Vehicle seat assembly and subassembly thereof

Abstract

Seat assemblies and subassemblies for attaching and retaining components are provided. The subassembly may include a trim cover with a buffer layer and various fasteners or retainers. The fastener may include a tie-down strap. The retainer may include a connector that translates through the seat cushion layer. The retainer may also include an envelope surrounding the buffer layer.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is a continuation-in-part of U.S. patent application No. 17 / 841,745 (Agent Docket No. LEAR20795PUS), filed on June 16, 2022; claims the benefit of U.S. Provisional Patent Application No. 63 / 357,060 (Agent Docket No. LEAR21101PRV), filed on June 30, 2022; claims the benefit of U.S. Provisional Patent Application No. 63 / 393,386 (Agent Docket No. LEAR21097PRV), filed on July 29, 2022; claims the benefit of U.S. Provisional Patent Application No. 63 / 393,382 (Agent Docket No. LEAR21097PRV), filed on July 29, 2022 Claims the benefit of U.S. Provisional Patent Application No. 63 / 393,389, filed on July 29, 2022 (Attorney Docket No. LEAR21099PRV); Claims the benefit of U.S. Provisional Patent Application No. 63 / 354,079, filed on June 21, 2022 (Attorney Docket No. LEAR20837PRV); Claims the benefit of U.S. Provisional Patent Application No. 63 / 393,392, filed on July 29, 2022 (Attorney Docket No. LEAR21040PRV); Claims the benefit of U.S. Provisional Patent Application No. 63 / 393,393, filed on July 29, 2022 (Attorney Docket No. LEAR21040PRV); Claims the benefit of U.S. Provisional Patent Application No. 63 / 393,392, filed on September 29, 2022 (Attorney Docket No. LEAR21040PRV); Claims the benefit of U.S. Provisional Patent Application No. 63 / 393,392 ... 2022 (Agent Docket No. LEAR21182PRV); is a continuation-in-part of U.S. Patent Application No. 18 / 085,120 (Agent Docket No. LEAR21096PUS), filed on December 20, 2022; claims the benefit of U.S. Provisional Patent Application No. 63 / 354,412 (Agent Docket No. LEAR20886PRV), filed on June 22, 2022; claims the benefit of U.S. Provisional Patent Application No. 63 / 357,101 (Agent Docket No. LEAR20916PRV), filed on June 30, 2022 2PRV); is a continuation-in-part of U.S. Patent Application No. 18 / 087,223, filed on December 22, 2022 (Attorney Docket No. LEAR21094PUS); claims the benefit of U.S. Provisional Patent Application No. 63 / 354,319, filed on June 22, 2022 (Attorney Docket No. LEAR21102PRV); claims the benefit of U.S. Provisional Patent Application No. 63 / 356,324, filed on June 28, 2022 (Attorney Docket No. LEAR20831PRV); claims priority to Danish Patent Application No. PA2023 70030, filed on January 19, 2023 (Attorney Docket No. LEAR20831PDK); claims the benefit of U.S. Provisional Patent Application No. 63 / 356,093, filed on June 28, 2022 (Attorney Docket No. LEAR20905PRV);Claiming priority to Danish Patent Application No. PA2023 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. LEAR21103 ...3,141 filed on July 28, 2022 (Attorney Docket No. LEAR21086PRV); Claiming the benefit of U.S. Provisional Patent Application No. 63 / 393,914 filed on July 28, 2022 (Attorney Docket No. LEAR21103PRV); Claiming the benefit of U.S. Provisional Patent 392,926 (Agent Docket No. LEAR21104PRV); a continuation-in-part application of U.S. Patent Application No. 17 / 983,881 (Agent Docket No. LEAR21042PUS), filed on November 9, 2022; claims the benefit of U.S. Provisional Patent Application No. 63 / 433,599 (Agent Docket No. LEAR21149PRV), filed on December 19, 2022; a continuation-in-part application of U.S. Patent Application No. 18 / 087,850 (Agent 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 for use with a seat assembly.

[0010] Figure 6 Shows 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 Shows Figure 7 Another perspective view of the decorative component.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0034] Fig.30 According to some embodiments Fig. 27 A front elevation view of a massage assembly of a seating system.

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

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

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

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

[0039] Fig.35 is a side view of a conventional massage capsule.

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

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

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

[0043] Fig.39 is a PBD plot of a first embodiment of a massage assembly for a 50th percentile occupant.

[0044] Fig.40 is a PBD graph for a conventional massage assembly for a 50th percentile occupant.

[0045] Fig.41 is a PBD plot of a first embodiment of a massage assembly for a 95th percentile occupant.

[0046] Fig.42 is a PBD graph for a conventional massage assembly for a 95th percentile occupant.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0061] Fig.57 is a flow chart of a method of applying massage.

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

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

[0064] Fig.60 According to some embodiments, Fig.59 Schematic diagram of an actuator assembly of a seat assembly.

[0065] Fig.61 According to some embodiments Fig.60 A top view of the valve assembly of the actuator assembly.

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

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

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

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

[0070] Fig.66 yes Fig.62 A front perspective view of a valve subassembly.

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

[0072] Fig.68 yes Fig.62 A front perspective view of a conductive subassembly of a valve subassembly.

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

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

[0075] Fig.71 According to some embodiments Fig.70 A front elevation view of a gate valve assembly of a seating system.

[0076] Fig.72 yes Fig.71 A rear elevation view of a gate valve assembly.

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

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

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

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

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

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

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

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

[0085] Fig.81 The invention is shown integrated into a fluid system and with Fig.79 Used together with the seat components Fig.80 Schematic diagram of the system.

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

[0087] Fig.83 Shows Fig.80 A partial schematic diagram of the valve system.

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

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

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

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

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

[0093] Fig.88 A perspective view showing various materials used in a trim assembly.

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

[0095] Fig.90 A cross-sectional schematic diagram of a trim assembly according to some embodiments is shown.

[0096] Fig.91A cross-sectional schematic diagram of a trim assembly according to some embodiments is shown.

[0097] Fig.92 A cross-sectional schematic diagram of a trim assembly according to some embodiments is shown.

[0098] Fig.93 A cross-sectional schematic diagram of a trim assembly according to some embodiments is shown.

[0099] Fig.94 Schematic cross-sectional views of decoration components according to still some embodiments are shown.

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

[0101] Fig.96 A cross-sectional schematic diagram of a trim assembly according to some embodiments is shown.

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

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

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

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

[0106] Fig.100 is an elevation view showing the mesh body flexing to open the groove to receive the tie band prior to insertion of the spiral retainer.

[0107] Fig.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] Fig.101B Methods according to some embodiments are shown.

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

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

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

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

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

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

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

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

[0117] Fig.110 yes Fig.109 Another cross-sectional view of the seat assembly of FIG. 1 , showing further assembly.

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

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

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

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

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

[0123] Fig.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] Fig.116 and Fig.117 is based on Fig.115 Elevation view of the balloon and double catheter being processed in accordance with an embodiment of the present invention.

[0125] Fig.118 is based on Fig.115 An elevation view of a completed balloon and dial catheter of an embodiment of the invention.

[0126] Fig.119 It is explained as manufacturing Fig.115 A process flow diagram of the steps performed in accordance with an embodiment of the present invention.

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

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

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

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

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

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

[0133] Fig.126 is a schematic cross-sectional view of a third embodiment of a compression-resistant support structure.

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

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

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

[0137] Figure 131-Figure 132 They are Figure 129-130 A cross-sectional schematic diagram of an embodiment in which the cells are filled with foam.

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

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

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

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

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

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

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

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

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

[0147] Fig.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] Fig.146 is a side view of a non-foam / non-foam cushion assembly having a portion of a fluid system disposed therein.

[0149] Fig.147 yes Fig.146 Side view of a non-foam / no-foam cushion assembly with the fluid system removed.

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

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

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

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

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

[0155] Fig.153 is a perspective view of an embodiment of a non-foam / non-foam cushion.

[0156] Fig.154 is a schematic cross-sectional view of a non-foam / no-foam cushion assembly.

[0157] Fig.155 is a schematic cross-sectional view of a conventional gasket assembly.

[0158] Fig.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] Fig.157 is a cross-sectional side view of an embodiment of a manufacturing system.

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

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

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

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

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

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

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

[0167] Fig.165 Shows Fig.164 Schematic side view of the bladder assembly during inflation.

[0168] Fig.166 Shows that during the emission Fig.164 A schematic side view of a capsule assembly.

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

[0170] Fig.168 Shows Fig.167 A side view schematic diagram of a bladder and valve, with the valve in an open position.

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

[0172] Fig.170 Shows Fig.169 A partial side schematic view of a bladder of a bladder assembly.

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

[0174] Fig.172 Shows Fig.171 heat transfer system.

[0175] Fig.173 Shows Fig.171 Another view of the heat transfer system.

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

[0177] Fig.175 Shows Fig.174 Schematic diagram of a part of the heat transfer system.

[0178] Fig.176 Shows Fig.174 A perspective view of a portion of a heat transfer system.

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

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

[0181] Fig.179 is used for Fig.178 Schematic diagram of an actuator assembly of a seat assembly.

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

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

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

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

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

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

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

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

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

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

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

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

[0194] Fig.192 is suitable for Fig.191 Schematic diagram of a pneumatic system in a holding position used in a seat assembly.

[0195] Fig.193 It is inflated Fig.192 Schematic diagram of the pneumatic system.

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

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

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

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

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

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

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

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

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

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

[0206] Fig.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 embodiments, examples of which are illustrated in the accompanying drawings. In the detailed description that follows, many specific details are set forth in order to provide a thorough understanding of the various embodiments described. However, it is 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 are not described in detail to avoid unnecessarily obscuring aspects of the embodiments.

[0209] It should be understood that the disclosed embodiments are merely exemplary, and various alternatives are possible. The drawings are not necessarily drawn to scale. Some features may be enlarged or minimized to show the details of specific components. Therefore, the specific structural details and functional details disclosed herein should not be interpreted as limiting, but only 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 a function performed by one element, a function performed by more than one element (eg, in a distributed fashion), several functions performed by one element, several 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 only 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. Both the first surface and the second surface are surfaces, but they are not the same surface.

[0212] The terms used in the description of the various embodiments described herein are used only for the purpose of describing specific embodiments 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 should also be understood that the term "and / or" used herein refers to and includes any and all possible combinations of one or more of the relevant listed items. It should also be understood that when used in this specification, the terms "comprises" and / or "comprising" represent the presence of the recorded features, wholes, steps, operations, elements, and / or parts, rather than 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 the context requires. Similarly, the phrases "if it is determined" or "if [the condition or event] is detected" are 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 the context requires.

[0214] In addition, unless otherwise expressly stated, all numerical quantities in the present disclosure should be understood to be modified by the word "about" in a manner that describes the broader scope of the present disclosure. Practice within the stated numerical limits is generally preferred. In addition, unless expressly stated to the contrary: percentages, "parts of..." and ratio values ​​are calculated by weight. The term "polymer" includes "oligomers", "copolymers", "terpolymers", etc. Unless otherwise stated, the description of a material group or category that is suitable or preferred for a given purpose means that a mixture of any two or more members of the group or category is also suitable or preferred. The molecular weight provided for any polymer refers to the number-average molecular weight. The description of the ingredients in chemical terms refers to the ingredients when added to any combination specified in the description, and does not necessarily exclude chemical interactions between the ingredients of the mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation in this article, and applies to common grammatical variants of the initially defined abbreviation after necessary modifications. Unless expressly stated to the contrary, the measurement of the property is determined by the same technology as that mentioned in the preceding or following text 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 only for the purpose of describing specific embodiments and is not intended to be limiting in any way.

[0216] The terms "substantially" or "generally" may be used herein to describe disclosed or claimed embodiments. The term "substantially" may modify a value or relative property disclosed or claimed in the present disclosure. In this case, "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 a value or relative property.

[0217] It should also be appreciated that integer ranges explicitly include all intermediate integers. For example, integer ranges 1 to 10 explicitly include 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, ranges 1 to 100 include 1, 2, 3, 4, ..., 97, 98, 99, 100. Similarly, when any range is required, the difference between the upper and lower limits divided by 10 as the intermediate number of increments 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 lower or upper limits.

