Seat assembly including a modular foam arrangement with a modular ventilation section and method for manufacturing the same

Abstract

Seat assembly (10), comprising: a seat frame (22); a seat cushion (23) which is supported by the seat frame (22) and includes: a modular foam arrangement (38) comprising an inner surface (47) arranged therein, wherein the modular foam arrangement (38) comprises a modular venting section (48) in fluid communication with the inner surface (47), the modular venting section (48) comprising a chamber (61) formed therein and a plurality of vent openings (51) in fluid communication with the chamber (61); and an outer cover (36) that at least partially covers the modular foam arrangement (38); and an air movement device (53) which is in fluid communication with the modular venting section (48) for conveying air between the inner surface (47) and the air movement device (53), wherein the air movement device (53) is arranged in the chamber (61) of the modular venting section (48) and draws air from the inner surface (47) through the vent openings (51) to the air movement device (53) for removing heat from the seat cushion (23), wherein the modular venting section (48) is a modular foam venting section comprising a foam material.

Description

TECHNICAL FIELD

[0001] The technical field generally relates to seat assemblies, and more particularly, to seat assemblies including a seat cushion having a modular foam assembly including a modular venting portion for airflow, and a method of manufacturing such seat assemblies. BACKGROUND

[0002] The commercial and / or military transportation industry, e.g., the aircraft industry, the automotive industry, and the like, often includes seating assemblies in aircraft or motor vehicles for the comfortable transportation of a passenger(s). The seating assemblies include, for example, a seat frame supporting a plurality of seat cushions, such as a seat bottom cushion or a seat back cushion, to provide comfortable seating for a passenger.

[0003] During use of a seat assembly by a seated occupant, an increase in temperature may occur between the seated occupant and one or more of the seat cushions. This increase in temperature may cause the seat cushion(s) to become uncomfortably warm for the seated occupant.

[0004] In particular, seat cushions are typically formed from one or more pieces of foam that are hand-cut to shape. For example, the seat cushion may be formed from a single piece of foam, which can be cut to size as desired. Unfortunately, foam is generally a relatively good insulator (e.g., a relatively poor conductor of heat), and the heat transfer from a single piece of foam away from the seated occupant is minimal, which can cause the seat cushion to become uncomfortably warm after prolonged, uninterrupted use by the occupant.

[0005] In another example, the seat cushion may be formed from multiple hand-cut pieces of foam glued or bonded together with an adhesive. Unfortunately, in addition to the various foam pieces being relatively poor heat conductors, the adhesive can further delay heat dissipation through the foam structure, causing the seat cushion to become uncomfortably warm.

[0006] US 2016 / 0 096 460 A1 describes a motor vehicle seat in which a cushion body of a cushion and / or a backrest has a passage for air coming from an air conditioning system of the motor vehicle. US 6,848,742 B1 describes a seat climate control unit with a seat defining an air duct through which air flows towards a seat surface, and with two blower units for blowing air into the air duct. According to US 8,672,411 B2, a vehicle seat has a seat surface and a backrest extending upwards from the seat surface. The seat surface and the backrest are exposed to an air flow so that it reaches a passenger sitting on the vehicle seat. US 7,918,498 B2 relates to a ventilated seat with a valve plate with which the temperature of the seat can be regulated.

[0007] Accordingly, it is desirable to provide improved seat assemblies including a seat cushion that overcomes one or more of the above problems. Furthermore, other desirable features and characteristics of the various embodiments described herein will become apparent from the following detailed description and the appended claims, taken in combination with the accompanying drawings and this background. SUMMARY

[0008] Seat assemblies and methods of manufacturing seat assemblies are provided herein. In accordance with an exemplary embodiment, a seat assembly includes a seat frame and a seat cushion supported by the seat frame. The seat cushion includes a modular foam assembly having an interior surface disposed therein. The modular foam assembly includes a modular vent portion in fluid communication with the interior surface. An outer cover at least partially covers the modular foam assembly. An air moving device is in fluid communication with the modular vent portion for conveying air between the interior surface and the air moving device.

