Seat system and method

Abstract

To provide a seat system including seat components, a seat cushion material, and a trim cover.SOLUTION: Seat components include at least a fan, inflatable bladders, a heat mat, a foam layer, and an air distribution layer. A trim cover is disposed on a seat cushioning material, the seat components are disposed between the seat cushioning material and the trim cover and are secured together with at least one fastener.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] Various embodiments relate to trim covers, breathability, modularity, packaging, fluid linesheets, wearable bladders, and seat assemblies and subassemblies related to methods of manufacturing the assemblies, fluid linesheets, and wearable bladders. [Prior art documents] [Patent documents]

[0002] [Patent Document 1] U.S. Patent No. 11,440,791 [Patent Document 2] U.S. Patent No. 10,065,543 [Brief explanation of the drawings]

[0003] [Figure 1] FIG. 1 is a partial cross-sectional front perspective view of a seat assembly according to some embodiments. [Figure 2] FIG. 2 is a front elevation view of a modular packaging subassembly of the sheet assembly of FIG. 1 according to some embodiments. [Figure 3] FIG. 2 is a front elevation view of a modular packaging subassembly of the sheet assembly of FIG. 1 according to some embodiments. [Figure 4] FIG. 2 is a front elevation view of a modular packaging subassembly of the sheet assembly of FIG. 1 according to some embodiments. [Figure 5] FIG. 5 is a rear elevation view of the modular packaging subassembly of FIG. 4. [Figure 6] FIG. 5 is a side elevation view of the modular packaging subassembly of FIG. 4. [Figure 7] FIG. 2 is a bottom view of a modular packaging subassembly of the sheet assembly of FIG. 1 according to some embodiments. [Figure 8]FIG. 1 is a front perspective view of a seat assembly according to some embodiments. [Figure 9] FIG. 9 is a partial cross-sectional view of a subassembly of the seat assembly of FIG. 8. [Figure 10] 10 is another partial cross-sectional view of the subassembly of FIG. 9 according to some embodiments. [Figure 11] 10 is another partial cross-sectional view of a portion of the subassembly of FIG. 9 according to some embodiments. [Figure 12] 10 is another partial cross-sectional view of a portion of the subassembly of FIG. 9 according to some embodiments. [Figure 13] 1 illustrates a method according to some embodiments. [Figure 14] 1 shows a schematic perspective view of a seat assembly according to some embodiments with a fluid assembly that provides a fluid massage. [Figure 15] 1 illustrates a side elevation view of a fluid coupling of a fluid assembly, according to some embodiments. [Figure 16] FIG. 1 illustrates a side view of a fluid bladder according to some embodiments. [Figure 17] 1 illustrates a side exploded view of a fluid assembly according to some embodiments. [Figure 18] FIG. 1 illustrates a side view of a fluid bladder of a fluid assembly according to some embodiments. [Figure 19] 1 shows an exploded perspective view of a portion of a fluid assembly according to some embodiments. [Figure 20] FIG. 1 illustrates a side view of a fluid bladder according to some embodiments. [Figure 21] 1 illustrates an exploded side view of a fluid assembly according to some embodiments. [Figure 22] 1 illustrates an exploded side view of a fluid assembly according to some embodiments. [Figure 23] 1 illustrates an exploded side view of a fluid assembly according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0004] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth to provide a thorough understanding of the various described embodiments. However, it will be apparent to those skilled in the art that the various described embodiments may 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.

[0005] It is understood that the disclosed embodiments are merely exemplary and that various alternative forms are possible. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art how to variously use the embodiments according to the present invention.

[0006] "One or more" includes functions performed by one element, functions performed by more than one element, e.g., in a distributed manner, several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0007] It is also understood that although terms such as "first," "second," etc. are used herein to describe various elements in some instances, these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first layer may be referred to as a second layer, and similarly, a second layer may be referred to as a first layer, without departing from the scope of the various described embodiments. The first layer and the second layer are both layers, but are not the same layer.

[0008] 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. When used in the description of the various described embodiments and the appended claims, the singular forms "a," "an," "the," and "said" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It is also understood that the term "and / or," as used herein, refers to and includes any and all possible combinations of one or more of the associated listed items. It is further understood that the terms "comprise," "comprising," and / or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0009] As used herein, the term "when" is interpreted to mean "when," "when," or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrase "when determined" or "when [a stated condition or event] is detected" is interpreted to mean "in determining" or "in response to determining" or "in detecting [a stated condition or event]" or "in response to detecting [a stated condition or event]," depending on the context.