[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, which 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-temporary computer-readable medium, which 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, and the cushion assembly 20 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 a temperature control assembly 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 assembly 25, 30 includes, for example, a heat transfer assembly. In some embodiments, a valve assembly is included to control the flow of a 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 the subassemblies 10, 15, 20, 25, 30, 35 may each be provided separately. According to some embodiments, the assemblies 10, 15, 20, 25, 30, 35 and the subassemblies 10, 15, 20, 25, 30, 35 may be provided as preassembled modules 10, 15, 20, 25, 30, 35. The assemblies 10, 15, 20, 25, 30 or the subassemblies 10, 15, 20, 25, 30 may be preassembled to the frame assembly 35. The assemblies 10, 15, 25, 30, 35 or the subassemblies 10, 15, 25, 30, 35 may also be preassembled to the cushion assembly 20. Components 10, 15, 25, 30, 35 or sub-components 10, 15, 25, 30, 35 may also be integrated into the material of the seat cushion assembly 20, such as into a foam or extruded thermoplastic web. In some embodiments, the cushion assembly 20 may be formed by an additive manufacturing process, such as the process disclosed in U.S. Pat. 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 preassembling the sub-components 10, 15, 20, 25, 30, 35 or components 10, 15, 20, 25, 30, 35 as modules, or preassembling to the frame assembly 35, or preassembling to the 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 adjacent to the seat occupant, that is, the decorative cover can include the outermost layer or include a surface as the outermost surface. The decorative cover 210 can cover the remaining components of the seat assembly 100 and is the main contact surface with the occupant. The decorative cover 210 can be configured to provide ventilation to the occupant when the occupant is seated and during operation. For example, the decorative cover 210 may include one or more perforations 211 and / or permeable fluids (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 to 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, the outer layer 214 may be polyurethane leatherette or polyester fabric, while the 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). The inner layer 215 may be permeable to fluid flow such as air, but the outer layer 214 may be made of an impermeable material such as leatherette or leather. If the outer layer 214 is an impermeable material, the outer layer 214 may be perforated so that when the outer layer 214 receives fluid flow from the inner layer 215, the outer layer 214 can provide ventilation to adjacent occupants.

[0223] The decorative cover 210 can be fixed and / or sealed to the film 220 so that the film 220 cannot be removed without damaging the decorative cover 210, the film 220, or the fixing / sealing medium (e.g., stitching or welding). In a variation, the decorative cover 210 and the film 220 can be fixed and / or sealed at least partially along or near the outer periphery or periphery of the seat surface 218, for example. In a variation, the decorative cover 210 can be fixed / sealed to the film 220 so that it is impermeable or does not leak fluid flow, such as air, at the connection interface. In a refinement, fixing can refer to an unchanging connection so that it excludes peeling and sticking adhesives that can be easily disconnected without damaging the material. The film 220 can be disposed between the decorative cover 210 and the substrate 250. In a variation, the film 220 can be adjacent to the decorative cover 210. The film 220 can also be disposed adjacent to one or more additional layers 240. One or more additional layers 240 can be disposed between the film 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. Therefore, the channel is arranged opposite to 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 can be arranged and sealed around the outlet of the blower 260, such as by an annular gasket or annular snap. Alternatively, the channel can be arranged in the outlet or engage 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 a cavity defined by the breathable bag. The spacer 230 can be any suitable structure that resists compression that would impede fluid flow from penetrating 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 sewing, hot riveting, ultrasonic riveting, hot plate welding, hot die forging, cold pressing, etc., so that they do not allow the fluid flow to escape except through one or more designated holes. In a variation, the first sheet 224 can be permeable to a fluid flow (such as air). Therefore, the breathable bag 222 can be configured to provide fluid communication with the decorative cover 210. In an 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 a pad or comfort material 241. The pad or comfort material 241 may provide comfort to the occupant when the occupant is seated. For example, the pad or comfort material may be foam. In a variation, the pad or comfort material 241 may be a foam-free net. In an improvement, the ventilation assembly 200 and / or the seat assembly 100 may be foam-free. In an improvement, the ventilation assembly may be foam-free so that it does not include a foam pad. In other words, the seat assembly may be foam-free.

[0228] Foam-free can refer to one or more stacked layers of non-foam material. Each layer can be formed by a knitted monofilament fabric material. An example of such a material is polyester, such as polyethylene terephthalate. The material can also be formed by 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, air permeability and compliance. The non-foam material can be made of monofilament fabric. For example, additional details of non-foam or non-foam materials can be found in the 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 non-foamed 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 an 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] One or more additional layers 240 may also include a substrate 250 that may support multiple components, such as a blower 260, a pump, an electrical circuit, a ventilation assembly 200, and / or a massage / bladder assembly, in which case the substrate 250 may be referred to as a carrier. The substrate 250 may be suspended to the seat frame 102 of the seat assembly 100, for example, by a suspension system (e.g., a suspension line). The substrate 250 may be a rigid plate, such as a plastic plate. The substrate 250 or carrier may define an orifice so that a fluid flow may 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 mechanically connected to 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 during operation and an outlet for delivering the fluid flow. Therefore, in one or more embodiments, ventilation assembly 200 may be configured to receive a fluid flow from blower 260 or deliver the 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 trim cover 210 and pass through trim cover 210, and vice versa, to provide ventilation to seated occupants 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) such as a vehicle (e.g., a motorcycle, an automobile, a locomotive, a boat, an 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 and provide ventilation from a fluid flow (e.g., air flow) when assembled in the seat (e.g., 100) during operation. The breathable bag (e.g., 222) defines a cavity and a channel in fluid communication with the cavity and disposed opposite to the trim cover (e.g., 210), the channel being configured to be connected to a blower (e.g., 260) through one or more additional layers (e.g., 240) (e.g., a cushioning / comfort material (e.g., 241) (which may be a foam-free net)), a substrate (e.g., 250) (e.g., a carrier plate, a rigid plate, a plastic plate). The air pocket (eg, 222) is secured to the trim cover (eg, 210) such that fluid flow (eg, air flow) travels from the air pocket (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 a 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, 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 pad (e.g., 241). The subassembly (e.g., 200) (e.g., a ventilation assembly) also includes a blower (e.g., 260) supported by a substrate (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, such as ) 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 mated (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). ), 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 ) define cavities and channels.

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

[0240] In one or more embodiments, the outer perimeter is an outer perimeter of a face (eg, 218) of a 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, such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt, such as ), 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 ), spacers (e.g., 230, such as spacer fabric), and one or more additional layers (e.g., 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 (eg, 210 ) is configured to provide ventilation to an occupant adjacent a first surface (eg, 212 ) (eg, an exposed surface) when receiving a fluid flow (eg, air flow) at a second surface (eg, 213 ) (eg, 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 ) is mated with the trim cover (e.g., 210) (e.g., fixed to the trim cover 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 between the trim cover (e.g., 210) and the carrier (e.g., 250) (e.g., a rigid plastic sheet). The 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 (e.g. 250) (e.g. a rigid plastic plate).

[0247] In various embodiments, the second sheet (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 mated (e.g., sealed to the first sheet by seaming, heat riveting, ultrasonic riveting, hot plate welding, hot die forging, cold pressing, etc., so 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 on 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 adjacent to the trim 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 a first sheet and a 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 cushion (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 ventilation is provided 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 film (eg, 220) is sewn to the trim cover (eg, 210). In other embodiments, the film (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 , a seat assembly 320 is illustrated, 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 a front passenger seat, a second row seat, a third row seat, or other rear seats, and can include a bench-style seat, a bucket seat, or other seat styles as shown. In addition, the seat assembly can be a non-stowable seat or a stowable seat that can be folded and stowed in a cavity in a vehicle floor. In addition, the seat assembly 320 can be configured to be used 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 member can be provided by a frame and / or a substrate. The seat assembly has a seat component, 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 pelvis and thighs of the occupant. The seat back 326 can be sized to extend upright from the seat bottom 324 to support the back of the occupant. The seat assembly can additionally 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 the seat components (e.g., seat bottom 324 and seat back 326) and can be configured as a plurality of frame members and / or substrates or panels that are movable relative to each other to provide adjustment of the seat assembly. The support structure 322 can be formed of stamped steel alloy, fiber reinforced polymer, or any suitable structural material.

[0267] One or more decorative components 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, and the decorative cover component 332 is partially cut away. In one example, the decorative cover component 332 covers both the cushions 328 and 330. In other examples, multiple decorative cover components are provided to cover the seat bottom cushion and the seat back cushion. The decorative cover component 332 according to various embodiments is further described in detail below. The decorative component 332 provides a decorative surface, or a visible surface or A surface of the seat assembly 320. The decorative component 332 also includes additional material layers as described below, and can provide ventilation for the seat in addition. The seat assembly 332 can 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 pad 340 is described in further detail below, and the description may be similarly applied to the seat bottom pad 328 or the seat back pad 330. According to various examples, the seat pad 340 may be formed of 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 may be provided without any pad 340, such that the trim assembly is supported directly on the support member 322, such 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 referred to 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, but other polymers and materials that are effective in providing the desired properties and functions 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 may be formed of multiple layers of material as described below. The decorative component 400 may be used as a decorative component 332 and a decorative component 333. 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] The trim assembly 400 has a perforated trim cover 402. The trim cover 402 can provide an A-surface for the trim assembly 400, or a seating surface visible to a seat occupant. The perforated trim cover 402 can be formed from one or more panels 404 of leather, artificial leather, vinyl, woven fabric, knitted fabric, or other material. The perforations in the panels 404 of the trim cover 402 allow air to flow through the trim cover 402. The perforations can be provided as small holes or orifices formed through the trim cover. The knit or woven pattern in the fabric trim cover can act as perforations and provide air flow 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 a 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 stitching 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 of a continuous plastic layer (e.g., a thermoplastic polyurethane sheet or film). The 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 described above with respect to the joint. Figure 4 An 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 layers 420 is formed of an air permeable material or contains perforations or other features to allow air to pass through and across the layer. 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. 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 of 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 of 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 firm support surface. In other examples, the first spacer material layer 422 and the second spacer material layer 424 can be formed of other materials that allow air to flow therethrough.

[0277] The first spacer layer 422 is in contact with the decorative cover layer 402, and the second spacer layer 424 is located between the first spacer layer 422 and the barrier layer 410. The first spacer layer 422 has a groove 426 or a groove formed therein. As used herein, the groove 426 may refer to an open channel or groove formed in the spacer layer 420 and intersecting one of the faces. In one example, the groove 426 has a bottom plate 428. As shown, the groove 426 can be formed on a face 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 in the groove, and the connecting portion 406 can be additionally received in the groove 426.

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

[0279] like Figure 4 As shown, the decorative cover layer 402 is connected to the barrier layer 410 around the perimeter of the trim 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. Additional decorative panels can be connected to the trim assembly, such as near the perimeter, to cover other portions of the seat or its surroundings, as shown below with reference to Figures 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. Fig. 9 4, for illustrative purposes, the film 430 is shown as having partial transparency below the spacer layer 420. In one example, the tie film 430 is formed of a non-woven fabric. A porous spacer material layer, such as a first spacer layer 422, is positioned between the decorative cover layer 402 and at least a portion of the tie film 430. As shown, the tie film 430 can be laminated between the first spacer material layer 422 and the second spacer material layer 424, and such that the tie film 430 is separated from the decorative cover layer 402 by the first porous spacer material layer 422. The tie film 430 can contact the first spacer layer 422 opposite the 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 plate 428 of the groove 426 in the first spacer material layer).

[0282] The stitching tension in the seam 432 connecting the excess 408 to the tie film 430, as well as the depth of the groove 426 and the thickness of the layer 422, help define the shape of the trim cover layer 402 and the appearance of the trim assembly 400 as it forms 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] The trim assembly 400 may be formed or assembled prior to being attached to the cushion 340 or the seat assembly 320. In another example, the trim cover assembly 400 may be assembled in a first facility or a first production line and then shipped or moved to a location or assembly line for the vehicle seat assembly 320. Because the trim assembly 400 may include components for features such as ventilation and / or heating preassembled within the assembly 400, the seat 320 may be easier to assemble 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 described above, 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 may 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 An 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 of a reticulated foam layer, and the second spacer layer 424 is formed of 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 and 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, such as near the perimeter to cover other portions of the seat or its surroundings. In addition, the additional decorative panel can be set as described with respect to the decorative assemblies 400, 500, or can be set without the barrier layer or other layers shown. Additional fasteners can be set around or adjacent to 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] The trim assembly 500 has a tie-down membrane 520 connected to the trim cover layer 402. In one example, the tie-down membrane 520 is formed of a breathable or porous material, and in the example shown, the tie-down membrane 520 is formed of a screen or a coated mesh. In one non-limiting example, the coated mesh is a vinyl-covered fiberglass screen. In other examples, the tie-down membrane 520 can be formed of a plastic material, such as a thermoplastic polyurethane sheet or film, and is perforated or otherwise formed to provide air flow 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 outwardly 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 located 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 and to the distal end 522, wherein the distal end is thus positioned outside 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 can remain inside 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 junction.

[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 orifice for use with these attachment features.

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

[0297] Figure 7 A method 600 of forming a trim cover assembly 332 is shown, and a method of assembling the trim cover assembly 332 and a seat assembly (such as a vehicle seat assembly 320) is also provided. In various examples, the steps can be performed in other orders, or can be performed sequentially or simultaneously. In addition, additional steps can be added, or steps can be omitted. According to various embodiments, the method 600 can 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 in a face that engages or faces the decorative cover layer 402. The decorative cover layer may be formed with a joint 406 between 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 on top of each other in a first stack 502, and the second portions of the spacer layers can be stacked on top of 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, the tie film 430 is laminated below the first spacer material layer 422 and opposite the groove 426. In another example, the tie film 430 is positioned between the first spacer material layer 422 and the second spacer material layer 424. The trim cover panel margin 408 is sewn to the tie film 430 through the spacer material layer 422 along the groove 426. The first spacer layer 422 and the 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 the distal end 522. The tie-down film 520 is connected, for example, sewn or otherwise connected 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 connected 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 so 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 be additionally used as a tie-down for a trim assembly to a 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 additional trim panels 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 port 412 of the barrier layer 410 from a fan and / or an air pump of the air system 350. Figure 2 and Figure 5 4 and 5. As shown schematically by arrows in FIG. 4 , the air can exit the trim assembly 332 only through the perforated trim cover layer 402 because the barrier layer 410 is air impermeable. The air flows into the trim assembly 332 and flows upward through the second spacing layer 424 and the first spacing layer 422 because each layer is porous and breathable. For the trim assembly 400 with the fasteners 430, the air generally flows around the fasteners, although some air can flow through the fasteners. For the trim assembly 500 with the fasteners 520, the air can flow laterally in the trim assembly 500 and through the fasteners 520, so that the air flows into various portions of the spacing 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 spacing 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 mesh spacer fabric) located 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 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 mesh spacer fabric) is positioned between the decorative cover layer (e.g., 402) and at least a portion of the tightening 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 reticulated spacer fabric).

