Foam pad with heating wire

Abstract

A foam pad with a heating wire is provided. An assembly includes: a foam seat cushion; and the heating wire is directly sewn to one side of the foam seat cushion. A method includes sewing a heating wire directly to a side of a foam seat cushion.

Description

[0001] Related Applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 543,572, filed on October 11, 2023, the entire contents of which are incorporated herein by reference. background

[0004] Some vehicles may include seats associated with a heating system that selectively generates heat for occupant comfort. A typical heating system includes an electrical energy source mounted within a heating pad disposed within the vehicle seat. Traditionally, the heating pad is typically flat and rectangular in shape and includes conductive wires integrated into the pad. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 is a schematic side view of a vehicle seat cushion having a heating wire.

[0007] Figure 2 is a cross-sectional view of a seat foam pad having heating wires.

[0008] Figure 3 yes Figure 2 Bottom view of the seat foam padding.

[0009] Figure 4 yes Figure 2 Top view of the seat foam padding.

[0010] Figure 5 is an example of blind stitching used to attach heating wires to seat foam padding.

[0011] Figure 6 is another example of blind stitching used to attach a heating wire to a seat foam pad.

[0012] Figure 7 is used Figure 6 Schematic diagram of the tunnel formed by blind suture. Detailed Description

[0014] 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.

[0015] “One or more” includes a function performed by one element, a function performed by more than one element (eg, in a distributed manner), several functions performed by one element, several functions performed by several elements, or any combination of the foregoing.

[0016] 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 element. For example, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact without departing from the scope of the various embodiments described. Both the first contact and the second contact are contacts, but they are not the same contact.

[0017] The terms used in the description of the various embodiments described herein are only used 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 also include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and covers any and all possible combinations of one or more of the associated listed items. It should be further understood that when used in this specification, the terms "includes", "including", "comprises" and / or "comprising" specify the presence of the features, wholes, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts and / or groups thereof.

[0018] 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.

[0019] It should be understood that terms such as "about," "substantially," and "approximately" are not intended to be open-ended terms, and should be interpreted in the same manner as those skilled in the art would interpret these terms.

[0020] The present disclosure is directed to a trim cover module in which a heating wire is sewn directly onto the top of a foam pad, rather than sewing the heating wire into a cushion and then attaching it to the foam pad.

[0021] Figure 1-Figure 4 A vehicle seat component 10 is shown, which includes a foam seat pad 12 and a heating wire 14 sewn directly to the foam seat pad 12. In one example, the seat component 10 includes a seat bottom pad, however, the seat component may also include a seat back associated with the seat bottom. In one example, the foam seat pad 12 is made of PU foam, Hacoflex, reticulated foam or other foam material. In one example, the heating wire 14 is a conductive wire, such as, for example, a thin metal heating element, which is sewn directly to one side of the foam seat pad 12. The heating wire 14 is connected to a power source PS in a known manner.

[0022] In an embodiment, the foam seat pad 12 includes a scrim material layer 24, wherein the heating wire 14 is directly attached to the foam seat pad 12 through the scrim material. In one example, the scrim material includes a lightweight reinforcing fabric and is used to increase the strength, stability, and durability of the pad 12. In addition, the scrim material helps maintain the shape of the pad 12 over time and provides support for the foam or other padding material within the seat pad.

[0023] In one example, the heating wire 14 and associated stitching are located on only one side of the liner 12. The scrim material layer 24 is located on the upper surface 44 of the liner 12. Figure 1 As shown, the foam seat pad 12 and scrim layer 24 include a first side 16 and a second side 18 opposite the first side 16. The heating wire 14 and thread 20 for stitching associated with the heating wire 14 are located entirely on one side, such as the first side 16.

[0024] In other words, the stitching does not extend through the entire thickness of the foam seat pad 12. This leaves the opposite side (e.g., second side 18) free of stitching associated with the heating wire 14. Thus, stitching does not appear on the side opposite to where the heating wire 14 is attached (e.g., second side 18). Figure 3 ).

[0025] In an embodiment, the heating wire 14 can be used with the foam material of the cushion which can have any thickness. In one example, the heating wire 14 and the associated stitching are located within a thickness range less than the entire thickness of the cushion 12. Figure 1 As shown, the foam seat pad 12 and the scrim layer 24 have an overall thickness T extending from the first side 16 to the second side 18. Figure 1). The foam seat pad 12 and scrim layer 24 include a zone 22 or area having a heating wire and a stitching zone thickness T1. The zone 22 forms a designated area within the foam seat pad 12, starting from the wire stitching surface at the first side 16 and extending into the pad body. The zone 22 includes the heating wire 14 and any thread 20 used for associated stitching. The heating wire and stitching zone thickness T1 are less than the total thickness T, so that the stitching does not extend through the entire thickness T, but is only located on one side 16 of the pad 12 (see Figure 2 ).

[0026] In one example, the stitching for the heating wire 14 is maintained within a limited depth from the stitching surface at the first side 16. In one example, the limited depth includes the heating wire and the stitching area thickness T1. In one example, the stitching associated with the heating wire 14 is within a depth of 10 mm from the outer surface of the first side 16 of the foam seat pad 12. In another example, the heating wire 14 is within a depth of 5 mm from the outer surface of the first side 16 of the foam seat pad 12 and the scrim layer 24.