[0010] Furthermore, all numerical quantities in this disclosure are understood to represent two examples: one is the numerical quantity itself and the other, when describing the broad scope of the present disclosure, modified by the word "about." Also, unless otherwise specified, percents, "portions of," and ratio values ​​are by weight. The term "polymer" includes "oligomer," "copolymer," "terpolymer," and the like. Molecular weights given for any polymer refer to number-average molecular weights. Descriptions of components in chemical terms refer to the components at the time of addition to the combination specified in the description and do not necessarily exclude chemical interactions between the components of the mixture once mixed. The initial definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation herein and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation. Unless expressly stated to the contrary, measurements of properties are determined by the same techniques as previously or subsequently referenced for the same property.

[0011] Because particular components and / or conditions may vary, the present disclosure is not limited to the specific embodiments and methods described below. Further, the terminology used herein is used only for the purpose of describing particular embodiments and is not intended to be limiting in any way.

[0012] The terms "substantially" or "generally" may be used herein to describe the disclosed or claimed embodiments. The term "substantially" may modify a value or relative property disclosed or claimed in this disclosure. In such cases, "substantially" and "generally" may mean that the value or relative property is within its manufacturing tolerance, or within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, or 10% of the value or relative property.

[0013] It should also be understood that integer ranges expressly include all intervening integers. For example, the integer range of 1 to 10 expressly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range of 1 to 100 includes 1, 2, 3, 4, ..., 97, 98, 99, and 100. Similarly, where any range is claimed, intervening numbers that are increments of the difference between the upper and lower limits divided by 10 can serve as alternative upper or lower limits. For example, if the range is 1.1 to 2.1, 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.

[0014] The term "controller" may refer to one or more controllers or control modules for various components and systems. Controllers and control systems may include any number of controllers, may be integrated into a single controller, or may have various modules. Some or all of the controllers may be connected via a controller area network (CAN) or other system. It is recognized that any controller, circuit, or other electrical device disclosed herein may include any number of microprocessors, integrated circuits, memory devices (e.g., 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 variations thereof), and software that cooperate with each other to perform the operations disclosed herein. Additionally, any one or more of the electrical devices disclosed herein may be configured to execute a computer program embodied in a non-transitory computer-readable medium programmed to perform any number of functions as disclosed herein.

[0015] Referring to FIG. 1 , a seat assembly (e.g., system) 10 is disclosed. The seat assembly 10 may be used in land vehicles, watercraft, aircraft, etc. The seat assembly 10 may be a seat assembly for a passenger car, straddle-type vehicle, etc. The seat assembly 10 may include one or more subassemblies 15 to 35. For example, the seat subassembly (cover) 10 includes a trim assembly 15 disposed on a cushion subassembly 20 supported by a frame subassembly 35. In some embodiments, the trim subassembly 15 includes a vent. In some embodiments, the seat subassembly 10 also includes a fluid subassembly 30. In some embodiments, the seat assembly 10 includes a temperature control subassembly 25, 30. In various embodiments, the fluid subassemblies 25, 30 are vent assemblies and / or massage assemblies. In some embodiments, the fluid subassemblies 25, 30 cooperate with the vent of the trim subassembly 15, and in some embodiments, the fluid subassemblies 25, 30 include the vent of the trim assembly 15. In some embodiments, the fluid subassembly 25, 30 includes a temperature control subassembly 25, 30. The temperature control subassembly 25, 30 includes, for example, a heat transfer subassembly. In some embodiments, a valve subassembly is included to control the flow of fluid. In some embodiments, retainers or fasteners may attach various components to the cushion.