[0315] In some embodiments, 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 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 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 (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) includes a reticulated foam.

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

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

[0319] In one or more embodiments, the assembly (eg, 400) further includes one or more trim panels (eg, 404) coupled 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, such as airtight, such as 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 a 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 a stitching line on two panels connected together) of a first panel and a second panel (e.g., 404).

[0325] In some embodiments, 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 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 line on 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 connected together) is sewn to the tie-down membrane (e.g., 430) via a 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).

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

[0328] In some embodiments, the perforated decorative covering layer (eg, 402) comprises leather, faux 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 reinforcing 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 reinforcing 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-down membrane (eg, 430 ) (eg, 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 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 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 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 mesh spacer fabric) 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).

[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 a distal end.

[0338] In one or more embodiments, 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) is positioned between a distal end of a 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, such as urethane or other foam material or a spacer fabric, such as a knitted or reticulated spacer fabric) such that a 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, such as airtight, such as a continuous plastic layer, such as 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-down membrane (eg, 430) (eg, the reinforcement layer) is perforated.

[0341] In one or more embodiments, the tie-down membrane (eg, 430 ) (eg, reinforcement layer) includes 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, a 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 coupled 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, the method (e.g., 460) includes positioning (i.e., step 461) one or more porous spacer material 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 a perforated decorative cover layer (e.g., 402) and a barrier layer (e.g., 410) (e.g., an impermeable layer, such as an air-impermeable, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film), with a tie-down membrane (e.g., 430) (e.g., 431) positioned between the decorative cover layer (e.g., 402) and the tie-down membrane (e.g., 432). a spacer 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 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 fastening membrane (e.g., 430) (e.g., a 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 reticulated 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 air-impermeable, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film) further includes 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 reticulated 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 air-impermeable, such as a continuous plastic layer, such as a thermoplastic polyurethane sheet or film) A foam, such as urethane or other foam material or spacer fabric, such as a knitted or mesh spacer fabric) and 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 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 (e.g., 402) and the barrier 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).

[0348] In some embodiments, the method (e.g., 460) also 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 excess (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 connected together) into the groove (e.g., 426).

[0349] In one or more embodiments, the method (e.g., 460) also includes layering (i.e., step 464) 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, 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., a reinforcement layer).

[0350] In various embodiments, the step of positioning 461, i.e., 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 includes 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 a layer of other features of 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 465) a fastening membrane (e.g., 430) (e.g., a reinforcement layer) so that it extends transversely to the decorative cover layer 402 and extends to a distal end (e.g., 522) between the first and second portions of a spacer material layer 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).

[0351] In some embodiments, method such as 460 also 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 air-impermeable, 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 a 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) also 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 a perforated decorative cover layer (e.g., 402) into an inlet port (e.g., 412) (i.e., step 474) to ventilate the decorative component (e.g., 400).

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

[0357] Fig.11 A vehicle seat assembly 720 according to some embodiments is shown. The vehicle seat assembly 720 is provided with a seat bottom 722 adapted to be mounted to a vehicle floor. The vehicle seat assembly 720 can be provided 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 for any type of vehicle, including land vehicles, watercraft, aircraft, etc. The vehicle seat assembly 720 can be any seat assembly, such as an office chair, furniture, etc.

[0358] The vehicle seat assembly 720 is provided with a plurality of adjacent trim cover sections 728, 729 over the seat bottom 722, seat back 724 and 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] Fig.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 multiple adjacent trim cover sections 728, 729. According to some embodiments, the first fluid impermeable layer 732 can be glued or welded to multiple 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 of 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 a plurality of adjacent decorative cover segments 738, 729 are impermeable and have holes formed therethrough, the plurality of vents 734 are 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 zone 738 and the second portion 748 extends through the second zone 740. The first portion 746 of the second fluid-impermeable layer 742 is provided with a first flap 766 extending between the first zone 738 and the second zone 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 zone 738 and the second zone 740.

[0362] Continue to refer Fig.12 , the trim cover assembly 731 is also 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 of an elastic and porous material, such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material, etc. The first fluid permeable layer 754, 755 is displaced along the first fluid impermeable layer 732. The first fluid permeable layer 754, 755 extends through the first zone 38 and the second zone 740, and is separated at the seam 736 as a first fluid permeable layer portion 754, 755, each of which is located in one of the zones 738, 740. According to some embodiments, the first fluid permeable layer 754, 755 is sewn to the seam 736. According to some embodiments, the first fluid permeable layer 754, 755 is laminated and may not be sewn to the seam 736.

[0363] The second fluid permeable layer 756, 757 is a spacer fabric that is sized to be contained within the fluid chamber 44 and is spaced apart from the first fluid permeable layer 754, 755. The second fluid permeable layer 756, 757 extends through the first zone 738 and the second zone 740 and is separated at the seam 736 into second fluid permeable layer portions 756, 757, each within one of the zones 738, 740. The second fluid permeable layer 756, 757 is also displaced along the perforated second fluid impermeable layer 742, thereby allowing air to flow through the first zone 738 and the second zone 740. Without the permeable layer 754, 755, 756, 757, the impermeable layer 732, 742 may be compressed when weight from an occupant is applied, which may cut off airflow when the fan 752 is used. When the trim cover assembly 731 utilizes a compressor instead of the fan 752, the permeable layer 754, 755, 756, 757 may be omitted.

[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 an outer decorative cover section 728, 729 disposed above the first fluid impermeable layer 732 and the second fluid impermeable layer 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 zone 738 and the second zone 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 Fig.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 installed between the decorative cover 728 and the seat cushion 730. The seat cushion 730 includes a receiving portion sized to receive the fan 752. Conventional fans are installed below the vehicle seat cushion and outside the decorative cover assembly. Installing 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 below the cushion. The fluid conduit is then assembled through the cushion and trim cover of the conventional seat assembly. The fluid impermeable layers 732, 742, the permeable layers 754, 755, 756, 757, the heat transfer layer 758, and the fluid actuator 750 are all preassembled within the trim cover assembly 731 so that the trim cover assembly 731 can be mounted to the seat frame as a whole. This reduces manufacturing costs and time compared to the prior art.

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

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

[0369] Fig.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 zone 738 and the second zone 740. The second fluid impermeable layer 742 is provided with a first wing 760 and a second wing 762. The first wing 760 extends between the first zone 738 and the second zone 740. In addition, the first wing 760 is perforated to allow air to pass through the first zone 738 and the second zone 740. The second wing 762 extends in an opposite direction to the first wing 760 and can be attached to the seat pad 730. The first wing 760 and the second wing 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 an 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 an impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), and seams (e.g., 736) extending through 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 an impermeable polymer material, such as polyethylene).

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

[0372] In some embodiments, the 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 zone (e.g., 738) and a second zone (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 air-impermeable 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, component such as 731 also includes a fluid actuator such as 750 (e.g., a fan) attached to a second fluid-impermeable layer such as 742 (e.g., any air-impermeable material or an impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to transport fluid (e.g., air) through fluid chambers such as 744 and out of the first fluid-impermeable layer such as 732 (e.g., any air-impermeable material or an 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 connectivity 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 an 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 an 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 an 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 stitched to the seam (e.g., 736).

[0382] In one or more embodiments, the component (e.g., 731) also 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 in 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 an impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) of a component (e.g., 731) extends through a first zone (e.g., 738) and a second zone (e.g., 740), and the 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) also includes a first perforated portion (e.g., 746) extending to a seam (e.g., 736) of a trim cover segment (e.g., 728, 729) and a second portion (e.g., 748) connected to a seat pad (e.g., 730) (a foam or non-foamed 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 above 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 air-impermeable material or an 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 air-impermeable material or an impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to produce 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., step 776) 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) in a cooperative manner (e.g., sewing, welding, adhering or otherwise fastening) with a perforated first portion (e.g., 746) extending through the first zone (e.g., 738) and the second zone (e.g., 740).

[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, the assembly, such as 731, includes a first fluid-impermeable layer, such as 732 (e.g., any air-impermeable material or an impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), which is 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 (e.g., 732) (e.g., any air-impermeable material or an 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 (e.g., 728, 729) are sewn to the first fluid-impermeable layer by seams (e.g., 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 the perforated 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) 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 an impermeable polymer material, such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to form a first zone (e.g., 738) and a second zone (e.g., 740). A fluid chamber (e.g., 744) is provided between the first zone (e.g., 738) and the second zone (e.g., 740), wherein 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 provided with a first portion such as 746 extending vertically through the first zone (e.g., 738) and the second zone (e.g., 740), and a second portion (e.g., 748) connected to the seat pad (e.g., 730) is sized to be received by 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 the first fluid permeable layer (e.g., 754, 755 )(e.g., elastic and porous materials, such as porous foams, extruded thermoplastic resin meshes, knitted three-dimensional spacer materials), 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 an 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 materials) displaced along 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),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] Fig.15 A vehicle seat assembly 810 according to some embodiments is shown. The vehicle seat assembly 810 is provided with a seat bottom 812 adapted to be mounted to a vehicle floor. The vehicle seat assembly 810 can be provided 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 for any type of vehicle, including land vehicles, watercraft, aircraft, etc. The vehicle seat assembly 810 can be any seat assembly, such as an office chair, furniture, etc.

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

[0395] Fig.16 A decorative cover assembly 822 is shown according to some embodiments. The decorative 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 illustrated and described, any number of vents 836 may be utilized. The vents 836 direct airflow through the decorative 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 in 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 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 displaced 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, which 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 Fig.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 installed between the decorative cover 818 and the seat cushion 820. The seat cushion 820 includes a receiving portion sized to receive the fan 832. Conventional fans are installed below the vehicle seat cushion and outside the decorative cover assembly. Installing 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 below the seat cushion. The fluid conduit is then assembled through the cushion and trim cover of the conventional seat assembly. The fluid impermeable layers 824, 826, the permeable layers 828, 830, the heat transfer layer 834, and the fluid actuator 832 are all preassembled within the trim cover assembly 822 so that the trim cover assembly 822 can be mounted to the seat frame as a whole. This reduces manufacturing costs and time compared to the prior art.

[0400] The trim cover assembly 822 can operate with a breathable non-foam seat pad 820 formed of a thermoplastic web. The second fluid impermeable layer 826 provides a barrier between the fluid chamber 825 and the seat pad 820. When used with the foam pad 820, the second fluid impermeable layer 826 can be omitted if the pad 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 vent 836 of the fluid impermeable layer 824. Alternatively, the fluid actuator 832 can be separate from the trim cover 818.

[0401] Fig.17 An outer decorative layer 818, a first fluid impermeable layer 824, and a 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 does not escape the fluid chamber 825. Alternatively, the layers 818, 824, 826 may be attached or welded together with an adhesive rather than 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 nonwoven 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) also 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 matched (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 a fluid (e.g., air) through a fluid chamber (e.g., 825) and then out of 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) also 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 also includes 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) also includes an external decorative layer (e.g., 818), which is disposed above 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 a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) without an 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 above 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 external 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 external 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 fluid impermeable layer and the second fluid impermeable layer.

[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 826 (e.g., an impermeable polymer material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) is coupled (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 (e.g., 825). 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) which is 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); and 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). C) film, polyethylene); 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 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 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] Fig.18 A vehicle seat assembly 910 according to some embodiments is shown. The vehicle seat assembly 910 is provided with a seat bottom 912 adapted to be mounted to a vehicle floor. The vehicle seat assembly 910 can be provided 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 for any type of vehicle, including land vehicles, watercraft, aircraft, etc. The vehicle seat assembly 910 can be any seat assembly, such as an office chair, furniture, etc.

[0423] The vehicle seat assembly 910 is provided with a trim cover 918 over the seat bottom 912, the seat back 914 and the head restraint 916 to hide the frame, cushioning components and functional components. The seat bottom 912 is provided with a seat cushion 920. The seat cushion 920 can be composed of a twisted thermoplastic mesh or foam. The vehicle seat assembly 910 is also provided with a controller and pump 944. The controller and pump 944 can be arranged in a module below the seat cushion 920 and can be a multi-function controller that also controls other functions in the vehicle.