[0009] In another exemplary embodiment, a seat assembly includes a seating bottom portion having a rear portion and a front portion on a side opposite the rear portion. The seating bottom portion includes a seating bottom structural portion and a seating bottom cushion supported by the seating bottom structural portion. The seating bottom cushion includes a modular foam assembly having an interior surface disposed therein generally forward of the rear portion of the seating bottom portion. The modular foam assembly includes a modular vent portion in fluid communication with the interior surface. An outer cover at least partially covers the modular foam assembly. An air moving device is in fluid communication with the modular vent portion for conveying air between the interior surface and the air moving device.A seat back portion is coupled to the seating bottom portion and is configured to extend substantially upright upwardly from the rear portion of the seating bottom portion.

[0010] In accordance with an exemplary embodiment, a method of manufacturing a seat assembly is provided. The method includes disposing a modular vent section in fluid communication with an interior surface within a modular foam assembly. The modular foam assembly is at least partially covered by an outer cover to form a seat cushion. The seat cushion is supported by a seat frame. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The various embodiments are described hereinafter in conjunction with the following drawing figures, wherein like reference numerals denote like elements, and wherein: Fig. 1 illustrates a perspective view of a seat assembly in accordance with an exemplary embodiment; Fig. 2 illustrates a side view of a portion of a seat assembly including a seat frame, a seat bottom cushion, and a seat back cushion in accordance with an exemplary embodiment; Fig. 3 illustrates an exploded top perspective view of a modular foam seat cushion assembly in accordance with an exemplary embodiment; Fig. 4 an exploded perspective view of the modular foam assembly of Fig. 3 from below; Fig. 5 illustrates a partial view of a portion of a seat cushion in accordance with an exemplary embodiment; and Fig. 6 illustrates a method of manufacturing a seat assembly in accordance with an exemplary embodiment. DETAILED DESCRIPTION

[0012] The following detailed description is merely exemplary in nature and is not intended to limit the various embodiments or their application and uses. Furthermore, there is no intention to be bound by any theory presented in the foregoing background or the following detailed description.

[0013] Various embodiments presented herein relate to seat assemblies and methods of manufacturing seat assemblies. The exemplary embodiments taught herein provide a seat assembly including a seat frame and one or more seat cushions, such as a seat bottom cushion and / or a seat back cushion, supported by the seat frame. The seat cushion includes a modular foam assembly having an interior surface disposed therein and a modular vent portion in fluid communication with the interior surface. In one example, the modular vent portion is formed of foam and has a plurality of vent openings formed therein to permit airflow through the modular vent portion.

[0014] In an exemplary embodiment, the modular foam assembly further includes a plurality of modular foam sections coupled together, one or more of which define at least a portion of the interior surface. In one example, the modular foam sections include a plurality of interlocking and non-interlocking features that function as interlocking features that respectively engage with each other to couple the modular foam sections together. An outer cover at least partially covers the modular foam assembly.

[0015] An air movement device is in fluid communication with the modular venting section. The air movement device is configured to convey air between the interior surface within the modular foam assembly and the air movement device to remove heat from the seat cushion. In an exemplary embodiment, it has been found that by using the air movement device to convey air along the interior surface of the modular foam assembly to the modular vented section, heat can be efficiently removed from the interior surface through a forced convection process to prevent the seat cushion from becoming uncomfortably warm for a seated occupant.

[0016] Furthermore, in an exemplary embodiment, it has been found that by forming the seat cushion including modular foam sections coupled together using interlocking features that engage with each other, the use of adhesive to couple the various modular foam sections together can be reduced or eliminated to produce a more comfortable, temperature-stable seat cushion for the seated occupant.