[0016] 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 pre-assembled modules 10, 15, 20, 25, 30, 35. The assemblies 10, 15, 20, 25, 30 or the subassemblies 10, 15, 20, 25, 30 may be pre-assembled to the frame subassembly 35. The assemblies 10, 15, 25, 30, 35 or the subassemblies 10, 15, 25, 30, 35 may be pre-assembled to the cushion subassembly 20. The assemblies 10, 15, 25, 30, 35 or subassemblies 10, 15, 25, 30, 35 may be pre-assembled to the trim assembly 15. The assemblies 10, 15, 25, 30, 35 or subassemblies 10, 15, 25, 30, 35 may be integrated into the seat cushion subassembly 20, for example, into a foam or an extruded thermoplastic mesh. The cushion subassembly 20 may be a pad and may include a fluid-permeable spacer fabric. In some embodiments, the cushion subassembly 20 may be formed from an additive manufacturing process, such as the process disclosed in U.S. Patent Publication No. 11,440,791 to Migneco et al., issued September 13, 2022 to Lear Corporation. Various options are available for pre-assembling the sub-subassemblies 10, 15, 20, 25, 30, 35 or assemblies 10, 15, 20, 25, 30, 35 as modules or to the frame subassembly 35 or to the seat cushioning subassembly 20.

[0017] 2 and 3 show multiple stacked layers of assemblies 15, 20, 25, 30 or subassemblies 15, 20, 25, 30. The assemblies 15, 20, 25, 30 or subassemblies 15, 20, 25, 30 are shown pre-assembled with multiple fasteners 36. The fasteners 36 are mechanical devices that hold two or more things together, for example, to assemble or pre-assemble any combination of assemblies 15, 20, 25, 30 or subassemblies 15, 20, 25, 30. The fasteners 36 extend through a successive pair of layers or any number of layers of the assemblies 15, 20, 25, 30 or subassemblies 15, 20, 25, 30. The fasteners 36 may also be arranged into various fastener arrays, as depicted in the examples of FIGS. 2 and 3. Assemblies 15, 20, 25, 30 or subassemblies 15, 20, 25, 30 may be pre-assembled as modules that are subsequently assembled to frame subassembly 35. Any combination of assemblies 15, 20, 25, 30 or subassemblies 15, 20, 25, 30 may be pre-assembled to support various manufacturing strategies, such as just-in-time manufacturing. Assemblies 20, 25, 30 or subassemblies 20, 25, 30 may be pre-assembled and then subsequently assembled to trim cover subassembly 15.

[0018] 4-6 show a subassembly 38 according to some embodiments. In the depicted embodiment, the subassembly 38 is a seat module sized to be installed in a seat back 40 (also FIG. 1) of the seat assembly 10 (FIG. 1). The subassembly 38 includes a substrate 42 sized to be installed in the seat back 40. In some embodiments, the subassembly 38 and substrate 42 are sized to be attached to a seat bottom 44 (FIG. 1) of the seat assembly 10. The substrate 42 is formed from any suitable material. For example, the substrate 42, in some embodiments, is formed from a fluid-impermeable layer of thermoplastic polyurethane.

[0019] The subassembly 38, according to some embodiments, includes a massage subassembly 46 mounted to the substrate 42. The massage subassembly 38 is provided with at least one, and as depicted, a plurality of, inflatable massage bladders 48 (FIGS. 4 and 6). The cushion subassembly 20 may include a plurality of recesses formed in the cushion, each recessed to receive one of the bladders 48. A recess refers to a bulk space, as opposed to a hollow cell within a foam. The massage subassembly 46 includes air bladders 48 in various areas of the seat assembly 10, such as the lumbar region 66 (FIG. 1) of the seat back 40. The subassembly 38 and massage subassembly 46, according to some embodiments, are sized to be received within the trim cover subassembly 15. In some other embodiments, the massage subassembly 46 is disposed external to the trim cover subassembly 15 and the seat module subassembly 38.

[0020] Subassembly 38 also includes a pair of fluid actuator subassemblies 50, which according to some embodiments are fan subassemblies 50. Fan subassembly 50 is mounted to a rear side 52 (FIG. 5) of substrate 42 and aligned with an opening 54 through substrate 42 to force air through substrate 42 from a front side 56 of substrate 42.

[0021] The subassembly 38 may also include another fluid actuator subassembly 58, according to some embodiments, as shown in Figures 5 and 6. The fluid actuator subassembly 58 may include a pump and valve manifold 58 for delivering a fluid, such as pressurized air, to the massage subassembly 38. The fluid actuator subassembly 58 is also mounted to the substrate 42. The fluid actuator subassembly 58 may include a controller that controls the pump and valve manifold of the fluid actuator subassembly 58. The controller may be a multi-function controller that also controls other functions of the vehicle. Alternatively, the controller may be separate from the fluid actuator subassembly 58.

