Welding pipes in multi-chamber unit

Abstract

The invention relates to welding pipes in a multi-chamber unit. A multi-chamber bladder is constructed from a stack of a plurality of bladder sheets including at least a first bladder sheet, a second bladder sheet, and a third bladder sheet, where the first bladder sheet and the second bladder sheet have aligned chamber apertures, and where the third bladder sheet encapsulates one end of the multi-chamber bladder. A tube is positioned between the second bladder sheet and the third bladder sheet such that one end of the tube extends outwardly from an outer periphery of the plurality of bladder sheets. A single attachment interface attaches the outer peripheries of the tube and the second and third bladder sheets together.

Description

BACKGROUND

[0001] A vehicle seat includes a seat cushion and a seat back that can include inflatable bladders for massage, lumbar support, or wing support purposes. BRIEF DESCRIPTION OF DRAWINGS

[0002] Figure 1 is a perspective view of a seat assembly.

[0003] Figure 2 is a perspective view of a seat bladder assembly and associated fluid supply system.

[0004] Figure 3 is a schematic view of a multi-chamber bladder with an associated tube and mandrel.

[0005] Figure 4 is a magnified perspective view of a single attachment interface that secures adjacent bladder sheets and tubes together to form a multi-chamber bladder.

[0006] Figure 5A is a top view of an interior portion of a multi-chamber bladder.

[0007] Figure 5B is a top view of an interior portion of Figure 5A removed from a tooling apparatus.

[0008] Figure 5C is similar to Figure 5B but with end bladder sheets placed over the mandrel and tube.

[0009] Figure 5D is a perspective view of a completed multi-chamber bladder removed from a tooling apparatus.

[0010] Figure 5E is a perspective view of a completed multi-chamber bladder with the mandrel removed. DETAILED DESCRIPTION

[0011] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments can be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0012] “one or more” includes a function performed by one element, by more than one element (in a distributed fashion, in a virtualized fashion, etc.), by a combination of one or more elements, by one or more elements in combination with a function performed by one or more other elements, or any combination of the above. For example “one or more” includes a function performed by one element, by more than one element (in a distributed fashion, in a virtualized fashion, etc.), by a combination of one or more elements, by one or more elements in combination with a function performed by one or more other elements, or any combination of the above.

[0013] It should also be understood that, although 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 contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. Both the first contact and the second contact are contacts, but they are not the same contact.

[0014] The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and / or," as used herein, refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms "includes," "including," "comprises," and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0015] As used herein, the term "if' is, optionally, interpreted as meaning "when" or "while" or "in response to a determination" or "in response to detecting," depending on the context. Similarly, the phrase "if determined" or "if [the condition or event] is detected," is, optionally, interpreted as meaning "upon a determination" or "in response to a determination" or "upon detecting [the condition or event]" or "in response to detecting [the condition or event]," depending on the context.

[0016] It should be understood that terms such as "about," "substantially," and "generally" are not intended to be limiting and should be interpreted consistent with how a person of ordinary skill in the art would interpret these terms.

[0017] The present disclosure relates to a multi-chambered bladder having an associated tube positioned between adjacent bladder panels such that one end of the tube extends outwardly from the outer periphery of the bladder panels, with a single attachment interface being formed that attaches the tube and the outer periphery of the bladder panels together. In embodiments, the single attachment interface is formed via a single welding operation.

[0018] Figure 1A seat assembly 10 according to an exemplary embodiment is shown. The seat assembly 10 can be used as a vehicle seat assembly 10 for seating in a vehicle such as a car, aircraft, ship, or any other seating environment. The seat assembly 10 includes a seat base 12, which can be adapted to be mounted for electrically driven adjustable translation in the forward and rearward directions and in the upward and downward directions of the vehicle. The seat assembly 10 includes a seat back 14, which can be pivotally connected to the seat base 12 to extend substantially upright relative to the seat base 12 for pivotal adjustment about an axis relative to the seat base 12.

[0019] The seat back 14 may include a head restraint 16 configured to support the head of a seat occupant. The head restraint 16 may be located at the top of the seat back 14. The head restraint 16 may be integral with the seat back 14, or it may be a separate component adjustablely positioned relative to the top of the seat back 14. The seat base 12 may be configured to support the seat occupant. In vehicle applications, the seat base 12 may be mounted to a supporting surface, such as a vehicle floor. It should be understood that this is merely one example of a seat construction, and other constructions may also be utilized.