[0017] Fig. 1 illustrates a perspective view of a seat assembly 10 in accordance with an exemplary embodiment. Fig. Figure 2 is a side view of a portion of the seat assembly 10 shown in Fig. 1. With reference to Fig. 1-2, the seat assembly 10 includes a seat bottom portion 18 and a seat back portion 20 extending substantially vertically upward from the seat bottom portion 18. In one example, the seat back portion 20 is fixedly coupled to the seat bottom portion 18 such that the seat back portion 20 is permanently fixed in a substantially upright configuration. In another example, the seat assembly 10 is an adjustable seat assembly in which the seat back portion 20 is pivotally coupled to the seat bottom portion 18 for translation between a substantially upright position and, for example, a substantially reclined and / or inclined (e.g., forward leaning) position(s).

[0018] As shown, the seat assembly 10 includes a seat frame 22 for supporting the seat assembly 10, including supporting armrest portions 16 and a plurality of seat cushions 23. The seat frame 22 is formed from a relatively rigid support material such as metal, e.g., aluminum or the like, a composite, or any other structural material(s) known to one skilled in the art.

[0019] The seat frame 22 includes a seat bottom structural portion 24 and a seat back structural portion 26 operably coupled (e.g., fixedly coupled or pivotally coupled) to the seat bottom structural portion 24 to extend in a substantially upright position from the seat bottom structural portion 24. The seat bottom structural portion 24 of the seat frame 22 supports a seat bottom cushion 28 (e.g., one of the seat cushions 23), which together form at least a portion of the seat bottom portion 18 of the seat assembly 10. Likewise, the seat back structural portion 26 of the seat assembly 22 supports a seat back cushion 30 (e.g., another of the seat cushions 23), which together form at least a portion of the seat back portion 31 of the seat assembly 10.Various other trim and / or sheathing panels or components 31 may be directly or indirectly coupled to the seat frame 22 to form any remaining parts or portions of the seat bottom portion 18 and / or the seat back portion 20 of the seat assembly 10.

[0020] As discussed in further detail below, the seat bottom and backrest cushions 28 and 30 are each formed from relatively pliable and / or soft materials such as a foam material(s) 34, which is covered or at least partially covered by an outer covering 36. The outer covering 36 is a relatively pliable and / or soft surface material such as leather, cloth, or textile fabric (e.g., a woven or knotted design), a thermoplastic surface material such as TPO, PVC, or the like. The outer covering 36 may be formed using a conventional leather molding process, a thermoforming process, a tray or rotational molding process, and / or any other conventional method for forming an interior trim outer surface covering that is relatively pliable and / or soft.

[0021] With reference to the Fig. 1-4, in an exemplary embodiment, the foam material(s) 34 in the seat bottom cushion 28 is configured as a plurality of modular pieces or modular foam sections 40, 42, 44, 46, 50, 52, 54, and 56 that are coupled together to form a modular foam assembly 38. As illustrated, the modular foam section 40 is an outer modular foam section disposed adjacent to and underlying the outer cover 36 along an outermost region of the modular foam assembly 38. The modular foam section 40 extends generally forwardly from a rearward portion 66 of the seat bottom portion 18, which underlies the seat back portion 20, to a forward portion 68 of the seat bottom portion 18.The modular foam portion 40 has a downwardly extending edge 70 that wraps around the forward portion 68 immediately adjacent the outer cover 36. As such, the modular foam portion 40 forms a portion of the modular foam assembly 38 of the seat cushion 28 that is closest to a seated occupant, immediately adjacent the outer cover 36.

[0022] The remaining modular foam sections 42, 44, 46, 50, 52, 54, and 56 are inner modular foam sections disposed in the interior region of the modular foam assembly 38 below the modular foam section 40. As illustrated, the modular foam sections 42, 44, 46, 50, and 56 are disposed immediately adjacent to the modular foam section 40 along a side opposite the outer cover 36, while the modular foam sections 52 and 54 are spaced from the modular foam section 40 in a further interior region of the modular foam assembly 38.