[0424] Fig.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 on 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 may be formed of a cushioning material such as foam. The second fluid impermeable layer 928 may be formed of 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 holes formed therethrough, the first fluid impermeable layer 924 and the vents 926 may be optional. In addition, 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 pad 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, 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] The second fluid permeable layer 936 is displaced along and spaced apart from the first fluid impermeable layer 924. The first fluid permeable layer 934 and the second fluid permeable layer 936 ensure that the first fluid impermeable layer 924 and the second fluid impermeable layer 928 are not compressed together by the weight of the occupant. Without the permeable layers 934, 936, the impermeable layers 924, 928 may be compressed when weight from the occupant is applied, which may cut off airflow when the fan 942 is used. When the trim assembly 922 utilizes a compressor instead of the fan 942, the permeable layers 934, 936 may be omitted.

[0429] The decorative cover assembly 922 is also provided with a heat transfer layer 938, which is displaced 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 displaced 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 displaced 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 disposed 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 an adhesive. According to some embodiments, the decorative layer 918 is glued to the first fluid-impermeable layer 924.

[0430] Continue to refer Fig.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 installed between the decorative cover 918 and the seat cushion 920. The seat cushion 920 includes a receiving portion sized to receive the fan 942. Conventional fans are installed below the vehicle seat cushion and outside the decorative cover assembly. Installing 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 below the cushion. The fluid conduit is then assembled through the cushion and trim cover of the conventional seat assembly. The fluid impermeable layers 924, 928, the permeable layers 934, 936, the heat transfer layer 938, the air bladder assembly 932, and the fluid actuator 940 are all preassembled within the trim cover assembly 922 so that the trim cover assembly 922 can be mounted to the seat frame as a whole. This preassembly reduces manufacturing costs and time compared to the prior art.

[0432] The trim cover assembly 922 can operate with a breathable non-foam seat pad 920 formed of a thermoplastic web. The second fluid impermeable layer 928 provides a barrier between the fluid chamber 930 and the seat pad 920. When used with a foam pad 920, the second fluid impermeable layer 928 can be omitted if the pad 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) also 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 coupled (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 component (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) also 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), which is displaced along 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) and is separated from the first fluid permeable layer (e.g., 934) (e.g., an elastic and porous material, such as a porous foam or an extruded thermoplastic resin mesh).

[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) also includes an outer decorative layer (e.g., 918) disposed above 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, a 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 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 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 by 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 an 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) that is 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 a thermoplastic polyurethane (TPU) film, a 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 a second impermeable layer (e.g., 928) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene); at least one inflatable bladder component (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), which 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), which 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) 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 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 an electrically conductive heater pad.

[0455] Fig. 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, etc.

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

[0457] The seat back assembly 1024 includes a seat support member of a 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 lumbar and chest areas of the occupant. A pair of pillows 1032 each extend laterally outward from the central area 1030 in a front-to-back direction and extend forward from the central area 1030 to provide lateral support to the lumbar and chest areas of the occupant. The cushion 1028 also includes a shoulder area 1034 that extends above the central area 1030 and slightly forward to receive and support the shoulders of the occupant. On the front surface of the pad 1028, the central region 1030, the pillow 1032, and the shoulder region 1034 collectively provide a support surface 1036 for contacting and supporting an occupant.

[0458] Reference now Fig. 20 and Fig.21, the seat assembly 1020 includes a localized pressure assembly, such as a 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 in the seat assembly 1020, the massage assembly 1038 includes a plurality of localized pressure devices, such as a massage device 1040, each of which is located in one of a plurality of zones along a central region 1030 of the cushion 1028. Although the massage devices 1040 are positioned in the central region 1030, the massage devices 1040 may be used in any area of ​​the seat assembly 1020. Although massage devices are illustrated and described, any localized pressure device may be employed, such as a tactile device, a lumbar adjustment device, a bolster adjustment device, a shoulder adjustment device, etc.

[0459] Massage device 1040 is positioned on rear surface 1042 of seat cushion 1028, as shown in FIG. Fig.21 The rear surface 1042 of the seat cushion 1028 is spaced apart from the support surface 1036 and is dimensioned to be mounted to a 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 airbag 1040. To this end, the seat assembly 1020 includes a pump and valve assembly 1044 that fluidly cooperates with each airbag 1040 to inflate and deflate the airbag 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 a seat assembly having a massage assembly. The prior art massage assembly typically includes a massage device positioned on a support surface of a seat cushion. The front surface placement of the massage device allows the massage effect to be directly distributed to the occupant. However, placing 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 tubes or wiring extending through the cushion to the rear surface of the seat cushion to connect to a pneumatic air source or power source. Positioning the massage device on the support surface increases the complexity, manufacturing time, and cost of the prior art massage assembly.

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

[0463] In order to effectively provide an effective massage effect from the rear surface 1042 of the seat pad 1028, a plurality of movable or articulated portions 1048 are formed in the seat pad 1028. The movable portions 1048 can translate relative to the rest of the seat pad 1028 due to the weakened area 1050 formed between the movable portions 1048 and the seat pad 1028. The weakened area 1050 partially separates the movable portions 1048 relative to the central area 1030 to allow the movable portions 1048 to translate while maintaining the connection of the movable portions 1048 to the seat pad 1028. The movable portions 1048 can be formed of a different material than the seat pad 1028 to suit the applicable function. For example, the seat pad 1028 can be formed of a foam such as polyurethane; while the movable portions 1048 can include compressed fibers or other materials for elasticity as an articulation device. The additional material in the movable portion 1048 can be insert molded into the foam of the movable portion 1048.

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

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

[0466] Figure 22-Figure 24The overall shape of the movable portion 1048 is shown to be defined by the 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 a majority 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 pad 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 Fig.24 1048 and the central region 1030. The recess 1056 extends around the perimeter of the movable portion 1048 and intersects the slot 1052. According to some embodiments, the weakened area 1050 can be provided with the recess 1056 formed around the perimeter of the movable portion 1048 without the slot 1052, so that the tether 1054 extends around the perimeter of the movable portion 1048 as a web. 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, tether 1054 can be sized to be severed after initial operation of massage device 1040. For example, tether 1054 can be sized to maintain the position and orientation of movable portion 1048 until movable portion 1048 adheres to massage device 1040. Then, after several cycles of massage device 1040, tether 1054 can be torn to allow tetherless translation of movable portion 1048, thereby further improving travel performance.

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

[0470] Reference now Figure 20-Figure 25, the 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 with respect to a seated occupant. The massage device 1040 and related components (e.g., 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 on the frame 1058.

[0471] Fig.26 A seat pad 1062 is shown according to 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 of 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 may be formed of a higher density or durometer foam that is molded separately from the remainder of the seat pad 1028. The reinforcement portion 1064 may be molded separately as a unitary body and then insert molded with the softer foam used for the remainder of the seat pad 1028. Alternatively, the reinforcement portion 1064 and the seat pad 1028 may 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, a base, or a frame) to support a cushion (e.g., 1028) that includes a cushioning material (e.g., polyurethane foam). The support member defines a support surface (e.g., 1036) that is sized to support an occupant and includes a weakened area (e.g., 1050, such as a pair of slots 1052 formed through the 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., the 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 a pressurized bladder applied to a rear surface of the movable portion (e.g., 1048) from a localized pressure device (e.g., massage device 1040). The local 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 segment (e.g., 1048), such as 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, 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), such as by being formed from compressed fibers rather than polyurethane foam or from a higher stiffness, higher density or hardness 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 on 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., 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, comprising a seat frame (e.g., 1058 (e.g., a rigid material such as metal, plastic, wood, or a combination thereof)), a local pressure device (e.g., 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 local pressure device (e.g., 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) also 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 fibers or foams having higher stiffness, hardness, and / or density)). The plurality of recesses allow translation of a local pressure effect (e.g., a massage effect) applied to the movable portion (e.g., 1048) from a local pressure device (e.g., a 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 the 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 support member is formed with a first rigidity, and the movable portion is formed with a second rigidity greater than the first rigidity.

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

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

[0487] The seating system 1120 provides contact surfaces 1128, 1130 for receiving and comfortably supporting an occupant. The seating system 1120 includes at least one actuator assembly 1132 disposed within the seating system 1120 within the contact surfaces 1128, 1130. Although one actuator assembly 1132 is illustrated and described, any number or location of actuator assemblies 1132 may be employed. The actuator assemblies 1132 may be used to apply tactile effects to the occupant, such as vibrations for conveying an alert, vibrations for applying a massage, pressure for applying a pressurized massage effect, support to 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 electric valves 1136 may be employed. Alternatively, multiple pumps 1138 may be employed without any electric valves 1136.

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

[0491] The system 1120 also includes an interface 1142 in electrical communication with the controller 1140. The interface 1142 receives a manual selection of a massage effect. The interface 1142 transmits the massage request to the controller 1140. The interface 1142 can be a mechanical selector switch or multiple switches. The interface 1142 can also be another human-machine interface, such as a graphical user interface, for the occupant to select the massage effect. The interface 1142 can be integrated into the seat system 1120, or can be provided elsewhere in the vehicle. The interface 1142 can be integrated with the 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 operation of the massage component 1132 may be activated as a service, incentive, subscription, promotion, or any other marketing or retail effort. For example, the hardware of the massage component 1132 is installed in the seating system 1120, but is not operable until after the activation operation.

[0493] The activation code may be provided in a software application accessible by a personal digital assistant (PDA) 1144, such as a smart phone, etc. The PDA 1144 may be any controller configured to receive the activation code and transmit the code to the controller 1140. The PDA 1144 communicates wirelessly with a receiver 1146 in the vehicle or seating system 1120, which in turn communicates with the controller 1140. For example, an occupant may install an application configured with the activation code on the PDA 1144. The occupant may subscribe to a service or otherwise access an activation code, which is transmitted to the controller 1140 to activate or otherwise unlock the operation of the massage assembly 1132. The interface 42 may also be provided in a software application with the activation code 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] Fig.28 A massage assembly 1148 is shown that can be installed in the seating system 1120 as the massage assembly 1132. The massage assembly 1148 includes a pair of lumbar bladders 1150 positioned in the lumbar region of the seating surface 1130 to apply a pressurized massage effect to the occupant. A valve assembly 1152 is in fluid communication with the lumbar bladders 1150 and a pump 1154 to deliver pressurized air from the pump 1154 through the valve assembly 1152 to the lumbar bladders 1150. According to some embodiments, the massage assembly 1148 provides one massage effect: inflation and deflation of the lumbar bladders 1150. Alternatively, the massage assembly 1148 can provide multiple massage effects through additional valves or additional massage programs.

[0496] Fig.29 An example method for operating a massage assembly 1148 in a 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 by a selection at the interface 42. If a massage effect is not requested, block 1158 is repeated. If a massage effect is requested, a massage operation is performed at block 1160.

[0497] Fig.30 A massage assembly 1162 is shown according to some embodiments. The massage assembly 1162 is shown mounted to a suspension 1164 that supports the massage assembly 1162 for mounting to a seat frame. The massage assembly 1162 includes a plurality of inflatable airbags, including a lumbar bladder 1166, an array of incrementally spaced airbags 1168, a cervical bladder 1170, and a pair of side bolster airbags 1172. Each of these airbags 1166, 1168, 1170, 1172 can be individually inflated to support an occupant. Each of the airbags 1166, 1168, 1170, 1172 can also be individually inflatable, or in groups, for performing 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 end users to obtain various authorization codes.

[0499] Fig.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 performed 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 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) 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) communicating with the 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 various embodiments, the controller (e.g., 1140) is provided as one or more controllers or control modules for various components and systems. Controller (e.g., 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 (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, which 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-temporary 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, pillow 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 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), 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, pillow bladders, and / or shoulder bladders, valve assemblies 1136 / 1152, and pumps 1138 / 1154).

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

[0504] In some embodiments, the massage actuator (e.g., 1148) includes at least one air bag. 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 bag 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 at least one air bag assembly (e.g., 1150) in response to a signal from the controller (e.g., 1140).

[0505] A seat assembly (e.g., 1120) is described, the seat assembly (e.g., 1120) including 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) including 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 components (e.g., 1148) described herein 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., manually selected 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 an input indicative of authorization.

[0508] A method is also provided, which 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 vibrating massage) and deactivating (i.e., step 1196) the massage actuator 1148 to prevent operation of the massage actuator 1148. In various embodiments, the method also 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 the operation of the massage actuator (e.g., 1148), programming (i.e., step 1194) the controller (e.g., 1140) to deactivate the 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, the massage actuator (e.g., 1148) is activated with 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 also 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, which includes 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), which is operable to provide a massage effect (e.g., a pressurized or vibrating massage). The controller (e.g., 1140) is programmed to receive input indicating authorization (e.g., an authorization code) to operate the massage actuator, receive input indicating a massage request (e.g., manually select 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., manually select a massage effect). In various embodiments, the massage actuator (e.g., 1148) is operable to provide at least two massage effects (e.g., pressurized and vibrating massage effects). 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 device may further comprise a control unit configured to receive an input indicating an authorization (e.g., an authorization code) for operating a massage actuator (e.g., 1148) for a second massage effect (e.g., pressurization or vibration), receive an input indicating an authorization (e.g., an authorization code) for operating a massage actuator (e.g., 1148) for a second massage effect (e.g., pressurization or vibration massage effect), receive an input indicating a request (e.g., a manually selected massage effect) for a second massage effect (e.g., pressurization or vibration massage effect), and in response to the second massage effect authorization (e.g., the authorization code) and the second massage effect request (e.g., the manually selected massage effect), output a second massage effect signal to operate the massage actuator (e.g., 1148) to provide the second massage effect (e.g., pressurization or vibration massage effect).