[0020] In this embodiment, each of the seat back 14 and the seat bottom 12 includes a foam pad 18. The foam pad 18 can be conventionally attached to the seat frame (not shown) by any method known in the art. The foam pad 18 may independently contain any suitable comfort foam material, such as, but not limited to, a suitable resilient polymer, and may be independently formed in any suitable manner. For example, the foam pad 18 may be formed from conventional polyurethane foam, soy-based foam, silicone, thermoplastic olefins, thermoplastic polyurethane and / or natural oil-based foamed polyurethane, soy-based polyurethane, polymer fibers, nonwoven polyester pads, latex foam, etc. The foam pad 18 is formed from any suitable comfort material that provides soft resilience when the seat assembly flexes during use when the occupant is in a seated position.

[0021] Figure 2Examples of a sac assembly and associated fluid supply system 20 for use with seat assembly 10 are shown. In an embodiment, the sac assembly and associated fluid supply system 20 may include one or more of the following: shoulder sacs 22; one or more side wing sacs 24; one or more lumbar sacs 26; and one or more massage sacs 28. In an embodiment, these sacs 22, 24, 26, 28 are supported by one of the pads 18 of seat assembly 10. In an embodiment, a cover 30 may be disposed above or on the pad 18 and may cover the sacs 22, 24, 26, 28. The cover 30 provides at least a portion of the visible outer surface of seat assembly 10. In an embodiment, the cover 30 may include a plurality of decorative panels that may be assembled in any suitable manner, such as by stitching. The decorative panels may be made of any suitable one or more materials, such as fabric, leather, vinyl, or combinations thereof.

[0022] In one embodiment, the shoulder pouch 22 provides upper body support, the side wing pouch 24 provides lateral support to the seated occupant when the vehicle undergoes a turn or corner, the lumbar pouch provides lower back support, and the massage pouch 28 is used to massage designated body areas.

[0023] In one embodiment, the bladder assembly and associated fluid supply system 20 may include a compressor or pneumatic pump 32 connected to a valve assembly 34 having multiple valves 38 to supply fluid to the bladders 22, 24, 26, 28. In one example, the valves 38 are associated with actuators, such as solenoids, shape memory alloy components, or other types of actuating components. In one embodiment, multiple fluid conduits 40 are used to connect the various bladders 22, 24, 26, 28 to the fluid supply system 20. The fluid supply system 20 also includes a seat control module generally identified as a controller 42. In one example, the controller 42 regulates the compressed air entering and leaving the bladder assemblies 22, 24, 26, 28 in the seat assembly 10. For example, the controller 42 and associated valve actuators may be mounted in the seat bottom 12 or seat back 14, or the controller 42 may be mounted under the seat assembly 10, or anywhere suitable in the vehicle.

[0024] Controller 42 may include a processing unit and non-transitory memory for executing various control strategies. The processing unit may be a custom or commercially available processor, a central processing unit (CPU), or generally any means for executing software instructions. The memory may include any or a combination of volatile and / or non-volatile memory elements. The processing unit may be programmed to execute one or more programs stored in the memory. For example, the program may be stored in the memory as software code. The program stored in the memory may include one or more additional or separate programs, each including an ordered list of executable instructions for implementing the logical functions associated with the control valve assembly. Although shown as a single controller, controller 42 may consist of one or more controllers. Controller 42 may also communicate with and respond to instructions from another controller.

[0025] In embodiments, one or more of the sacs 22, 24, 26, and 28 may include, for example: Figure 3 The multi-chambered sac 44 is shown. The multi-chambered sac 44 may include a massage sac 28, a lumbar sac 26, a lateral sac 24, or a shoulder sac 22.

[0026] In one example, the multi-chamber bladder 44 comprises a discrete inflatable / ventable bag or unit having multiple fluidly connected inner chambers. In an embodiment, the multi-chamber bladder 44 may be composed of a stack of multiple bladder sheets (e.g., flat sheets of polymer material) including at least a first bladder sheet 46, a second bladder sheet 48, and a third bladder sheet 50, wherein the first bladder sheet 46 and the second bladder sheet 48 have aligned chamber openings 52, and wherein the third bladder sheet 50 encloses one end of the multi-chamber bladder 44. An additional fourth bladder sheet 54 may enclose the opposite ends of the multi-chamber bladder 44. Alternatively, inner bladder sheets may be used as needed.

[0027] In one instance, the capsule sheet is made of thermoplastic polyurethane (TPU).

[0028] In one example, a first chamber 56 is formed between a second bladder sheet 48 and a third bladder sheet 50, a second chamber 58 is formed between a first bladder sheet 46 and a second bladder sheet 48, and a third chamber 60 is formed between a fourth bladder sheet 54 and a first bladder sheet 46. Chambers 56, 58, and 60 are in fluid communication with each other via aligned chamber openings 52.