[0022] Subassembly 38, according to some embodiments, may also include a vent subassembly 60 mounted to substrate 42. Vent subassembly 60 includes a plurality of tubing in fluid communication with massage subassembly 46 and valve / pump subassembly 58, conveying pressurized fluid from valve / pump subassembly 58 to massage subassembly 46. Alternatively, vent subassembly 60 may be integrally formed with substrate 42, as is known in the art.

[0023] Each of the subassemblies 46, 50, 58, and 60 of the seat module subassembly 38 is pre-assembled to the base plate 42 before installation in the seat assembly 10. Each of the subassemblies 46, 50, 58, and 60 is fastened to the base plate 42 via fasteners 62. The fasteners 62 may include interlocking key and tab (e.g., "T-tabs"), welds, rivets, tag pins, barbed fasteners, ribbed shank rivets, staples, clips, adhesives, tie-downs, snaps, toggle closures, and the like. The rivets 62 may be rivets as disclosed in U.S. Patent Publication No. 10,065,543 to Persson et al., issued September 4, 2018 to KongsbergAutomotive AB. The fasteners 62 may allow longitudinal movement of the respective subassemblies 46, 50, 58, and 60 or the base plate 42 along the length of the fasteners 62. One or more of the base plate 42, the massage subassembly 46, the fluid actuator subassemblies 50, 58, and the vent subassembly 60 include a plurality of alignment apertures 64 for receiving the fasteners 62. The plurality of alignment apertures 64 may include notches formed in the periphery for aligning the layers. The fasteners 62 may be used to attach the subassembly 38 to the seat frame subassembly 35. The fasteners 62 may also include elastic straps for attaching the subassembly 38 to the seat frame subassembly 35. The fasteners 62 may attach the base plate 42 to the trim cover subassembly 15. The elastic straps may be attached to an inner surface of the trim cover subassembly 15. The cushion subassembly 20 may include apertures for receiving the elastic straps of the fasteners 62 through the cushion subassembly 20.

[0024] 1 , a heat transfer subassembly 68 may be disposed within the trim cover subassembly 15. The heat transfer subassembly 68 may be a heater mat that heats the seat assembly 10. The heat transfer subassembly 68 may also be pre-assembled to the other subassemblies 38, 46, 50, 58, 60.

[0025] A sensor 70 is provided in some embodiments in the cushion subassembly 20 within the trim cover subassembly 15. One or more sensors 70 may be used to measure data from the occupant. Wiring 72 is also enclosed within the trim cover subassembly 15 for communication and operation of the various subassemblies 38, 46, 50, 58, 60, 68.

[0026] Continuing to refer to FIG. 1 , the trim cover subassembly 15 is attached to the underlying substrate 42. This provides a chamber within the cover subassembly 15 for enclosing or at least partially enclosing the cushion subassembly 20, the seat module subassembly 38, and the accessory subassemblies 46, 50, 58, and 60 between the cover subassembly 15 and the substrate 42. The cover subassembly 15 may also be formed from a fluid-impermeable layer, such as a thermoplastic polyurethane, according to some embodiments. The cover subassembly 15 may be attached to the substrate 42 along the periphery of the substrate 42. The cover subassembly 15 may be bonded to the substrate 42 for a fluid-tight chamber within the cover subassembly 15. The cover subassembly 15 may be welded, sewn, or otherwise attached to the substrate 42. The trim cover subassembly 15 includes a sidewall 74 connected to the substrate 42. According to some embodiments, the sidewall 74 is foldable. According to other embodiments, the sidewall 74 includes multiple stackable sections as a corrugated bellows joint.

[0027] FIG. 7 illustrates a seat module subassembly 76 according to some embodiments. The seat module subassembly 76 is sized to fit within the seat bottom 44. The subassembly 76 includes a substrate 78 formed from one or more layers. A plurality of apertures 80 are formed through the substrate 78 (i.e., the air distribution layer) to cooperate with other subassemblies, such as ventilation subassemblies or heat transfer subassemblies. A plurality of fan subassemblies 82 are fastened to the substrate 78 by fasteners 62. Wiring 84 is also provided for powering and controlling the fan subassemblies 82. The seat module subassembly 76 and associated subassemblies 82 and components are housed (i.e., nested) within a chamber cavity of the trim cover subassembly 15.