[0023] In an exemplary embodiment, interior surfaces 47 are disposed within the modular foam assembly 38, for example, along one or more of the surfaces 74, 76, 78, 80, 82, and 84 between the adjacent modular foam sections 40, 42, 44, 46, 50, 52, 54, and 56. As illustrated, and as discussed in further detail below, at least a portion of the interior surfaces 47 are accordingly disposed along the opposing outer interior surfaces of the modular foam section 40 and the modular foam section 46, which are separated by an air space 49 (e.g., a space containing air) and which define the interface 74.

[0024] The modular foam assembly 38 includes a modular vent section 48 in fluid communication with the interior surfaces 47 defining the air space 49. An air moving device 53 is in fluid communication with the modular vent section 48 for conveying air between the interior surfaces 47 and the air moving device 53. In an exemplary embodiment, heat from a seated occupant or otherwise transfers from an upper region of the seat bottom cushion 28 (e.g., near the outer cover 36) through the modular foam assembly 38 to the interior surfaces 47. The air moving device 53, for example, draws air through the air space 49 toward the modular vent section 48 to efficiently remove heat from the interior surfaces 47 via forced convection to help maintain the seat bottom cushion 28 at a comfortable temperature.

[0025] As shown, the modular vent section 48 includes a plurality of vent openings 51 configured to allow airflow through the modular vent section 48 to the air moving device 53. The modular vent section 48 is disposed in the rearward portion 66 of the seat bottom portion 18 below the seat back portion 20. In an exemplary embodiment, the air moving device 53 is disposed within the seat bottom cushion 28 in a chamber 61 formed within the modular vent section 48 near a downwardly facing wall 59 adjacent the seat frame 22. The vent openings 51 extend from a forwardly facing wall 57 of the modular vent section 48 to the chamber 61 to provide fluid communication to the air moving device 53.As such, warm air drawn from the interior surfaces 47 of the modular foam assembly 38 to the air movement device 53 may be vented into the open space(s) formed in the seat frame 22 near the rear portion 66 of the seating bottom area 18.

[0026] In an exemplary embodiment, the modular venting section 48 is a modular venting foam section formed from the foam material 34. Alternatively, the modular venting section 48 may be formed from another material, for example, a molded plastic material or the like.

[0027] In one exemplary embodiment, the air movement device 53 is, for example, a fan that generates relatively little audible noise. Alternatively, the air movement device 53 may be configured as an air pump or other device for moving air to create forced convection known to those skilled in the art.

[0028] With reference to Fig. 2, in an exemplary embodiment, the seat assembly 10 further includes a sensor 90 (e.g., infrared sensor, infrared camera, thermocouple, or the like) configured to monitor a temperature associated with the seat assembly 10. For example, the sensor 90 may be an infrared camera positioned external to the seat assembly 10 to monitor the temperature of a seat occupant and / or one of the seat cushions 23, or both. Alternatively, the sensor 90 may be positioned, for example, within one of the seat cushions 23 in the modular foam assembly 38 to monitor the temperature of the seat cushion 23.

[0029] In an exemplary embodiment, sensor 90 is operatively coupled to air moving device 53 for "turning on" air moving device 53 to move air and for "turning off" air moving device 53 to stop moving air. As illustrated, sensor 90 is operatively coupled to air moving device 53 via a controller 91 and lines 92 and 94. In an exemplary embodiment, sensor 90 communicates a temperature associated with seat assembly 10 to controller 91 via line 94. When the temperature is at or above a first predetermined temperature, controller 91 sends a "turn on" signal via line 92 to air moving device 53.When the temperature associated with the seat assembly 10 is at or below a second predetermined temperature, the controller 91 sends a "turn off" signal over line 92 to the air moving device 53. In an exemplary embodiment, the first predetermined temperature is about 26 to about 30°C and the second predetermined temperature is about 22 to about 25.5°C.