[0029] In one embodiment, the chambers 56, 58, and 60 of the multi-chamber sac 44 include a series of selectively inflatable chambers aligned along a common axis A, such that chambers 56, 58, and 60 are continuously inflated and deflated.

[0030] In one embodiment, the tube 62 (e.g., a hollow cylinder) is positioned between the second bladder sheet 48 and the third bladder sheet 50, such that one end 64 of the tube extends outward from the outer periphery of the bladder sheets 48 and 50, and the opposite end 66 is positioned together with the first chamber 56 (e.g., Figure 4 (as shown in the image).

[0031] In one embodiment, a single attachment interface 68 attaches the tube 62 together with the outer peripheries of the second capsule sheet 48 and the third capsule sheet 50. In another embodiment, the single attachment interface 68 includes a common attachment for both the capsule sheets 48, 50 and the tube 62.

[0032] In an implementation, a single attachment interface 68 includes a welding interface. In one instance, the welding interface is provided, for example, via a welding operation (such as high-frequency welding or other suitable welding operation).

[0033] In one embodiment, the method for attaching the tube 62 to the multi-chamber sac 44 includes welding the tube 62 and the periphery of the sac in a single welding step. For example, the method includes attaching adjacent inner sac sheets 48, 46 having aligned chamber openings 52 (e.g., coaxial openings) together to provide the internal portion 70 of the multi-chamber sac 44 (e.g., ...). Figure 5A (as shown in the image).

[0034] Next, the internal portion 70 of the multi-chamber bladder 44 is supported on a tooling platform 72 including the welding electrode 74 (e.g., Figure 5B (As shown in the diagram). In one example, the welding electrode 74 comprises an aluminum or brass body designed to carry a high-frequency current to generate heat and weld the materials together.

[0035] In one embodiment, the mandrel 76 has a first end 78 and a second end 80, the first end being inserted through an aligned chamber orifice 52, and the second end supporting the inner end 66 of the tube 62 (e.g., Figure 5B (As shown in the diagram). In one example, the mandrel 76 includes a strip or bar that is inserted into the hollow workpiece for support while the workpiece is being machined.

[0036] In this example, tube 62 is thus placed on the inner portion 70 formed by the capsule sheets 48, 50, such that the inner end 66 will be located in the first chamber 56, and the opposite end 64 will extend beyond the periphery 84 of the inner portion 70 (e.g., Figure 5B (as shown in the image).

[0037] In one embodiment, the end capsule sheet 50 is then placed over the portion 70, the mandrel 76, and the tube 62, such that the end 64 of the tube 62 extends outward from the outer periphery 86 of the end capsule sheet 50 (e.g., Figure 5C (as shown in the image).

[0038] In one embodiment, the multi-chambered bladder 44 is then formed by activating the welding electrode 74 to weld the outer periphery 86 of the tube 62 and the end bladder sheet 50, as well as the outer periphery 84 of the inner bladder portion 70, together in a single welding operation (see [link]). Figure 5C Therefore, the welding operation around the periphery of the stacked capsule will also weld the tube in place without any additional material handling or subsequent welding operations.

[0039] Finally, once the welding attachment interface 68 is completed, the multi-chamber bladder 44 is then removed from the tooling platform 72. Figure 5D ), and then the axial length 76 can be pulled out from the opposite side of the multi-chambered capsule 44 (e.g. Figure 5E (as shown in the image).

[0040] In an embodiment, the mandrel 76 includes at least a first portion 88 and a second portion 90 that are not collinear with each other (e.g., ...). Figure 3 (As shown in the diagram). In one example, sections 88 and 90 comprise linear, rigid rods.

[0041] In one instance, the first part 88 is perpendicular to the second part 90.

[0042] In one example, the first part 88 and the second part 90 form an L-shape.

[0043] In one instance, the second part, 90, is longer than the first part, 88.

[0044] In one instance, the first portion 88 is associated with tube 62, and the second portion 90 extends into a multi-chambered sac.

[0045] In implementation, the methods and apparatus of the subject matter can be used for any pipe length, such as long or short pipe constructions. For example, the methods and apparatus can be used for pipe lengths greater than 20 cm.

[0046] In implementations, once the inner diameter of the bladder is larger than the outer tube diameter, each tube diameter can be welded. In one instance, larger volume (e.g., larger size) bladders will require larger tube diameters to meet the requirements for inflation / deflation time. In implementations, typically for waist / shoulder / side bladders, a 6 (outer) mm / 4 (inner) mm tube diameter or a 4.7 / 3 mm tube diameter can be used. In implementations, typically for massage bladders, a 3 / 1.5 mm tube diameter can be used.