[0510] refer to Figure 32-Figure 33, a massage bladder 1200 having a circular portion 1210 is disclosed. In one improvement, the bladder 1200 includes a first sheet 1220, which cooperates with a second sheet 1230 to define a bladder chamber having a circular shape, which can be filled with a fluid. In one improvement, the first sheet 1220 and the second sheet 1230 can be matched, 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 local bond between the two sheets 1220, 1230 forming a seal. In one improvement, the sheets 1220, 1230 can be fixed by heat riveting along the periphery 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 spherical shape, a cylindrical shape, 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, such as Figure 32-Figure 33 The bladder 1200 also includes a fluid passage 1240 for allowing fluid to enter and leave the chamber.

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

[0513] In one or more embodiments, the circular portion protrudes sharply from the plane XX defined by the sheet, such as Fig.33As shown. In a variation, the circular portion of the sheet defines a cavity that is at least 30% of a circular shape, or more preferably at least 50%, or even more preferably at least 60%. For example, the circular portion defines a cavity that has a shape 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, Fig.36 As shown, the capsule 1600 includes a first sheet 1620 and a second sheet 1630, and the first sheet 1620 and the second sheet 1630 each have a circular shape 1610 (e.g., a hemisphere) molded therein. In a variation, the circular shapes molded therein are aligned so that the shape of the cavity they form is different from the shape molded into either one. The molded portions of the aligned sheets provide a cavity that embodies at least 60% of a circular shape, or more preferably at least 75% of a circular shape, or even more preferably at least 90% of a circular shape. For example, the first sheet 1620 and the second sheet 1630 each have a hemisphere molded therein that defines a spherical cavity when aligned together. 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 a 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 Figure 37-Figure 42 shown.

[0516] Figure 37-Figure 42 Shows the body pressure distribution when the maximum pressure is applied. The graph is obtained by placing a pressure sensitive pad between the occupant and the airbag assembly and measuring the pressure when the airbag is inflated and released. A group of occupants are tested to obtain pressure data, such as the average maximum pressure applied. Red areas indicate the highest pressure areas and blue areas indicate the lowest pressure areas. Fig.37 , Fig.39 and Fig.41 A capsule (such as Figure 32-Figure 33 Massage components such as those depicted in Fig.38 , Fig.40 and Fig.42 A conventional accordion-style capsule (such as Figure 34-35 As shown, conventional bladders are less focused and apply lower pressure to the occupant. Fig.37 and Fig.38 plots the average maximum pressure exerted on the 5th percentile occupant, Fig.39 and 40 depicts the average maximum pressure exerted on the 50th percentile occupant, and Fig.41 and 42 The average maximum pressure applied to the 95th percentile occupant is depicted.In one or more embodiments, the bladder may apply 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 to the occupant.

[0517] Table 1 (below) provides average maximum pressures 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 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. Fig.36 Similar results were obtained for the capsule depicted in .

[0521] refer to Fig.43 , discloses a method for Fig.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 also includes a seat frame 1706 and cushion 1708 for supporting assembly 1500. In one refinement, seat 1700 also includes a decorative cover 1710 disposed above cushion 1708. In one variation, seat 600 is a seat for a vehicle such as an automobile, motorcycle, boat, aircraft, and / or locomotive.

[0522] Massage assembly 1500 includes a plurality of bladders 1510 and a plurality of fluid channels 1512 as described herein, wherein a first end of the channel terminates at a chamber of the plurality of bladders 1510. A second end of the channel 1512 can cooperate with a flow inducing device such as a compressor or a pump so that they can receive fluid from the compressor or the pump. In one refinement, the second end of the channel 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 channel and the flow inducing device. In a variation, the first sheet 1502 and the second sheet cooperate to form a plurality of bladders and / or channels. For example, in Fig.44 In the embodiment of the present invention, 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 that forms 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 Fig.47 The carrier plate 1800 is supported by the frame 1706, for example Fig.48 Frame 1706 of seat back 1702 shown. In a modification, 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 modification, the thickness of carrier plate 700 is at least 0.5 mm, or more preferably at least 2 mm, or even more preferably at least 2.5 mm. In a modification, the thickness of carrier plate 700 is 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 fixing various other components such as flow induction devices, valve assemblies, inflatable subassemblies, electronic devices or a combination thereof to carrier plate 1800. In a modification, carrier plate 1800 includes a suspension system to fix it to seat assembly 1300, such as to a frame.

[0524] In one or more embodiments, the massage assembly 1500 can be arranged in a seat so 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 provided between the occupant and the bladder. In one refinement, the contact area can be around 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 Fig.49 As shown. 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 airbag in a seat so that the apex of the circular portion can protrude into a seated occupant during operation (i.e., 1940). For example, Fig.48 Describe the embodiment of the mold for shaping the first sheet and / or the second sheet. The mold has a circular shape so that it is molded into the sheet applied thereto. In one improvement, the mold and / or the sheet are heated to soften the sheet and assist in molding. 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 sheet and the second sheet are aligned to define a chamber. In yet another improvement, the first sheet and the second sheet are bonded together with an adhesive, heat riveted and / or ultrasonically welded or otherwise matched around the circular portion to produce a seal. In some embodiments, the sheets are bonded together with an adhesive, heat riveted and / or ultrasonically welded to define a fluid passage to the chamber. In other embodiments, the tube can be sealed to the capsule so that the fluid can enter and leave the chamber of the capsule 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) that fit together (e.g., sheets 1220 / 1620, 1230 / 1630 are heat-riveted together, fused together, bonded together, welded together, heat-welded together, ultrasonically welded together, hot-plate welded together, hot-forged together, cold-pressed together, adhered together by an adhesive, laser-welded together, glued together, high-frequency welded together, sewn together, chemically welded together) 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 so 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) has a rounded 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 a variation, 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 passage (e.g., 1240) leading to a circular chamber, which is defined by the first sheet (e.g., 1220 / 1620) and the second sheet (e.g., 1230 / 1630) (e.g., the sheets 1220 / 1620, 1230 / 1630 are heat-riveted together, fused together, bonded together, welded together, heat-welded together, ultrasonically welded together, hot-plate welded together, hot-forged together, cold-pressed together, adhered together by an adhesive, laser-welded together, glued together, high-frequency welded together, sewn together, chemically welded together). 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 to one or more chambers through one or more fluid channels (e.g., 1240). In an improvement, the circular portion (e.g., 1210 / 1610) of each capsule (e.g., 1200 / 1600) includes 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 vertex of at least one circular portion (e.g., 1210 / 1610) such that the bladder (e.g., 1200 / 1600) applies at least 2 PSI of pressure to the occupant and / or applies at least 2.5 PSI of pressure to the occupant.

[0530] refer to Fig.50 , a seat assembly 2000 such as for a vehicle is provided. For example, the seat assembly 2000 is used for a motorcycle, an automobile, a boat, an aircraft, or a train. In one or more embodiments, the seat assembly includes a decorative cover 2002 and a seat frame 2006 disposed above a cushion assembly 2004. Figure 51-Figure 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, the fluid system 2100 is disposed in a seat back of a cushion assembly 2004. In one refinement, the cushion of the cushion assembly 2004 is a 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, a blower, a compressor, and / or a 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 capsules 2102 arranged along a first direction and / or dimension and a second plurality of fluid capsules 2104 arranged along a second direction and / or dimension, for example, X and Y, respectively. 1 and Y 1 ,like Fig.53 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, X 1 and Y 1 are distinct, 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 and second pluralities of bladders are arranged in this manner, they provide greater range and capacity for different sized individuals, supports, massage programs and / or configurations. In various embodiments, the bladders or each plurality of bladders include 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 capsules 2106 and the fourth plurality of capsules 2108 are arranged along a third direction and / or dimension (eg, X). 2 ) and a fourth direction and / or dimension (e.g., Y 2 ) arrangement. In one refinement, X 2 With X 1 In one embodiment, the fluid system 2100 is a system of fluids arranged in a plurality of bladders, each of which is parallel or substantially parallel (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 to 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 a lower area 2110 (or upper area 2112) of a 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-Figure 53 As shown, multiple groups or bladders may be provided in the same area (eg, lower back, upper back, left side, right side).

[0535] In one or more embodiments, the dimension on which the plurality of bladders are disposed corresponds to an occupant dimension, 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 dimension is greater than the 10th percentile of the occupant dimension, or more preferably greater than the average dimension of the occupant, or even more preferably the 75th percentile or greater of the occupant dimension, still more preferably the 85th percentile or greater of the occupant dimension, or still more preferably the 90th percentile or greater of the occupant dimension.

[0536] For example, the dimension corresponds to shoulder width such that multiple pockets 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 capsules in the plurality of capsules are arranged to accommodate different occupant groups. For example, a first group of capsules (e.g., the innermost row of capsules including 2108) corresponds to an occupant group having a dimension smaller than average (e.g., shoulder width), a second group of capsules (e.g., the innermost row and the second innermost row of capsules including 2108 and 2104) corresponds to a second occupant group having an approximately average dimension (e.g., shoulder width), and a third group of capsules (e.g., the rows of all capsules) corresponds to a third occupant group having a dimension larger than average (e.g., shoulder width).

[0538] In one or more embodiments, a 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 a 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 Fig.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 / discharge one or more of the bladders 2122. In one or more embodiments, as Fig.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, cooperates with Fig.53 The invention is used together with a fluid system of the invention 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 occupants.

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

[0541] In one or more embodiments, the controller 2200 cooperates with and communicates with one or more sensors 2124. In one refinement, the 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 dimensions of the occupant exceed a threshold pressure, it indicates that the occupant is adjacent to one or more bladders.

[0542] In another or the same embodiment, if the (first) pressure is greater than the (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 2.00PSI when the occupant is seated, any pressure less than the threshold amount relative to the inner group of bladders may indicate that the occupant is not adjacent to the 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 the outer bladder group having a pressure greater than 1.0PSI, or more preferably greater than 1.5PSI, or even more preferably greater than 1.8PSI may indicate that the occupant is adjacent to the outer bladder group, i.e., the occupant's dimensions extend to at least the outer bladder group. However, if the second pressure associated with the outer bladder group is 1.8PSI or less, or more preferably 1.5PSI or less, or even more preferably 1.0PSI or less, the occupant is not adjacent to the outer bladder group, i.e., the occupant's dimensions do not extend to the outer group of occupants. In one or more embodiments, the pressure associated with each group or each bladder is detected to determine the size or dimension 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 dimension of the occupant is determined. In a 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 exemplary purposes. However, it should be understood that many groups are included in the scan, and different groups may overlap or share capsules. For example, the inner and outer groups may refer to the inner and outer rows along the back, but the scan may 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, the controller 2200 cooperates and communicates with the bladder 2122, the sensor 2124, the fluid displacement device 2118, the valve assembly 2120, and / or a control unit 2210 such as a mobile phone via a wired and / or wireless network 2206. For example, the 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, the control unit 2210 is used to control subcomponents such as the massage system 2100. For example, the occupant can initiate a scan from the control unit 2210, turn the massage unit on or off, select specific conditions such as desired support and / or massage program. Additionally or alternatively, the scan is automatically initiated 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. Fig.54 Given the occupant size in FIG. 2 , the system 2100 employs a massage using all 24 bladders, but may massage using only 16 bladders. Fig.55 In other words, controller 2200 employs a massage that does not use 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 large amounts of pressure. In various embodiments, the support or massage thereafter employed by the controller 2200 is directed or guided to the one or more points. For example, additional support is provided in other areas to relieve pressure in the hot spots. In one or more embodiments, the bladders are used to provide support as well as 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 group of bladders 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 so that one or more scans and different massage functions can be performed. For example, the scan includes filling various columns and rows of bladders to determine the occupant dimensions, but after determining the occupant's dimensions, the individual bladders can be filled to provide a massage effect such as a shiatsu effect within the dimensions.

[0549] Various massage effects are known, including acupressure, Swedish massage, deep tissue massage, trigger point massage, etc., and various techniques for simulating such massages. For example, an acupressure massage effect is provided by filling / inflating a bladder to a pressure that causes it to push into the occupant and then releasing the bladder to relieve the pressure. This can be repeated multiple times in different positions to simulate the application of pressure from the hand and / or fingers to the occupant. In any case, the massage effect refers to the application and relief of pressure by filling / inflating and releasing / discharging one or more bladders. As described above, the massage effect is based on the dimensions of the occupant. For example, bladders that are outside the occupant dimensions or extend beyond the occupant dimensions are excluded from the massage or support procedure. In other words, the pressure changes within the bladder are within the boundaries of the occupant 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 includes 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, that is, the trim cover 2002 includes an outermost layer that defines an outermost surface. In variations, the trim cover 2002 is disposed on one or more subassemblies, such as Figure 51-55 As shown. In a modification, the decorative cover 2002 includes a fabric, a textile fabric, an artificial leather or a leather surface. For example, the decorative cover 2002 includes 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 computer readable instructions configured to be executed by the processor provides execution of various functions for the operation of the system and seat assembly 2000, such as actuating a fluid displacement device and determining 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 includes one or more devices selected from a high-performance computing system, including 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, the memory includes 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 an improved solution, the non-volatile memory / storage device includes one or more persistent data storage devices, such as a hard disk drive, an optical drive, a tape drive, a non-volatile solid-state device, a cloud storage, or any other device capable of persistently storing information.