[0030] With reference to the Fig. 1-5, at least some of the modular foam sections 40, 42, 44, 46, 50, 52, and 54 include respective interlocking features 58 and 60 that engage the interlocking features 58 and 60 of one or more of the other adjacent modular foam sections 40, 42, 44, 46, 50, 52, and 54 to couple the modular foam sections 40, 42, 44, 46, 50, 52, and 54 together. In an exemplary embodiment, the interlocking features 60 are non-positive features such as depressions or holes, and the interlocking features 58 are positive features such as protrusions or projections that engage the non-positive features.In one example, the interlocking features 58 may be independently configured as a boss having a substantially cylindrical shape, and the interlocking features 60 may be independently configured as a hole having a substantially cylindrical shape for receiving and engaging the interlocking features 58. In another example, the interlocking features 58 may be independently configured as a boss having a substantially polygonal box shape, and the interlocking features 60 may be independently configured as a hole having a substantially polygonal shape for receiving and engaging the interlocking features 58.

[0031] In an exemplary embodiment, the outer surfaces of the form-fitting or interlocking features 58 extending from the modular foam section 46 to the modular foam section 40 form at least a portion of the inner surfaces 47. In particular, the interlocking features 58 of the modular foam section 46 contact and are at least partially disposed within the non-form-fitting or interlocking features 60 of the modular foam section 40. As illustrated, at least a portion of the outer surface of the interlocking features 58 of the modular foam section 46 is exposed in the air space 49.Therefore, when the air movement device 53 is in operation, the air moves through the air space 49 along the outer surfaces of the interlocking features 58 of the modular foam section 46 to efficiently remove heat from both modular foam sections 40 and 46 by forced convection.

[0032] The modular foam assembly 38 may include one or more channels 96 formed therein. As illustrated, the channels 96 are formed in the modular foam section 50 toward the front portion 68 of the seat bottom cushion 28. The channels 96 are in fluid communication with the interior surfaces 47 to facilitate the transfer of heat from the seat bottom cushion 28 to air moving through the channels 96 and back to the modular vent section 48. In an exemplary embodiment, the channels 96 help draw heat from the upper region of the seat bottom cushion 28 to the walls of the channels 96 in the interior of the modular foam assembly 38. In addition to the walls of the channels 96 forming part of the interior surfaces 47, the channels 96 further help direct the flow of air downstream to remove additional heat from other areas of the interior surfaces 47.

[0033] The modular foam sections 40, 42, 44, 46, 50, 52, 54, and 56 and the modular vent section 48 may be formed from the same type of foam or from different types of foam. For example, one or more of the modular foam sections 40, 42, 44, 46, 50, 52, 54, and 56 and the modular vent section 48 may be formed from a thermosetting type material (e.g., polyurethane or polyurea type foam material) based on conventional foam formation processes of reacting two or more components, such as, for example, reacting polyols with diisocyanates in the presence of a foaming agent. Alternatively, one or more of 40, 42, 44, 46, 50, 52, 54 and 56 and the modular vent section 48 may be made of a thermoplastic material (e.g.Polyolefin-type foam) based on conventional foam formation processes for foaming thermoplastic materials, such as, for example, by saturating a thermoplastic material with liquid nitrogen and decompressing the liquid nitrogen-saturated thermoplastic material in an autoclave to form a thermoplastic foam.

[0034] The modular foam sections 40, 42, 44, 46, 50, 52, 54, and 56 and the modular vent section 48 may be manufactured by first forming one or more foam blocks using one or more conventional foam forming processes, such as those described above, or by any other foam forming process known to those skilled in the art. In an exemplary embodiment, the one or more foam blocks are then cut, milled, and / or otherwise trimmed using a CNC (computer numerical control) process, for example, to form the intricate shapes that define the modular foam sections 40, 42, 44, 46, 50, 52, 54, and 56 and the modular vent section 48, including the corresponding interlocking features 58 and 60, the vent openings 51, and / or the chamber 61.