[0027] In an embodiment, the foam seat pad 12 includes an upper scrim material surface, wherein the heating wire 14 is directly attached to the foam seat pad 12 through the scrim material 24. In one example, the foam seat pad 12 includes a single-piece foam body having the scrim material 24 on the outer surface 44 of only one side (e.g., the first side 16). The heating wire 14 is sewn directly to the scrim material. In one example, the scrim material includes a felt material; however, other types of materials may also be used.

[0028] In one example, specific stitching is used for wire attachment. In one example, the stitching associated with the heating wire 14 includes a blind stitch, which provides an invisible stitch or a slip stitch that is not visible on at least one side of the pad 12.

[0029] In an embodiment, blind stitching is a sewing technique used to create a nearly invisible seam or seam on a fabric. The stitches are designed to be hidden within an area of ​​the associated fabric or material so that the stitches are barely noticeable from an external view.

[0030] Figure 5 An example of blind stitching for wire attachment is shown. In this example, the blind stitching includes a heating wire 14 surrounded by a stitching loop 26. The blind stitching method includes replacing one blind stitch line with the heating wire 14 and stitching around the heating wire 14 with another blind stitch line 28 (as indicated entering the page at 30 and exiting the page at 32), so that the heating wire 14 extends through the stitching loop 26 of the remaining blind stitch line 28. In this example, the stitching includes a series of figure-8 loops, with the heating wire extending through one of the loops, as indicated at 34.

[0031] Figure 6-Figure 7 Another example of blind stitching for wire attachment is shown. In this example, blind stitching is used to attach a small piece of material 36 to the cushion 12 forming a channel 38. The heated wire 14 can be fed through the channel 38 attached to the cushion 12. In one example, the channel 38 includes a U-shaped or C-shaped structure with opposing edges 40, which is attached to the cushion 12 to form an open center area. The material used to form the channel 38 is attached to the first side 16 of the foam seat cushion 12 along a designated wire path. The designated wire path is a pattern specific to the desired wire location on the cushion 12.

[0032] In one example, the channel 38 is formed of a material having a thermal conductivity property above a predetermined level so that heat can be easily conducted through the material. In one example, the material comprises a woven material having a thermally conductive element. A person skilled in the art having the benefit of this specification will be able to determine the appropriate material for these purposes. The heating wire 14 is then located within the channel 38. The stitching used to attach the channel material to the pad 12 provides a channel path without stitching within the channel 38 so that the heating wire 14 can extend through the channel 38.

[0033] In one example, a trim cover 42 is included to form a trim cover module. Figure 1 In one example, a trim cover 42 is attached to the foam seat cushion 12 just above the scrim material surface of the cushion 12 to form a trim cover module. In one example, the trim cover 42 includes leather, PVC, PU, ​​textile material, or other suitable material for providing a desired aesthetic appearance. The heating wire is then positioned directly between the cushion and the trim cover.

[0034] In an embodiment, an assembly includes a foam seat pad and a heating wire sewn directly to one side of the foam seat pad.

[0035] Components may include any of the following, alone or in combination.

[0036] The assembly may include the heating wire and stitching associated with the heating wire being located entirely on one side of the foam seat pad.

[0037] The assembly may include where one side of the foam seat pad includes a first side, and where the foam seat pad includes a second side opposite the first side, and where the second side is free of stitching associated with the heater wire.

[0038] The component may include, wherein: one side of the foam seat pad includes a first side; the foam seat pad includes a second side opposite to the first side; the foam seat pad has a total thickness extending from the first side to the second side; and the foam seat pad includes a heating wire and a stitching area thickness starting from the first side, the heating wire and the stitching area thickness being less than the total thickness.

[0039] The assembly may include where the stitching associated with the heating wire is within a depth of 10 mm from an outer surface of one side of the foam seat pad.

[0040] The assembly may include wherein the stitching associated with the heater wire comprises a blind stitch.

[0041] The assembly may include where the blind suturing includes a heater wire extending through the suture loop.

[0042] The assembly may include a channel attached to a side of the foam seat pad along a designated wire path, the channel being formed of a material having thermal conductivity properties above a predetermined level, and wherein the heating wire is located within the channel.

[0043] The assembly may include where the foam seat pad includes a one-piece foam body having a scrim material on one side, and where the heating wire is stitched directly to the scrim material.

[0044] The assembly may include a trim cover attached to the foam seat pad over the scrim material and forming a trim cover module.

[0045] A method of attaching a heating wire directly to a foam cushion is also disclosed. The method includes sewing the heating wire directly to one side of the foam seat cushion.

[0046] The method may comprise any of the following method steps, alone or in combination.

[0047] The method may include positioning the entire heating wire and stitching associated with the heating wire on one side of the foam seat pad.

[0048] The method may include maintaining the second side free of stitching associated with the heater.