[0047] An assembly is disclosed comprising: a multi-chamber capsule comprising a plurality of stacked capsule sheets including at least a first capsule sheet, a second capsule sheet, and a third capsule sheet, wherein the first capsule sheet and the second capsule sheet have aligned chamber openings, and wherein the third capsule sheet encloses one end of the multi-chamber capsule; a tube positioned between the second capsule sheet and the third capsule sheet such that one end of the tube extends outwardly from the outer periphery of the plurality of capsule sheets; and a single attachment interface attaching the tube and the outer peripheries of the second capsule sheet and the third capsule sheet together.

[0048] The component may include any additional features, individually or in any combination thereof. In one or more instances, the multi-chamber capsule comprises a series of selectively inflatable chambers in fluid communication with each other.

[0049] In one or more instances, the multi-chamber sac includes at least one of a massage sac, a lumbar sac, or a lateral sac, or any combination thereof.

[0050] In one or more instances, the single attachment interface includes a welding interface.

[0051] In one or more instances, the stacked multiple capsule sheets are made of polyurethane material.

[0052] A method is disclosed, the method comprising: attaching an inner capsule sheet having a first chamber orifice to an additional capsule sheet having a second chamber orifice aligned with the first chamber orifice; placing a tube on the inner capsule sheet; inserting a mandrel through the first chamber orifice and the second chamber orifice and supporting a first end of the tube; placing an end capsule sheet over the inner capsule sheet and the tube such that a second end of the tube extends outward from the outer periphery of the end capsule sheet; and forming a multi-chamber capsule by welding the tube and the outer peripheries of the end capsule sheet and the inner capsule sheet together in a single welding operation.

[0053] The method may include any additional features, individually or in any combination thereof. In one or more instances, the method includes supporting at least one of the inner capsule sheet, the additional capsule sheet, or the end capsule sheet, or any combination thereof, on a welding electrode.

[0054] In one or more instances, the method includes removing the multi-chambered sac from the welding electrode after the welding operation.

[0055] In one or more instances, the method includes removing the spindle from the tube and the multi-chambered sac via the first chamber orifice and the second chamber orifice after removing the multi-chambered sac from the welding electrode.

[0056] In one or more instances of the method, the welding operation includes a high-frequency welding operation that provides a single attachment interface for attaching the tube, the inner bladder sheet, and the outer periphery of the end bladder sheet together.

[0057] In one or more instances of the method, the mandrel comprises at least a first portion and a second portion that are not collinear with each other.

[0058] In one or more instances of the method, the first portion includes a first linear bar, and the second portion includes a second linear bar perpendicular to the first linear bar.

[0059] In one or more instances, the method includes forming the capsule sheet from a polyurethane material.

[0060] A device is disclosed comprising: a plurality of capsule sheets, the plurality of capsule sheets including at least a first capsule sheet and a second capsule sheet, the first capsule sheet and the second capsule sheet being attached to each other and having aligned chamber openings; and a third capsule sheet stacked on the second capsule sheet and enclosing one end of the capsule; a welding electrode supporting the plurality of capsule sheets; a tube positioned between the second capsule sheet and the third capsule sheet such that one end of the tube extends outwardly from the outer periphery of the stacked plurality of capsule sheets; and a mandrel having one end for holding in place and an opposite end inserted through the aligned chamber opening and engageable with the end of the tube.

[0061] The device may include any additional features, individually or in any combination thereof. In one or more instances, the mandrel includes at least a first portion and a second portion that are not collinear with each other.

[0062] In one or more instances, the first part and the second part are perpendicular to each other.

[0063] In one or more instances, one of the first portion and the second portion is longer than the other of the first portion and the second portion.

[0064] In one or more instances, one of the first portion and the second portion is associated with the tube, and the other of the first portion and the second portion extends out of the sac.

[0065] In one or more instances, the welding electrode provides a single welding interface that attaches the tube together with the outer periphery of the second and third bladder sheets.

[0066] In one or more instances, the first, second, and third capsule sheets comprise multi-chamber capsules, wherein one end of the tube extending outward from the outer periphery of the stacked capsule sheets is connectable to a fluid supply source, and the opposite end of the tube is in fluid communication with a chamber of the multi-chamber capsule.

[0067] Although the different embodiments have the specific components shown in the figures, the embodiments of this disclosure are not limited to those specific combinations. Some components or features from one embodiment may be used in combination with features or components from another embodiment. In addition, the various figures accompanying this disclosure are not necessarily drawn to scale, and some features may be enlarged or minimized to show certain details of a particular component or arrangement.