[0028] Described herein is an assembly that may be a seat assembly or a subassembly thereof (e.g., a vehicle seat assembly 10, a trim cover subassembly 15, a cushion subassembly 20, fluid actuator subassemblies 25, 30, a seat module subassembly 38, a seat module subassembly 76). The assembly (e.g., a vehicle seat assembly 10, a trim cover subassembly 15, a cushion subassembly 20, a fluid actuator subassembly 25, 30, a seat module subassembly 38, a seat module subassembly 76) includes a substrate (e.g., a substrate 42) sized to be mounted to a seat bottom (e.g., a seat bottom 44) or a seat back (e.g., a seat back 40).

[0029] The substrate may be formed from a fluid-impermeable layer of thermoplastic polyurethane and may be integrally formed with the cover. A massage subassembly (e.g., massage subassembly 46) is attached to the substrate (e.g., substrate 42). The massage subassembly may include one or more massage bladders, which may be at least partially enclosed by the cover, disposed outside the cover and substrate, or disposed between the cover and substrate.

[0030] Fluid actuator subassemblies (e.g., fluid actuator subassemblies 50, 58) are mounted on a substrate (e.g., substrate 42). The fluid actuator subassemblies may include a fan assembly, a valve subassembly, a pump in fluid communication with the valve subassembly, and at least one inflatable bladder assembly supported by the first fluid-impermeable layer to apply pressure to an occupant. The vehicle seat assembly may include a seat bottom adapted to be mounted to a vehicle floor. The vehicle seat assembly may be installed in any row of the vehicle. The vehicle seat assembly may include a seat back extending upright from the seat bottom. The vehicle seat assembly may also include a headrest extending above the seat back. The vehicle seat assembly may be employed in any type of vehicle, including land vehicles, watercraft, aircraft, etc. The vehicle seat assembly may be any seat assembly, such as an office chair, furniture, etc. The vehicle seat assembly may include trim covers covering the seat bottom, seat back, and headrest, respectively, to hide the frame, cushion, and functional components.

[0031] The seat bottom may be provided with a seat cushioning material. The seat cushioning material may be constructed from a thermoplastic yarn or foam. The vehicle seat assembly may also be provided with a controller and a pump. The controller and pump may be provided in a module below the seat cushioning material and may be a multi-function controller that also controls other functions in the vehicle.

[0032] In at least one embodiment, the non-foamed material is formed from twisted strands of a thermoplastic resin, such as a linear low-density polyethylene (LLPDE) material. However, other polymers and materials useful for imparting desired properties and functionality are contemplated, including, but not limited to, polyamides, polyesters, polyimides, polyolefins (e.g., polypropylene, polyethylene, etc.), polystyrenes, or combinations thereof. At least one of the strands is looped and bonded to at least one other strand to form a three-dimensional structure. The use of thermoplastics offers several advantages over traditional polyurethane foams, including reduced toxicity, reduced weight, reduced manufacturing costs, and improved recyclability. It will be appreciated that the material properties of the resin can be adjusted to vary the hardness of the material and, therefore, the firmness of the resulting cushion. Similarly, adjusting the density and orientation of the strands can vary the firmness of the resulting cushion, porosity, and therefore the airflow through the resulting material.

[0033] In at least one embodiment, strands of thermoplastic material are extruded. The material is discharged from a container holding beads, granules, flakes, pellets, or powder of resin. It is then melted and extruded through a die head. The size and orientation of the holes through which the molten resin is extruded can be varied to achieve different properties of the resulting cushion. The extruded strands are then deposited in a water bath, which serves to loop and bond at least one strand to other strands to form a mesh, as well as to initiate a cooling process that returns the strands from a molten state to a hardened state. The distance of the die head from the water bath can be adjusted to affect the diameter of the resin strands, for example, due to thinning that occurs when the filament extends over an increased distance and the material is in a molten, unhardened state. The water bath can be equipped with various rollers and conveyors to move the filament through and out of the water bath, and the filament structure can be cut to the desired size and shape to form a cushion blank, for example, using a cut-off wheel, water jet, or other technique.