[0049] The method may include providing a foam seat pad having a total thickness extending from a first side to a second side, and forming a heating wire and stitching area thickness that starts from the first side and terminates before reaching the second side so that the heating wire and stitching area thickness is less than the total thickness.

[0050] The method may include sewing a heating wire within a depth of 10 mm from an outer surface of one side of the foam seat pad.

[0051] The method may include blind stitching the heating wire to one side of the foam seat pad.

[0052] The method may include replacing one blind suture with a heating wire and suturing around the heating wire such that the heating wire extends through the suture loop of the remaining blind suture.

[0053] The method may include providing a channel material having thermal conductivity above a predetermined level, attaching a channel formed from the channel material to a side of a foam seat pad along a designated wire path, and then feeding a heating wire through the channel along the designated wire path.

[0054] The method may include providing the foam seat pad as a one-piece foam body having a scrim material on one side, and the method includes sewing the heating wire directly to the scrim material.

[0055] The method may include attaching a trim cover to the foam seat pad over the scrim material and forming a trim cover module.

[0056] The subject disclosure provides a seat assembly in which a heating wire is sewn directly on top of a foam pad, rather than sewing the heating wire into another layer (e.g., a nonwoven pad) and then attached to the foam pad. This is advantageous because it reduces material usage and cost within the seat assembly. In addition, the number of material layers is reduced and there is no read through.

[0057] Although different examples have specific components shown in the drawings, embodiments of the present disclosure are not limited to those specific combinations. Some components or features in one example may be used in combination with features or components in another example. In addition, the various drawings accompanying the present disclosure are not necessarily to scale, and some features may be enlarged or minimized to show certain details of a particular component or arrangement.

[0058] Those skilled in the art will appreciate that the above embodiments are exemplary and not restrictive. That is, modifications to the present disclosure will fall within the scope of the claims. Therefore, the appended claims should be studied to determine their true scope and content.

Claims

1. A component comprising: foam seat padding; and A heating wire is sewn directly to one side of the foam seat pad.

2. The assembly according to claim 1, wherein The heating wire and stitching associated with the heating wire are located entirely on the one side of the foam seat pad.

3. The assembly according to claim 2, wherein: The one side of the foam seat pad includes a first side, and wherein the foam seat pad includes a second side opposite the first side, and wherein the second side is free of stitching associated with the heater wire.

4. The assembly of claim 1, wherein: said one side of said foam seat pad comprises a first side; the foam seat pad including a second side opposite the first side; the foam seat pad having an overall thickness extending from the first side to the second side; and The foam seat pad includes a heating wire and a stitching area thickness starting from the first side, the heating wire and the stitching area thickness being less than the total thickness.

5. The assembly according to claim 1, wherein: The stitching associated with the heating wire is within a 10 mm depth from the outer surface of the one side of the foam seat pad.

6. The assembly according to claim 1, wherein: The stitching associated with the heater wire comprises a blind stitch.

7. The assembly according to claim 6, wherein: The blind suture includes the heater wire extending through the suture loop.

8. The assembly of claim 6, comprising a channel attached to said one side of said foam seat pad along a designated wire path, said channel being formed of a material having thermal conductivity properties above a predetermined level, and wherein said heating wire is located within said channel.

9. The assembly of claim 1, wherein: The foam seat pad includes a one-piece foam body having a scrim material on the one side, and wherein the heating wire is stitched directly to the scrim material.

10. The assembly of claim 9 including a trim cover attached to the foam seat pad over the scrim material and forming a trim cover module.

11. A method comprising: Sew the heating wire directly to one side of the foam seat padding.

12. The method of claim 11 including positioning the entirety of the heater wire and stitching associated with the heater wire on the one side of the foam seat pad.

13. The method according to claim 11, wherein: The one side of the foam seat pad includes a first side, and wherein the foam seat pad includes a second side opposite the first side, and the method includes maintaining the second side free of stitching associated with the heater wire.

14. The method according to claim 11, wherein: said one side of said foam seat pad comprises a first side; the foam seat pad including a second side opposite the first side; the foam seat pad having an overall thickness extending from the first side to the second side; and The method includes forming a heating filament and a seam zone thickness that starts from the first side and ends before reaching the second side such that the heating filament and the seam zone thickness is less than the total thickness.

15. The method of claim 11, comprising sewing the heating wire within a depth of 10 mm from the outer surface of the one side of the foam seat pad.

16. The method of claim 11 including blind stitching the heating wire to the one side of the foam seat pad.

17. The method of claim 16 including replacing one blind stitch on the one side of the foam seat pad with the heating wire and stitching around the heating wire so that the heating wire extends through the stitching loop of the remaining blind stitch.

18. The method according to claim 16, comprising: providing a channel material having a thermal conductivity property above a predetermined level; attaching a channel formed by the channel material to the one side of the foam seat pad along a designated wire path; and The heating wire is then fed through the channel along the designated wire path.

19. The method according to claim 11, wherein: The foam seat pad includes a one-piece foam body having a scrim material on the one side, and the method includes sewing the heating wire directly to the scrim material.

20. The method of claim 19 including attaching a trim cover to the foam seat pad over the scrim material and forming a trim cover module.

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