[0068] Those skilled in the art will understand that the above embodiments are exemplary and non-limiting. That is, modifications to this disclosure will fall within the scope of the claims. Therefore, the following claims should be studied to determine their true scope and content.

Claims

1. An assembly comprising: a multi-chambered bladder constructed from a stacked plurality of bladder sheets including at least a first bladder sheet, a second bladder sheet, and a third bladder sheet, wherein the first bladder sheet and the second bladder sheet have aligned chamber apertures, and wherein the third bladder sheet encloses one end of the multi-chambered bladder; a tube positioned between the second bladder sheet and the third bladder sheet such that one end of the tube extends outward from an outer periphery of the plurality of bladder sheets; and a single attachment interface attaching the tube together with the outer peripheries of the second bladder sheet and the third bladder sheet.

2. The assembly of claim 1, wherein the multi-chambered bladder includes a series of selectively inflatable chambers in fluid communication with one another.

3. The assembly of any of claims 1-2, wherein the multi-chambered bladder includes at least one of a massage bladder, a lumbar bladder, or a wing bladder, or any combination thereof.

4. The assembly of any of claims 1-3, wherein the single attachment interface includes a welded interface.

5. The assembly of any of claims 1-4, wherein the stacked plurality of bladder sheets are constructed from a polyurethane material.

6. A method comprising: attaching an inner bladder sheet having a first chamber aperture to an additional bladder sheet having a second chamber aperture aligned with the first chamber aperture; placing a tube on the inner bladder sheet; inserting a mandrel through the first chamber aperture and the second chamber aperture and supporting a first end of the tube; placing an end bladder sheet over the inner bladder sheet and the tube such that a second end of the tube extends outward from an outer periphery of the end bladder sheet; and forming a multi-chambered bladder by welding the tube together with the outer peripheries of the end bladder sheet and the inner bladder sheet in a single welding operation.

7. The method of claim 6, comprising supporting at least one of the inner bladder sheet, the additional bladder sheet, or the end bladder sheet, or any combination thereof, on a welding electrode.

8. The method of any of claims 6-7, comprising removing the multi-chambered bladder from the welding electrode after the welding operation.

9. The method of claim 8, comprising removing the mandrel from the tube and the multi-chambered bladder via the first chamber aperture and the second chamber aperture after removing the multi-chambered bladder from the welding electrode.

10. The method of any of claims 6-9, wherein the welding operation includes a high frequency welding operation that provides a single attachment interface attaching the tube together with the outer peripheries of the inner bladder sheet and the end bladder sheet.

11. The method of any of claims 6-10, wherein the mandrel includes at least a first portion and a second portion that are non-collinear with one another.

12. The method of any of claims 6-11, wherein the first portion includes a first linear rod and the second portion includes a second linear rod perpendicular to the first linear rod.

13. The method of any of claims 6-12, comprising forming the bladder sheets from a polyurethane material.

14. An apparatus comprising: a plurality of bladder sheets including at least a first bladder sheet and a second bladder sheet that are attached to one another and have aligned chamber apertures, and a third bladder sheet that is stacked on the second bladder sheet and encloses one end of a bladder; a welding electrode that supports the plurality of bladder sheets; a tube positioned between the second bladder sheet and the third bladder sheet such that one end of the tube extends outward from an outer periphery of the plurality of stacked bladder sheets; and a mandrel having a fixed one end and an opposite end that is insertable through the aligned chamber apertures and engageable with the end of the tube.

15. The apparatus of claim 14, wherein the mandrel includes at least a first portion and a second portion that are non-collinear with one another.

16. The apparatus of claim 15, wherein the first portion and the second portion are perpendicular to one another.

17. The apparatus of any one of claims 15-16, wherein one of the first portion and the second portion is longer than the other of the first portion and the second portion.

18. The apparatus of any one of claims 15-17, wherein one of the first portion and the second portion is associated with the tube and the other of the first portion and the second portion extends out of the bladder.

19. The apparatus of any one of claims 14-18, wherein the welding electrode provides a single welding interface that attaches the tube and outer peripheries of the second and third bladder sheets together.

20. The apparatus of any one of claims 14-19, wherein the first, second, and third bladder sheets comprise a multi-chamber bladder, wherein the one end of the tube that extends outward from an outer periphery of the plurality of stacked bladder sheets is connectable to a fluid supply and the opposite end of the tube is in fluid communication with a chamber of the multi-chamber bladder.

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