[0034] The result of the process, in one embodiment, is a mesh structure of relatively uniform dimensions, such as rectangular blocks or prisms. In other embodiments, the yarn can be manipulated during any step in the process to produce a mesh structure with features such as contours, notches, trenches, skins, etc. Manipulations include, for example, changing the extrusion speed, changing the speed at which the yarn is drawn from the water bath, introducing a stream of air or water that is blown onto the yarn before it reaches the water bath, agitating the water bath, adding layers of permeable or impermeable material, etc.

[0035] In some embodiments, the mesh structure may be further processed to introduce new shapes and features into the mesh. For example, in one embodiment, the mesh structure is cut into multiple blanks that are placed in a mold. To permanently configure the shape of the blank, the cushion blank is heated to a temperature at which the polymeric material from which it is formed begins to soften. Controlling the temperature and other manufacturing processes may result in limited and unintended localized melting of the polymeric material, but any melting is negligible, and the majority of the cushion blank remains in a non-liquid state. Thus, the cushion blank enters the molding process in a solid state and remains mostly or completely solid throughout the process. In one embodiment, this is accomplished by passing a first fluid having a first predetermined temperature through the mold and through the cushion blank itself. This introduces a first fluid flow to bring the cushion blank to the desired temperature.

[0036] The fluid in the fluid stream may be a gas, a liquid, or a combination of a gas and a liquid. For example, the fluid may be air, steam, superheated steam, water, etc. The first predetermined temperature depends on the particular material from which the cushion blank 12 is made. For example, for a twisted mesh material made from linear low-density polyethylene, as described above, the first predetermined temperature may be in the range of 85 to 100°C. Other types of polymeric materials may have different temperature ranges over which they become compliant. For example, for high-density polyethylene or polypropylene, the first predetermined temperature may be 100 to 130°C.

[0037] Because the cushion blank is made from twisted mesh material, the heated air flows generally evenly throughout the thickness of the blank, which helps ensure compliant, even heating of all material in the cushion blank.

[0038] A second fluid is subsequently passed through the mold to effect cooling of the cushion and hardening it to the shape of the mold. The second fluid may be air, steam, superheated steam, water, or the like.

[0039] The seat subassembly may include a second fluid-impermeable layer sized to be disposed over the seat cushion material. The first fluid-impermeable layer may be constructed from cushion material. The second fluid-impermeable layer may be formed from an impermeable polymer material such as thermoplastic polyurethane (TPU) film, polyvinyl chloride (PVC) film, polyethylene, or the like.

[0040] The first fluid-impermeable layer may have a plurality of vents formed therethrough. Any number of vents may be utilized. The plurality of vents may direct airflow through the seat subassembly. The first fluid-impermeable layer and vents may be optional if the trim cover has a plurality of holes therethrough. The first fluid-impermeable layer may be insulating. The first and second fluid-impermeable layers may be joined together by a sewn, glued, welded, etc. seam around the peripheral edges of the layers. The second fluid-impermeable layer may cooperate with the first fluid-impermeable layer to provide a fluid chamber therebetween.

[0041] The inflatable bladder assembly may be supported by the first fluid-impermeable layer and positioned within the fluid chamber. The inflatable bladder assembly may be positioned outside the fluid chamber, such as between the second fluid-impermeable layer and the seat cushion material.

[0042] The controller may be in electrical communication with the pump, which may be in fluid communication with the inflatable bladder assembly to inflate the assembly. The controller may be programmed to receive input indicative of a manual adjustment to adjust the inflatable bladder assembly to apply pressure to the occupant. The controller may be programmed to receive input indicative of a massage program to operate the inflatable bladder assembly to apply a pressurized massage effect to the occupant.

[0043] The seat subassembly may further include a fluid-permeable layer. The fluid-permeable layer may be formed from a resilient porous material, such as a porous foam or an extruded thermoplastic mesh. The fluid-permeable layer may be sized to be received within a fluid chamber disposed in an inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly may be disposed between a first fluid-impermeable layer and a second fluid-impermeable layer. Any number of air bladders may be used.

[0044] The fluid-permeable layer may ensure that the first and second fluid-impermeable layers are not compressed together by the weight of an occupant. Without the permeable layer, the weight from the occupant could compress the impermeable layers and block airflow when the fan is in use. If the seat subassembly utilizes a compressor as opposed to a fan, the permeable layer may be omitted.