[0035] In an exemplary embodiment, the modular vent section 48 is attached to the adjacent modular foam sections 40, 46, 52, and 54 with an adhesive 72. As illustrated, no adhesive or substantially no adhesive (e.g., substantially adhesive-free) is present between the connecting surfaces 74, 76, 80, 82, and 84 between the adjacent modular foam sections 40, 42, 44, 46, 50, and 54, thereby reducing the amount of adhesive used in the modular foam assembly 38 compared to conventional seat cushions.

[0036] With reference to Fig. 2, the foam material(s) 34 in the seat back cushion 30 may be configured with multiple modular pieces, or alternatively, may be formed from a single piece of foam or multiple pieces of foam secured together by an adhesive. In an exemplary embodiment, the seat back cushion 30 includes a modular foam assembly configured similarly to the modular foam assembly 38 discussed above with respect to the seat bottom cushion 28.

[0037] With reference to Fig.6, a method 600 for manufacturing a seat assembly is provided. The method 600 includes disposing (STEP 602) a modular vent section in fluid communication with an interior surface within a modular foam assembly. The modular foam assembly is at least partially covered with an outer cover to form a seat cushion (STEP 604). The seat cushion is supported by a seat frame (STEP 606).

[0038] While at least one exemplary embodiment has been presented in the foregoing detailed description of the disclosure, it should be understood that a wide number of variations exist. It should also be understood that the exemplary embodiment or exemplary embodiments are only examples and are not intended to limit the scope, applicability, or interpretation of the disclosure in any way. Rather, the foregoing detailed description provides those skilled in the art with convenient guidance for implementing an exemplary embodiment of the disclosure. It is understood that numerous changes in the function and arrangement of elements described in an exemplary embodiment may be made without departing from the scope of the disclosure as set forth in the appended claims.