[0553] In one or more embodiments, executable code / instructions may reside in a software module. In an improved scheme, 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 techniques, including but not limited to the following items alone or in combination: Java, C, C++, C#, Objective C, Fortran, Pascal, Java Script, Python, Perl, and PL / SQL. 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 and 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 tapes, 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 to a computer, another type of programmable data processing device or another device form of a computer-readable storage medium via a network, or downloaded to an external computer or external storage device.

[0555] In one or more embodiments, the computer-readable program instructions stored in the computer-readable medium can be used to instruct a computer, other types of programmable data processing devices, or other devices 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 can be reordered, processed serially, and / or processed concurrently.

[0556] refer to Fig.57 , a method 2300 for scanning and / or applying massage is also disclosed. In one or more embodiments, the method 2300 includes determining a first pressure 410 and a 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 the second pressure 440. For example, a sensor detects or measures a pressure associated with a bladder. The first pressure and the second pressure are compared to each other or to a threshold pressure to determine the first occupant dimension. In one refinement, the method 2300 includes determining a third pressure associated with a third bladder 430. In various embodiments, the method 2300 includes determining a second occupant dimension based on the third pressure 450. In a variant, 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 (eg, 2000, such as in a vehicle seat such as for a motorcycle, automobile, boat, aircraft, or train) is provided, comprising a first direction X 1A first plurality of bladders (e.g., 2102) such as fluid bladders (e.g., pneumatic bladders) arranged in a horizontal direction (e.g., along the width of the seat back) or a vertical direction (e.g., along the height of the 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) are top row bladders, middle row bladders 2106, bottom row bladders 2102, left column bladders 2104, middle column bladders 2108, or right column bladders. In some embodiments, the first plurality of bladders (e.g., 2114) are outer or inner rows or columns 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 an associated 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). Controller 2200 may be provided as one or more controllers or control modules for various components and systems. Controller 2200 and the 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-Figure 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, inner 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, inner 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 a pressure of a 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) including 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 (eg, a seat massage assembly 2000, such as in a vehicle seat) comprising a massage device disposed along a first axis (eg, X 1 ) (e.g., horizontal axis, vertical axis, inner axis, outer axis, diagonal axis) and a first capsule (e.g., 2106) arranged along a first axis (e.g., X 1 ) a different second axis (e.g., X 2A second plurality of bladders (e.g., 2102) are arranged in a plurality of planes (e.g., horizontal axis, vertical axis, inner axis, outer axis, diagonal axis), 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 exhaust duct (e.g., 2129) that serves all bladders (e.g., 2122), or the sensor (e.g., 2124) serves an exhaust duct (e.g., 2128) for each column or row of bladders. In various embodiments, the bladders (e.g., 2122) are configured to be filled individually, such as by a valve assembly (e.g., 2120), such as to scan an occupant and simultaneously, such as to employ a massage effect. A seat component, such as a seat back or seat bottom, is also provided, which includes 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 position (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 position (e.g., top, bottom, middle) along the width of the seat back that is different from the first position. 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, the first plurality of bladders (e.g., 2104) are arranged at a first portion (e.g., left, right, middle) along the height of the seat back, and the second plurality of bladders (e.g., 2108) are arranged at a second position (e.g., left, right, middle) along the height of the seat back that is different from the first position. 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 a fluid and determining an associated pressure, such as a pressure applied by the occupant on the one or more bladders (e.g., 2122) or a pressure of a fluid flow (e.g., air flow) released from 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 of scanning and massaging an occupant is described. The 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 pressure and the second pressure (i.e., step 2340). In various embodiments, the first pressure and the second pressure are determined by releasing fluid from the first and second bladders. In some embodiments, the method 2300 also includes applying a massage effect to the occupant based on the first occupant dimension (i.e., step 2360). In a variation, the method 2300 also 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 pressure and / or the second pressure (i.e., step 2350). In one or more embodiments, the method 2300 also includes applying a massage effect based on the first dimension and the second dimension (i.e., step 2360).

[0560] Fig.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 boat, 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] The seat assembly 2420 includes a seat bottom 2422 for supporting the pelvis and thighs of the occupant. The seat bottom 2422 is supported on an underlying support surface, such as a vehicle floor. A seat back 2424 extends from the seat bottom 2422 in an upright orientation to support the back and shoulders of the occupant. The seat back 2424 can be supported by the seat bottom 2422 or the underlying support surface. A head restraint 2426 can also be provided on the seat back 2424 to support the head of the occupant.

[0562] The seat assembly 2420 provides contact surfaces 2428, 2430 for receiving and comfortably supporting an occupant. The seat assembly 2420 includes a plurality of actuators 2432, 2434 disposed within the contact surfaces 2428, 2430 within the seat assembly 2420. Although two actuators 2432, 2434 are shown and described, any number or location of actuators 2432, 2434 may be employed. The actuators 2432, 2434 may be used to apply tactile effects to the occupant, such as vibrations for conveying an alert, vibrations for applying a massage, pressure for applying 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. Fig.60An actuator assembly 2436 for a seat assembly 2420 is shown according to some embodiments. The actuator assembly 2436 is schematically shown and can be installed within the seat assembly 2420. The actuator assembly 2436 includes a fluid pump 2438, such as a pneumatic pump 2438, to provide a source of pressurized air. The actuator assembly 2436 also includes a valve assembly 2440 in fluid communication with the pump 2438. A first fluid line 2442 connects the pump 2438 to the valve assembly 2440 to deliver pressurized air from the pump 2438 to the 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 conducted through the solenoids.

[0565] The prior art utilizes separate valve subassemblies to inflate and deflate air bags in a seat assembly. To minimize the number of valve subassemblies 2450, 2452 in valve assembly 2440, each of valve subassemblies 2450, 2452 is a two-way valve having 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 air bags 2432, 2434. By using two-way valves, half the number of valves are 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 of the valve subassemblies 2450, 2452 includes a second seal 2474 and a third seal 2476 on the valve body 2464 that are sequentially spaced from the first seal 2462. The housing 2444 also includes a third port 2478, 2480 formed through the housing and into each fluid chamber 2446, 2448 as an exhaust port. In the charging 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 exhaust position of the second valve subassembly 2452, the first port 2458 is sealed to disconnect the fluid chamber 2448 from the pressurized air. In the exhaust position, the spring 2460 extends the valve body 2464 so that the second seal 2474 and the third seal 2476 move beyond the second port 2468. In the exhaust position, the second port 2468 and the third port 2480 are in fluid communication so that pressurized air in the airbag 2434 can be decompressed and pass through the second fluid line 2472, through the second port 2468, through the fluid chamber 2448, and out the exhaust port 2480 to the atmosphere. The compression of the seated occupant against the airbag 2434 can further assist in the deflation of the airbag 2434.

[0569] Fig.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 in one of the fluid chambers 2486.

[0570] Fig.62 and Fig.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 of a structurally resilient but lightweight material, such as a polymer 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 Fig.61 , the housing 2484 includes a main inlet port 2492. The main inlet port 2492 is connected to the pump 2438 to receive pressurized air. The housing 2484 includes a pressure chamber 2494 in fluid communication with the main inlet port 2492. The pressure chamber 2494 provides a reservoir for pressurized air storage to the plurality of valve subassemblies 2488. A plurality of first valve ports 2496 provide fluid communication from the pressure chamber 2494 to each fluid chamber 2486.

[0572] Reference again Fig.62 and Fig.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 Fig.61 , the valve body 2490 extends to the exhaust position. In the exhaust 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] Fig.62 and Fig.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 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 Fig.63 As can be observed in FIG. 25 , the valve body 2490 has a thickness greater than 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. Referring now to Fig.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 Fig.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 the valve body 2490 aligned with the translation path toward and away from the first port 2496.

[0575] like Fig.62 and Fig.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 electric current being conducted through the SMA 2516. For example, the SMA 2516 may be formed of a nickel-titanium alloy that contracts when an electric current is passed through the material. When an electric current is conducted 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] Fig.64 A partially broken-away valve assembly 2482 is shown with one of the valve subassemblies 2488 cut away. Fig.64 All valve bodies 2490 are shown in the deflated position. The housing 2484 includes a plurality of second ports 2518, each of which is connected to one of the fluid chambers 2486 and one of the plurality of airbags 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. Fig.64 In the deflated position, air can be deflated from the airbags 2432, 2434 through the second port 2518, into the fluid chamber 2486, and exhausted from 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] Reference now Fig.65, shows the cut-away valve subassembly 2488 in the charging position. In this figure, the controller 2454 conducts current through the terminals 2512, 2514 and the SMA 2516. The current through the SMA 2516 causes the length of the SMA to decrease, thereby actuating the valve body 2490 and compressing the spring 2502. The valve body 2490 translates in the fluid chamber 2486 so that the second seal 2500 engages and seals the exhaust port 2520. In the charging position, the movement of the valve body 2490 removes the first seal 2498 from the first port 2496. In this position, pressurized air enters the first port 2496 from the pressure chamber 2494, passes through the fluid chamber 2486 and exits from the second port 2518 to one of the airbags 2432, 2434 to inflate the airbags 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 Fig.64 In the absence of a signal to SMA 2516, airbags 2432 and 2434 are deflated. This situation is usually referred to as normal discharge.

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

[0581] Fig.69 The assembly steps for attaching SMA 2516 to valve body 2490 are shown. Fig.67 When the intermediate ring 2522 of the SMA 2516 slides onto the beam 2504, the intermediate ring 2522 of the SMA 2516 slides on 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 on the retainer 2524 and slides into the slot 2526 to retain the SMA 2516 on the distal end of the valve body 2490.

[0582] The valve subassembly 2488 operates to inflate the bladders 2432, 2434 and allow deflation, thereby reducing the number of valves. The integrated spring 2502 further reduces the number of parts. Only one signal is required to operate each valve subassembly 2488, thereby simplifying the controller 2454 programming and cost. The translatable valve body 2490 also eliminates the 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 assembly 2440, 2482, valve subassembly 2450, 2452, 2488) having a valve body (e.g., valve body 2464, 2490) sized to translate within a fluid chamber (e.g., fluid chamber 2446, 2448) is described. The valve body can be elongated and can be formed of a lightweight and resilient material such as a polymer material such as polypropylene, can be reinforced with fiberglass, or can be formed of 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 lateral protrusions extending outwardly from the beam and received in a slot in the housing to prevent axial translation of the beam, and 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 protrusion may extend toward the valve body and provide an alignment spacer between the valve body and the beam to keep 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 positions. 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 in 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 fill a fluid bladder (such as a lumbar bladder, a pillow bladder, a shoulder bladder), while the third port is sealed with 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 with 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 body 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 may extend from the terminal, along the beam, along the spring, and around a distal end of the valve body adjacent the first seal. The shape memory alloy may be formed of 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 may translate the valve body in response to an electrical current being conducted through the shape memory alloy such that the length of the SMA shortens, 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) also includes 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 electric 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 the distal end of the beam that is electrically connected to 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 to the first seal. The shape memory alloy can be formed of a material that is actuated in response to an electric current (e.g., a nickel-titanium alloy) that contracts when an electric 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 a distal end of the elongated valve body (e.g., valve bodies 2464, 2490).

[0586] In some embodiments, the housing (e.g., housing 2444, 2484) is provided with a fluid chamber (e.g., fluid chamber 2446, 2448), wherein 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 in fluid communication with 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, a fastener, a laser weld, a friction weld and / or an adhesive. 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 external atmosphere. A valve body (eg, valve bodies 2464, 2490) is positioned within a fluid chamber (eg, fluid chambers 2446, 2448) for translation relative thereto.

