 1 less than the first number.

72. An assembly according to claim 70 or claim 71, wherein The second number is equal to 2 raised to the power of the first number.

73. An assembly according to any one of claims 70 to 72, wherein The pneumatic valve network comprises: at least a first number of AND-type valves; and The second number of signal valve assemblies, each signal valve assembly is used to guide air from the pressure source to the first signal pipeline when and only when the corresponding binary electrical signal is in the on state, and to guide air from the pressure source to the second signal pipeline when and only when the corresponding binary electrical signal is in the off state.

74. The assembly of claim 73, wherein: Each of the signal valve assemblies comprises: a single output signal valve to direct air from a pressure source to said first signal line if and only if a corresponding binary electrical signal is in an on state; and A NOT type valve is provided to direct air from the pressure source to the second signal line when and only when the first signal line is not pressurized.

75. An assembly according to claim 73 or claim 74, wherein The signal valve assemblies each utilize a single valve core in a single bore to direct air to either the first signal line or the second signal line.

76. An assembly according to any one of claims 70 to 75, wherein Each of the respective subsets of pneumatic massage actuators comprises exactly one pneumatic massage actuator.

77. The assembly of claim 1, further comprising: said first number of pneumatic massage actuators; the air pump; and The pneumatic valve network is used to: distributing air from the air pump to respective subsets of the pneumatic massage actuators and only to the subsets, the subsets being selected based on the states of the second number of binary electrical signals, wherein the first number exceeds the second number, and Air is exhausted from all pneumatic massage actuators that are not in the selected subset.

78. The assembly of claim 77, wherein: The second number exceeds 2 raised to a power of 1 less than the first number.

79. An assembly according to claim 77 or claim 78, wherein The second number is equal to 2 raised to the power of the first number.

80. The seat assembly of any one of claims 77-79, wherein: Each of the respective subsets of pneumatic massage actuators comprises exactly one pneumatic massage actuator.

81. The assembly of claim 1, further comprising: said massage actuator adapted to be attached to said seat cushion; the air pump; and The valve comprises: fluidly connected to the pressure port of the air pump, fluidly connected to the at least one outlet port of the massage actuator, The ventilation port, The valve core slides in the bore, the at least one spring biasing the spool toward the neutral position in which the at least one outlet port is isolated from both the pressure port and the vent port, and The solenoid moves the valve core to the first position in response to current in the first direction and moves the valve core to the second position in response to current in the second direction, the at least one outlet port being fluidly connected to the pressure port when the valve core is in the first position, and the at least one outlet port being fluidly connected to the vent port when the valve core is in the second position.

82. The assembly of claim 81, wherein The at least one spring includes two compression springs, one on each side of the valve core.

83. The assembly of claim 82, wherein: The at least one outlet port includes a first outlet port axially located between the vent port and the pressure port and blocked by the valve spool when the valve spool is in the neutral position.

84. The assembly of claim 83, wherein: The at least one outlet port further includes a second outlet port such that the pressure port is axially located between the first outlet port and the second outlet port, and wherein the pressure port is blocked by the valve spool when the valve spool is in the neutral position.

85. The assembly of claim 84, wherein: When the valve core is in the second position, the pressure port is also blocked by the valve core.

86. The assembly of claim 85, wherein: When the valve core is in the first position, the first outlet port is also blocked by the valve core.

87. A seat assembly comprising: Seat padding; as well as An assembly according to any one of claims 81 to 86.

88. The seat assembly of claim 87, wherein: The seat cushion is a seat back.

89. A seat assembly according to claim 87 or 88, wherein: The massage actuator is one of a plurality of massage actuators attached to the seat pad.

90. The assembly of claim 1, further comprising: said pressure port; said at least one outlet port; the ventilation port; the valve core sliding in the bore; the at least one spring biasing the spool toward the neutral position in which the at least one outlet port is isolated from both the pressure port and the vent port; and The solenoid moves the valve core to the first position in response to current in the first direction and moves the valve core to the second position in response to current in the second direction, the at least one outlet port being fluidly connected to the pressure port when the valve core is in the first position, and the at least one outlet port being fluidly connected to the vent port when the valve core is in the second position.

91. The assembly of claim 90, wherein: The at least one spring includes two compression springs, one on each side of the valve core.

92. An assembly according to claim 90 or 91, wherein The at least one outlet port includes a first outlet port axially located between the vent port and the pressure port and blocked by the valve spool when the valve spool is in the neutral position.

93. The assembly of claim 92, wherein: The at least one outlet port further includes a second outlet port such that the pressure port is axially located between the first outlet port and the second outlet port, and wherein the pressure port is blocked by the valve spool when the valve spool is in the neutral position.

94. The assembly of claim 93, wherein: When the valve core is in the second position, the pressure port is also blocked by the valve core.

95. An assembly according to claim 93 or 94, wherein When the valve core is in the first position, the first outlet port is also blocked by the valve core.

96. The components include: said massage actuator adapted to be attached to said seat cushion; the air pump; and The valve comprises: fluidly connected to the pressure port of the air pump, fluidly connected to the at least one outlet port of the massage actuator, The ventilation port, The valve core slides in the bore, the at least one spring biasing the spool toward the holding position in which the actuator is held in its current charge state, and The solenoid moves the valve core to the filling position in response to current in the first direction, and moves the valve core to the exhaust position in response to current in the second direction. When the valve core is in the filling position, air is directed from the air pump to the massage actuator, and when the valve core is in the exhaust position, air is directed from the massage actuator to the environment via the vent port.

97. The assembly of claim 96, wherein: The at least one spring includes two compression springs, one on each side of the valve core.

98. An assembly according to claim 96 or 97, wherein The at least one outlet port includes a first outlet port axially located between the vent port and the pressure port and blocked by the valve spool when the valve spool is in the holding position.

99. The assembly of claim 98, wherein: The at least one outlet port further includes a second outlet port such that the pressure port is axially located between the first outlet port and the second outlet port, and wherein the pressure port is blocked by the valve spool when the valve spool is in the holding position.

100. The assembly of claim 99, wherein: When the valve core is in the exhaust position, the pressure port is also blocked by the valve core.

101. The assembly of claim 99 or 100, wherein: The first outlet port is also blocked by the valve spool when the valve spool is in the filling position.

102. A method comprising: pumping a fluid flow to a first rail via a control valve in a first position; pumping a fluid flow to a second rail via the control valve in a second position; actuating a first actuator to a first position to move a first valve element in a first valve and a second valve element in a second valve to an open position, wherein the control valve is in the first position, thereby filling a first bladder connected to the first valve while maintaining exhaustion of a second bladder connected to the second valve; actuating the first actuator to the first position, thereby moving the first valve element and the second valve element to an open position, wherein the control valve is in the second position, thereby filling the second bladder connected to the second valve without changing the filling state of the first bladder; and Actuating the second actuator to a first position thereby moving the third valve element in the first valve and the fourth valve element in the third valve to an open position, wherein the control valve is in the first position thereby discharging the first bladder connected to the first valve while maintaining the third bladder connected to the third valve discharging.

103. The method of claim 102, further comprising opening a vent valve to a vent position to fluidly couple the second rail to atmosphere; and The check valve is opened in response to pressure in the second rail being less than pressure in the first valve, thereby defusing the first bladder with the second actuator in the first position.

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