Claims

[1] Seat assembly (10) comprising: a seat frame (22); a seat cushion (23) supported by the seat frame (22) and comprising: a modular foam assembly (38) having an inner surface (47) disposed therein, the modular foam assembly (38) including a modular venting portion (48) in fluid communication with the inner surface (47), the modular venting portion (48) having a chamber (61) formed therein and a plurality of vent openings (51) in fluid communication with the chamber (61); and an outer cover (36) at least partially covering the modular foam assembly (38); and an air movement device (53) in fluid communication with the modular venting section (48) for conveying air between the inner surface (47) and the air movement device (53), wherein the air movement device (53) is disposed in the chamber (61) of the modular venting section (48) and draws air from the inner surface (47) through the vent openings (51) to the air movement device (53) for removing heat from the seat cushion (23), wherein the modular venting section (48) is a modular foam venting section comprising a foam material. [2] The seat assembly (10) of claim 1, wherein the modular vent portion (48) has a plurality of vent openings (51) formed therein to allow air flow between the interior surface (47) and the air moving device (53). [3] Seat assembly (10) according to claim 1, wherein the air movement device (53) is arranged in the seat cushion (23) between the seat frame (22) and the outer cover (36). [4] Seat assembly (10) according to claim 3, wherein the air movement device (53) is arranged in the modular venting section (48). [5] Seat assembly (10) according to claim 1, wherein the air moving device (53) is a fan. [6] Seat assembly (10) according to claim 1, wherein the seat cushion (23) is a seat cushion. [7] Seat assembly (10) according to claim 1, wherein the seat cushion (23) is a seat back cushion. [8] The seat assembly (10) of claim 1, wherein the modular foam assembly (38) comprises a first modular foam portion and a second modular foam portion disposed adjacent to the first modular foam portion, and wherein at least one of the first modular foam portion and the second modular foam portion comprises at least a portion of the interior surface (47). [9] The seat assembly (10) of claim 8, wherein the second modular foam portion has a form-fitting feature extending therefrom, and wherein the form-fitting feature has an outer surface that includes the at least a portion of the inner surface (47). [10] The seat assembly (10) of claim 9, wherein the form-fitting feature extends from the second modular foam section to the first modular foam section. [11] The seat assembly (10) of claim 10, wherein an air space is formed above the interlocking feature between the first and second modular foam sections, and wherein the air moving device (53) is in fluid communication with the air space to enable air to be conveyed above the interlocking feature and to the modular vent section (48). [12] The seat assembly (10) of claim 10, wherein the first modular foam portion includes a non-form-fitting feature, and wherein the form-fitting feature of the second modular foam portion is at least partially disposed within the non-form-fitting feature. [13] The seat assembly (10) of claim 12, wherein the non-positive and positive features are interlocking features that engage with each other to couple the first and second modular foam sections together. [14] The seat assembly (10) of claim 1, wherein the modular foam assembly (38) has a channel formed therein in fluid communication with the interior surface (47) to facilitate the transfer of heat from the seat cushion (23) to the air conveyed to the modular venting section (48). [15] The seat assembly (10) of claim 1, further comprising a sensor configured to monitor a temperature associated with the seat assembly (10), and wherein the sensor is operatively coupled to the air moving device (53) to turn on the air moving device (53) at a first predetermined temperature and to turn off the air moving device (53) at a second predetermined temperature that is lower than the first predetermined temperature. [16] Seat assembly (10) comprising: a seat portion (18) having a rear portion and a front portion on a side opposite the rear portion, the seat portion (18) comprising a seat structural portion and a seat cushion supported by the seat structural portion, the seat cushion comprising: a modular foam assembly (38) having an inner surface (47) disposed therein generally forward of the rear portion of the seating area (18), the modular foam assembly (38) including a modular venting portion (48) in fluid communication with the inner surface (47), the modular venting portion (48) having a chamber (61) formed therein and a plurality of vent openings (51) in fluid communication with the chamber (61); and an outer cover (36) at least partially covering the modular foam assembly (38); an air movement device (53) in fluid communication with the modular venting section (48) for conveying air between the inner surface (47) and the air movement device (53), wherein the air movement device (53) is disposed in the chamber (61) of the modular venting section (48) and draws air from the inner surface (47) through the vent openings (51) to the air movement device (53) for removing heat from the seat cushion (23), wherein the modular venting section (48) is a modular foam venting section comprising a foam material; and a seat back portion coupled to the seat bottom portion and configured to extend upright upwardly from the rear portion of the seat bottom area (18). [17] The seat assembly (10) of claim 16, wherein the modular venting portion (48) is disposed in the rear portion of the seat bottom region (18) below the seat back region. [18] The seat assembly (10) of claim 16, wherein the modular foam assembly (38) has a channel formed therein generally forward of the rear portion of the seating bottom area (18) and in fluid communication with the interior surface (47) to facilitate the transfer of heat from the seating bottom cushion to the air conveyed to the modular venting portion (48). [19] A method of manufacturing a seat assembly (10), the method comprising the following steps: Disposing a modular venting section (48) in fluid communication with an internal surface in a modular foam assembly (38), the modular venting section (48) having a chamber (61) formed therein and a plurality of vent openings (51) in fluid communication with the chamber (61); at least partially covering the modular foam assembly (38) with an outer cover (36) to form a seat cushion (23); and Supporting the seat cushion (23) by a seat frame (22); Disposing an air moving device (53) in fluid communication with the modular venting section (48) for conveying air between the internal surface and the air moving device (53), wherein the air moving device (53) is disposed in the chamber (61) of the modular venting section (48) and draws air from the internal surface through the vent openings (51) to the air moving device (53) for removing heat from the seat cushion (23), wherein the modular venting section (48) is a modular foam venting section comprising a foam material.

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