[0587] In some embodiments, the valve body (e.g., valve body 2464, 2490) can translate to a fill 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 fill a fluid bladder (e.g., fluid bladder 2432, 2434) while a third port (e.g., third port 2478, 2480, 2520) is sealed with a 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 haptic effects to the occupant, such as vibrations for conveying an alert, vibrations for applying a massage, 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 enters the second port (e.g., second port 2466, 2468, 2518) from the fluid sac (e.g., fluid sac 2432, 2434), passes through the fluid chamber (e.g., fluid chamber 2446, 2448) and exits the third port (e.g., third port 2478, 2480, 2520) to discharge the fluid sac (e.g., fluid sac 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, an actuator (e.g., fluid bladders 2432, 2434) is connected to a second port (e.g., second ports 2466, 2468, 2518). An actuator, such as a fluid bladder, such as an air bladder, such as a lumbar bladder, a pillow bladder, and / or a shoulder bladder, can apply a tactile effect to the occupant, such as a vibration for conveying a warning, a vibration 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 a gasket, a cover, a fastener, a laser weld, a friction weld, and / or an adhesive. 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 plurality of valve assemblies (e.g., valve assemblies 2440, 2482, valve subassemblies 2450, 2452, 2488) are provided. 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 in 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 subassembly 2450, 2452, 2488) having a valve body (e.g., valve body 2464, 2490) formed of a polymer material is described. The valve body can be elongated, can be formed of a lightweight and resilient material (such as polypropylene), can be reinforced with fiberglass, or formed of 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 lateral protrusions extending outwardly from the beam and received in a slot in the housing to prevent axial translation of the beam, and the slot can be slightly tapered so that when the protrusion is installed in the slot, the beam can be gradually positioned toward the first port to slightly compress and preload the spring. The protrusion can extend toward the valve body and provide an alignment spacer between the valve body and the beam to keep the valve body aligned 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 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 in the fluid chamber for translation to a fill position, whereby 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 (such as a lumbar bladder, a pillow bladder, a shoulder bladder), while the third port is sealed with the fluid chamber, and the valve body can translate to a discharge position, whereby 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 with 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. The 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 a 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 a 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 of a material that actuates in response to an electric current, such as a nickel-titanium alloy that contracts when an electric current passes through the material. The linear actuator can translate the valve body in response to an electric 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 an electric 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) also includes 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 electric 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 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 to the first seal. The shape memory alloy can be formed of a material that is actuated in response to an electric current, such as a nickel-titanium alloy, which contracts when an electric 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 may be substantially parallel to the valve body. The beam may be integrally formed with the spring. The beam may have a first thickness. The beam may include a plurality of transverse protrusions extending outwardly from the beam and received in a slot in the housing to prevent axial translation of the beam, the slot may be slightly tapered so that when the protrusions are installed in the slots, the beam is gradually positioned toward the first port to slightly compress and preload the spring. The protrusions may extend toward the valve body and provide an alignment spacer between the valve body and the beam to keep the valve body aligned with the translation path toward and away from the first port.

[0593] In some embodiments, the beam (e.g., beam 2504) has a first thickness. The 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, spring 2460, 2502) further comprises a compression spring. The spring may be a sinusoidal curve having an alternating curvature.

[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 may 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 may be formed of a material that actuates in response to an electric current, such as a nickel-titanium alloy that contracts when an electric current passes through the material.

[0596] In some embodiments, the housing (e.g., housing 2444, 2484) is provided with a fluid chamber (e.g., fluid chamber 2446, 2448), wherein 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 in fluid communication with 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, a fastener, a laser weld, a friction weld and / or an adhesive. 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 external atmosphere. A valve body (eg, valve bodies 2464, 2490) is positioned within a fluid chamber (eg, fluid chambers 2446, 2448) for translation relative thereto.

[0597] In some embodiments, the valve body (e.g., valve body 2464, 2490) can translate to a fill 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 fill a fluid bladder (e.g., fluid bladder 2432, 2434) while a third port (e.g., third port 2478, 2480, 2520) is sealed with a 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 haptic effects to the occupant, such as vibrations for conveying an alert, vibrations for applying a massage, 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 enters the second port (e.g., second port 2466, 2468, 2518) from the fluid sac (e.g., fluid sac 2432, 2434), passes through the fluid chamber (e.g., fluid chamber 2446, 2448) and exits the third port (e.g., third port 2478, 2480, 2520) to discharge the fluid sac (e.g., fluid sac 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, an actuator (e.g., fluid bladder 2432, 2434) is connected to the second port (e.g., second port 2466, 2468, 2518). An actuator, such as a fluid bladder, such as an air bladder, such as a lumbar bladder, a pillow bladder, and / or a shoulder bladder, can apply a tactile effect to the occupant, such as a vibration for conveying an alert, a vibration for applying a massage, a pressure for applying a pressurized massage effect. A pressurized fluid source (e.g., pump 2438) is connected to the first port (e.g., first port 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 a gasket, a cover, a fastener, a laser weld, a friction weld, and / or an adhesive. 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 plurality of valve assemblies (e.g., valve assemblies 2440, 2482, valve subassemblies 2450, 2452, 2488) are provided. 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 in 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) having a housing (e.g., housing 2444, 2484) is described, the housing being provided with a fluid chamber (e.g., fluid chamber 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 in fluid communication with 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, a fastener, a laser weld, a friction weld, and / or an adhesive. 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 external atmosphere. The first port (e.g., first port 2456, 2458, 2496) or the third port (e.g., third port 2478, 2480, 2520) is formed at the distal end of the fluid chamber (e.g., fluid chamber 2446, 2448). A valve (e.g., valve body 2464, 2490) is positioned in a fluid chamber (e.g., fluid chamber 2446, 2448) to translate to: a fill position, whereby fluid enters a first port (e.g., first port 2456, 2458, 2496) from a pressurized fluid source (e.g., pump 2438), passes through the fluid chamber (e.g., fluid chamber 2446, 2448) and exits a second port (e.g., second port 2466, 2468, 2518) to fill a fluid bladder (e.g., fluid bladder 2432, 2434), while a 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 vibrations for conveying an alert, vibrations for applying a massage, 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 port 2466, 2468, 2518), passes through the fluid chamber (e.g., fluid chamber 2446, 2448) and exits the third port (e.g., third port 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 with the fluid chamber (e.g., fluid chamber 2446, 2448).The valve body can be elongated and can be formed of a lightweight and resilient material (such as a polymer material, such as polypropylene), can be reinforced with glass fiber, or can be formed of 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 formed integrally with the spring. The beam can have a first thickness. The beam can include a plurality of lateral protrusions extending outwardly from the beam and accommodated in a narrow slot in the housing to prevent axial translation of the beam, and the narrow slot can be slightly tapered so that when the protrusion is installed in the narrow slot, the beam can be gradually positioned toward the first port to slightly compress and preload the spring. The protrusion can extend toward the valve body and provide an alignment spacer between the valve body and the beam to keep the valve body aligned 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 positions.

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

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

[0603] The seating system 2620 provides contact surfaces 2628, 2630 for receiving and comfortably supporting an occupant. The seating system 2620 includes a plurality of actuators 2632, 2634 disposed within the contact surfaces 2628, 2630 within the seating system 2620. Although an arrangement of the actuators 2632, 2634 is shown and described, any number or location of the actuators 2632, 2634 may be employed. The actuators 2632, 2634 may be used to apply tactile effects to the occupant, such as vibrations for conveying an alert, vibrations for applying a massage, pressure for applying a pressurized massage effect, support to 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] The seating system 2620 includes a gate valve assembly 2636 in fluid communication with the fluid bladders 2632, 2634. The gate valve assembly 2636 is in fluid communication with the fill valve assembly 2638 and the logic valve assembly 2640. A pump 2642, such as a compressor, is in fluid communication with the fill valve assembly 2638 and the logic valve assembly 2640 to provide a source of pressurized fluid, such as compressed air, to the fill valve assembly 2638 and the logic valve assembly 2640. Any number of pumps 2642 and electric valves 2638, 2640 may be employed. Alternatively, multiple pumps 2642 may be employed without any electric 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, 2640 are housed in a seat back 2624 or seat bottom 2622 of seating system 2620. Controller 2644 is housed in a vehicle and, according to some embodiments, in a seat back 2624 or seat bottom 2622. Fill valve assembly 2638 and logic valve assembly 2640 may be manufactured as a single unit. In this case, controller 2644 may 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 divided into two units, with each respective unit attached to a respective valve assembly 2638 , 2640 .

[0607] exist Fig.71 26. The gate valve assembly 2636 is shown in more 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 employs a matrix or linear array of two by three gate valve subassemblies 2646. Although a 2 by 3 matrix is ​​illustrated and described, any arrangement and number of gate valve subassemblies 2646 may be employed, such as 2 by 3, 1 by 4, 4 by 4, 6 by 9, etc.

[0608] The gate valve assembly 2636 utilizes the gate valve subassembly 2646 and pneumatic logic to charge and discharge a large number of fluid actuators while minimizing the number of electrically controlled valves 2638, 2640. The electrically controlled valves 2638, 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 weight. 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, 2634 to reduce one electrically operated valve assembly. According to another example, nine electrically operated valves can be used for a three-by-six matrix of gate valve subassemblies 2646 for actuating eighteen fluid actuators 2632, 2634 to reduce 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 has a gate valve subassembly 2646 therein. Fig.71 and Fig.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 may 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 Fig.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 fluid actuators 2634 under normal filling conditions, as will be explained in further detail below. The normal 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 fluid actuators 2632 under normal discharge conditions, which will also be explained in further detail below. The normal discharge condition is used for bladders 2632 that are quickly filled and discharged, such as massage bladders 2632.

[0611] The housing 2648 includes a plurality of filling connectors 2666, each providing a filling pressure inlet to a subset or column 2668, 2670, 2672 of the 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. The 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. The bus 2674 is also closed and sealed by a cover 2652 and a gasket 2656. The connector 2666 has a barb for connecting to a hose for receiving pressurized air from the fill valve assembly 2638.

[0612] Housing 2648 also includes a plurality of control connectors 2676, each of which provides a control pressure inlet to one of rows 2662, 2664 of gate valve subassemblies 2646. Each of two control connectors 2676 is connected to bus 2678, such as Fig.72 A bus 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 2678 is closed and sealed by a cover 2654 and a gasket 2658. The control connector 2676 receives pressurized air from the logic valve assembly 2640.

[0613] Fig.71 and Fig.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...

Claims

1. A component comprising: a) a decorative cover layer, a non-foam layer attached to the decorative cover layer, and one or more fasteners connected to the decorative cover layer and / or the non-foam layer; b) a webbed gasket of polymer fibers bonded together by melted portions of the polymer fibers, a seat cover, and a spiral retainer, wherein the webbed gasket is formed into a seat cushion, the seat cover includes a tie strap attached to the seat cover, wherein the tie strap defines a plurality of holes, the spiral retainer secures the tie strap to the polymer fibers, wherein the spiral retainer is wrapped through the holes and the spiral retainer loops into the welded polymer fibers; c) a base, a connector attached to the base, and a retainer, the base comprising a contact surface, the connector comprising a width less than a width of the base, the connector being sized to extend through a slot in a cushion, the retainer comprising a width greater than the width of the connector, the retainer comprising a thickness less than the retainer width, the retainer being pivotally attached to the connector spaced from the base and configured to be inserted into the slot in the cushion in a thickness direction and further configured to pivot outside of the cushion so that the retainer width engages the cushion, the retainer retaining the base on the cushion; d) a twisted thermoplastic mesh seat pad, a cover surrounding and conforming to the seat pad, and a multi-layer trim cover having an outer layer and an inner layer, the inner layer being attached to the cover by hook and loop fasteners; e) a stranded thermoplastic mesh seat pad, an envelope surrounding the seat pad, and a multi-layer trim cover having an outer layer and an inner layer secured to the envelope, wherein a partial vacuum is maintained within the envelope such that the envelope conforms to the seat pad; and / or f) a twisted thermoplastic mesh seat pad having a concave surface, a sleeve and a multi-layer trim cover, wherein the twisted thermoplastic mesh seat pad has a concave surface, the sleeve surrounds the seat pad and has a reinforcement adjacent to the concave surface to prevent the sleeve from separating from the concave surface, and the multi-layer trim cover has an outer layer and an inner layer fixed to the sleeve.

2. The assembly according to claim 1, further comprising a decorative assembly, the decorative assembly comprising: The decorative cover layer; said non-foam layer attached to said decorative cover layer; and The one or more fasteners are connected to the trim cover layer and / or the non-foam layer.

3. The decoration component according to claim 2, wherein: The non-foam layer includes a stranded mesh material member.

4. The decoration component according to claim 3, wherein: The stranded mesh material member includes a polymer mesh having a plurality of integrated polymer strands.

5. The decoration assembly according to claim 4, wherein: The non-foam layer includes a plastic spacer material.

6. The decoration component according to any one of claims 2 to 5, wherein: The non-foam layer defines a groove intersecting at least one of a first side and a second side of the non-foam layer.

7. The decoration component according to claim 6, wherein: The one or more fasteners further include a tie member connected to the trim cover layer and extending into the groove of the non-foam layer to a distal free end.

8. The trim assembly of any one of claims 2-7, wherein the one or more fasteners further comprise an arch, a hook fastener, a loop fastener, an arrow, a ring, a clip, a paddle, and / or a draw cord.

9. The decoration component according to any one of claims 2 to 8, wherein: The decorative cover layer is attached to the non-foam layer via a seam.

10. The decoration component according to any one of claims 2 to 9, wherein: The trim cover layer is attached to the non-foam layer via a welded connection.

11. The decoration component according to any one of claims 2 to 10, wherein: The trim assembly further includes a third layer connected to the trim cover layer and / or the non-foam layer; and The non-foam layer is located between the decorative cover layer and the third layer.

12. The decoration assembly according to claim 11, wherein: The third layer includes a nonwoven fabric.

13. The decoration component according to any one of claims 2 to 12, wherein: The trim component is provided without spacer fabric.

14. A seat assembly comprising: Supporting members; and A decorative assembly according to any one of claims 2 to 13.

15. The seat assembly of claim 14, wherein: The one or more fasteners connect the trim assembly to the support member.

16. The seat assembly of claim 14 or 15, further comprising a seat cushion defining a first surface for supporting an occupant and a second surface opposite the first surface; wherein the seat cushion is supported by the support member and positioned between the support member and the trim assembly; and Wherein, the trim assembly is connected to the seat cushion and / or the support member via the one or more fasteners.

17. The seat assembly of claim 16, wherein: The seat cushion includes a non-foam component and / or a foam component.

18. The seat assembly according to any one of claims 14-17, wherein: The support member includes at least one of a frame and a base.

19. The assembly of claim 1, further comprising: said web of polymer fibers bonded together by melted portions of said polymer fibers, wherein said web is formed into said seat pad; the seat cover including a tie-down strap attached to the seat cover, wherein the tie-down strap defines a plurality of apertures; and The spiral retainer secures the tie band to the polymer fibers, wherein the spiral retainer is wrapped through the holes and the spiral retainer loops into the welded polymer fibers.

20. The assembly of claim 19, wherein: The seat cover is formed by sewing together a plurality of cover material sections and attaching the plurality of cover material sections to the tie down straps.

21. An assembly according to claim 19 or 20, wherein The mesh mat of polymer fibers defines a plurality of grooves recessed into the mesh mat.

22. An assembly according to any one of claims 19 to 21, wherein The tie strap is a plastic strap including rib reinforcements.

23. An assembly according to any one of claims 19 to 22, wherein The tie-down straps each include a rib reinforcement and a flexible flange sewn to an edge of the seat cover.

24. An assembly according to any one of claims 19 to 23, wherein The tie straps each include a rib reinforcement and a flexible flange formed as a combination.

25. An assembly according to any one of claims 19 to 24, wherein The mesh gasket defines a groove and the seat cover includes a section of a flexible sheet material sewn together with the tie strap, wherein the tie strap is received in the groove and is positioned in the groove using a guide comb when the spiral retainer is wrapped through the groove to secure the tie strap to the welded polymer fibers.

26. An assembly according to any one of claims 19 to 25, wherein The welded polymer fibers hold the helical retainer in the mesh body.

27. An assembly according to any one of claims 19 to 26, wherein: The polymer fibers are polyethylene.

28. The assembly of claim 1, further comprising a retainer assembly, the retainer assembly comprising: the base, the base comprising the contact surface; the connector attached to the base, the connector comprising a width less than a width of the base, the connector sized to extend through the slot in the gasket; and The retainer includes a width greater than the width of the connector, the retainer includes a thickness less than the retainer width, the retainer is pivotally attached to the connector spaced apart from the base, and is configured to be inserted into the narrow slot in the pad in the thickness direction and pivoted outside the pad so that the retainer width engages the pad, and the retainer retains the base on the pad.

29. The retainer assembly of claim 28, further comprising a surface fastener on the contact surface of the base.

30. A holder assembly according to claim 28 or 29, wherein: The base provides a flat surface.

31. A retainer assembly according to any one of claims 28 to 30, wherein: The connector includes a textile material.

32. A retainer assembly according to any one of claims 28 to 31, wherein: The base includes a polymer material.

33. A retainer assembly according to any one of claims 28 to 32, wherein: The retainer comprises a polymer material.

34. A retainer assembly according to any one of claims 28 to 33, wherein: The connector is sewn to a surface of the base opposite the contact surface.

35. A retainer assembly according to any one of claims 28 to 34, wherein: The connector is sewn to the retainer.

36. A vehicle seat assembly, comprising: a seat bottom adapted to be attached to a vehicle floor; seat backs that extend in the upright position; a seat cushion connected to the seat bottom or the seat back; and A retainer assembly as claimed in any one of claims 28 to 35 attached to a portion of the seat pad.

37. The vehicle seat assembly of claim 36, wherein: The seat pad also includes a stranded thermoplastic web.

38. A vehicle seat assembly according to claim 36 or 37, wherein: A slot is formed through the gasket and is sized to receive the retainer assembly.

39. The vehicle seat assembly of any one of claims 36-38, further comprising a seat trim, an actuator, and / or a heat transfer layer attached to the contact surface of the base.

40. The vehicle seat assembly of any one of claims 36-39, wherein: The base also includes a seat trim, an actuator, and / or a heat transfer layer.

41. The vehicle seat assembly of any one of claims 36-40, wherein: The seat cushion also includes a stranded thermoplastic mesh seat cushion connected to the seat bottom or the seat back with slots formed through the cushion.

42. The vehicle seat assembly of claim 41 further comprising a surface fastener on a contact surface of the base.

43. The vehicle seat assembly of claim 41 or 42, further comprising at least one of a seat trim, an actuator, and a heat transfer layer attached to the contact surface of the base.

44. The vehicle seat assembly of any one of claims 41-43, wherein: The base also includes at least one of a seat trim, an actuator, and a heat transfer layer.

45. The assembly of claim 1, further comprising: said stranded thermoplastic mesh seat pad; said cover surrounding and conforming to said seat cushion; and The multi-layer decorative cover has the outer layer and the inner layer, the inner layer being attached to the envelope by the hook and loop fastener.

46. ​​The assembly of claim 45, wherein: The wrapper has a portion with loops, and the inner layer of the multi-layer trim cover includes hooks that engage the loops.

47. An assembly according to claim 45 or 46, wherein The inner layer of the multi-layer trim cover has a loop, and the wrapper has a hook portion that engages the loop.

48. An assembly according to any one of claims 45 to 47, wherein The multi-layer trim cover has a foam layer between the outer layer and the inner layer.

49. An assembly according to any one of claims 45 to 48, wherein A surface of the seat pad adjacent to the trim cover is concave.

50. The assembly of claim 49, wherein: The sleeve includes features that extend into the slot in the liner to prevent separation of the sleeve from the concave surface.

51. An assembly according to claim 49 or 50, wherein The sleeve has a reinforcement member adjacent to the concave surface, the reinforcement member preventing the sleeve from separating from the concave surface.

52. An assembly according to any one of claims 45 to 51, wherein A partial vacuum is maintained within the envelope so that the envelope conforms to the seat cushion.

53. The assembly of claim 52, wherein: The partial vacuum is maintained using an air pump that is part of the seat ventilation system.

54. The assembly of claim 1, further comprising: said stranded thermoplastic mesh seat pad; said cover surrounding said seat cushion; and said multi-layer decorative cover having said outer layer and said inner layer secured to said envelope; The partial vacuum is maintained within the envelope such that the envelope conforms to the seat cushion.

55. The assembly of claim 54, wherein: The wrapper has a portion with loops, and the inner layer of the multi-layer trim cover includes hooks that engage the loops.

56. An assembly according to claim 54 or 55, wherein The inner layer of the multi-layer trim cover has a loop, and the wrapper has a hook portion that engages the loop.

57. An assembly according to any one of claims 54 to 56, wherein The multi-layer trim cover has a foam layer between the outer layer and the inner layer.

58. An assembly according to any one of claims 54 to 57, wherein A surface of the seat pad adjacent to the trim cover is concave.

59. An assembly according to any one of claims 54 to 58, wherein The partial vacuum is maintained using an air pump that is part of the seat ventilation system.

60. The assembly of claim 1, further comprising: said stranded thermoplastic mesh seat pad having said concave surface; The cover surrounds the seat pad and has a reinforcement member adjacent the concave surface to prevent the cover from separating from the concave surface; and The multi-layer trim cover has the outer layer and the inner layer secured to the envelope.

61. The assembly of claim 60, wherein: The wrapper has a portion with loops, and the inner layer of the multi-layer trim cover includes hooks that engage the loops.

62. An assembly according to claim 60 or 61, wherein The inner layer of the multi-layer trim cover has a loop, and the wrapper has a hook portion that engages the loop.

63. An assembly according to any one of claims 60 to 62, wherein The multi-layer trim cover has a foam layer between the outer layer and the inner layer.

64. An assembly according to any one of claims 60 to 63, wherein The sleeve includes features that extend into the slot in the liner to prevent separation of the sleeve from the concave surface.

65. A machine comprising: a securing device receiving a mesh gasket of polymeric fibers, a seat cover, and a guide, the mesh gasket being bonded together in the form of a seat pad, the seat cover including a tie-down strap defining a plurality of apertures; and A rotary tool including a spiral retainer that rotates into the fixture and into a groove defined by the mesh gasket, wherein the spiral retainer is wound into the plurality of holes and through the welded polymer fibers of the mesh gasket to retain the tie band in a predetermined position in the mesh gasket.

66. The machine according to any one of the preceding claims 65, further comprising: A guide comb includes a plurality of teeth defining tooth gaps.

67. A machine according to any one of the preceding claims 65-66, wherein: The guide comb includes a plurality of teeth defining tooth gaps separated by a distance between each of the plurality of holes.

68. A machine according to any one of the preceding claims 65-67, wherein: The tie-down strap includes a plastic reinforcement and a flexible flange attached to the seat cover.

69. A machine according to any one of the preceding claims 65-68, wherein The polymer fibers are thermoplastic polymer fibers.

70. A method comprising: a) attaching a trim cover layer to a non-foam layer and attaching one or more fasteners to the trim cover layer and / or the non-foam layer such that the trim cover layer, the non-foam layer and the one or more fasteners form a trim assembly; b) selecting a mesh gasket of welded polymer fibers, the mesh gasket defining a plurality of grooves at predetermined locations, selecting a cover including tie straps, inserting at least one of the tie straps into at least one of the grooves defined in the mesh gasket, wherein each of the tie straps defines a plurality of equally spaced holes above reinforcing bars attached to the tie straps, and rotating a spiral retainer through the welded polymer fibers of the mesh gasket and around the reinforcing bars, through the tie straps and into the grooves, wherein the spiral retainer is wrapped through the plurality of equally spaced holes and the welded polymer fibers to retain the tie straps at the predetermined location; and / or c) collapsing the retainer along a connector of the retainer assembly, inserting the retainer and the connector of the retainer assembly into a slot formed through a seat cushion, translating the retainer through the seat cushion with the connector still at least partially within the slot, and expanding the retainer relative to the connector into contact with an area of ​​the cushion adjacent to the slot to retain the connector within the slot.

71. The method according to claim 70 further includes attaching the decorative cover layer to the non-foam layer, and attaching the one or more fasteners to the decorative cover layer and / or the non-foam layer, so that the decorative cover layer, the non-foam layer and the one or more fasteners form a decorative component.

72. The method of claim 71 further comprising attaching the trim assembly to a support structure of a seat assembly after forming the trim assembly.

73. The method of claim 71 or 72, further comprising: forming a decorative cover layer; and A non-foaming layer is formed.

74. The method of any one of claims 71-73, further comprising sewing the trim cover layer to the non-foam layer to form the trim assembly.

75. The method of claim 74, further comprising forming grooves in the non-foam layer; and A seam formed by sewing the decorative cover layer to the non-foam layer is positioned in the groove.

76. The method of any one of claims 71-75, further comprising forming grooves in the non-foam layer; and The trim cover layer is connected to the non-foam layer via one or more tab fasteners to form the trim assembly.

77. The method of any one of claims 71-76, further comprising laminating the trim cover layer to the non-foam layer to form the trim assembly.

78. The method of any one of claims 71-77, further comprising forming pockets in the decorative cover layer; inserting the non-foam layer into the bag; and The bag was closed.

79. The method of any one of 71-78, further comprising attaching a third layer to one of the trim cover layer and the non-foam layer to form the trim assembly.

80. The method of claim 79, further comprising positioning the non-foam layer between the trim cover layer and the third layer.

81. The method of any one of claims 71-80, further comprising connecting a cushion to the support structure prior to attaching the trim component.

82. The method of claim 81 further comprising forming the pad from a twisted mesh material or a foam.

83. The method of claim 70, further comprising: selecting a mesh gasket of welded polymer fibers, the mesh gasket defining a plurality of grooves at predetermined locations; selecting said cover to include tie-down straps; inserting at least one of the tie straps into at least one of the recesses defined in the mesh spacer, wherein each of the tie straps defines the plurality of equally spaced holes above the reinforcing bar attached to the tie strap; and The spiral retainer is rotated through the welded polymer fibers of the mesh gasket and around the reinforcing ribs, through the tie band and into the groove, wherein the spiral retainer is wrapped through the plurality of equally spaced holes and the welded polymer fibers to hold the tie band in the predetermined position.

84. The method of claim 83, further comprising: The mesh spacer is formed into the shape of a seat pad.

85. The method of claim 83 or 84, further comprising: The tie straps are sewn to the cover, wherein the cover is a seat cover.

86. The method of any one of claims 83-85, further comprising: A guide comb is inserted into the groove to align the equally spaced holes with the gaps defined by the guide comb and the plurality of turns of the spiral retainer.

87. The method of any one of claims 83-86, further comprising: A mandrel is inserted into the spiral retainer and guides the spiral retainer as it is rotated into the mesh body.

88. The method of claim 70, further comprising: collapsing the retainer along the connector of the retainer assembly; inserting the retainer and the connector of the retainer assembly into a slot formed through the seat pad; translating the retainer through the seat cushion with the connector still at least partially within the slot; and The retainer is expanded relative to the connector into contact with an area of ​​the gasket adjacent the slot to retain the connector within the slot.

89. The method of claim 88, further comprising connecting a base to the connector spaced apart from the retainer to engage an area of ​​the gasket adjacent the slot and spaced apart from the retainer.

90. The method of claim 88 or 89, further comprising securing at least one of a seat trim, an actuator, and a heat transfer layer to the base.

91. A vehicle seat assembly manufactured according to the method of any one of claims 70-90.

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