[0045] The seat subassembly may also include a heat transfer layer disposed along the first fluid-impermeable layer. The heat transfer layer is spaced apart from the second fluid-impermeable layer. The heat transfer layer may be disposed along the trim layer, or alternatively, may be disposed between the second fluid-impermeable layer and the fan. The heat transfer layer may be disposed between the first fluid-impermeable layer and the first fluid-permeable layer. A conductive heater mat may be provided on the heat transfer layer. The seat subassembly may be provided as a pre-assembled module that is subsequently assembled to a seat cushion material and / or a seat trim cover.

[0046] The seat subassembly may further include an outer trim layer disposed on the first and second fluid-impermeable layers. The trim layer may be perforated to allow fluid to pass through the outer trim layer. The trim layer may be adhered to the first fluid-impermeable layer.

[0047] The seat subassembly may be provided with a fluid actuator, such as a fan. The fluid actuator may be welded directly to the second fluid-impermeable layer to seal the connection around the fan. The fan may be connected to the second fluid-impermeable layer by a retaining ring. The fan may be located between the trim cover and the seat cushion material. The seat cushion material may include a receptacle sized to receive the fan. Locating the fan above the seat cushion material may allow the fan to displace within the seat subassembly.

[0048] The fluid impermeable layer, the permeable layer, the heat transfer layer, the air bladder assembly, and the fluid actuator may all be pre-assembled within the seat subassembly, with the seat subassembly as a whole being attached to the seat frame. The seat subassembly may be operable with an air-permeable, non-foam seat cushion material formed from the twisted yarn mesh described above. The second fluid impermeable layer may provide a barrier between the fluid chamber and the seat cushion material. When used with a foam or twisted yarn cushion, the second fluid impermeable layer may be omitted if the cushion is air impermeable. In this case, the fluid actuator may be welded directly to the first fluid impermeable layer 924 to transport fluid through vents in the fluid impermeable layer. The fluid actuator may be separate from the trim cover. The first and second fluid impermeable layers may be stitched along their peripheries. The stitching may seal the layers to prevent air from escaping from the fluid chamber. The layers may be attached with adhesive or welded together, as opposed to using stitching.

[0049] The second fluid-impermeable layer may have a first portion and a second portion. The first portion may further include a first flap. The first flap may be perforated to allow airflow between zones or seams within the subassembly. The first flap may be segmented to allow airflow between zones and / or within fluid chambers. The second portion may further include a second flap extending in an opposite direction from the first flap. These flaps may be used to attach the subassembly to other seat components or subassemblies. The second flap may be connected to the seat cushion material. The first and second portions may be sewn, welded, glued, or otherwise fastened together. The first and second portions may be ultrasonically or high-frequency friction welded together.

[0050] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may have a first flap and a second flap. The first flap may be perforated to allow air to pass through the first flap within the fluid chamber. The second flap may extend in the opposite direction from the first flap and may be attached to the seat cushion material. The first and second flaps may be sewn, welded, glued, or otherwise fastened to the second fluid-impermeable layer. The first and second flaps may be ultrasonically or high-frequency friction welded to the second fluid-impermeable layer.

[0051] The substrate may be at least partially enclosed by a cover, with the fluid actuator subassembly disposed between the cover and the substrate. A vent subassembly (e.g., vent subassembly 60) is in fluid communication with the massage subassembly (e.g., massage subassembly 46) and the fluid actuator subassemblies (e.g., fluid actuator subassemblies 50, 58). The vent subassembly may be formed in the substrate (i.e., tightly fitted, such as by overmolding), disposed within a chamber of a cover attached to the substrate, and / or at least partially enclosed by the cover.

[0052] The massage subassemblies (e.g., massage subassembly 46), fluid actuator subassemblies (e.g., fluid actuator subassemblies 50, 58), and ventilation subassemblies (e.g., ventilation subassembly 60) are pre-assembled to a substrate (e.g., substrate 42) before being installed in a seat bottom (e.g., seat bottom 44) or seat back (e.g., seat back 40). The massage subassemblies, fluid actuator subassemblies, and ventilation subassemblies may be fastened together by welding, fasteners, rivets, tag pins, barbed fasteners, or ribbed shank rivets, where the fasteners may attach the massage subassemblies and / or fluid actuator subassemblies to the substrate or may attach the assemblies to the frame of the seat bottom or seat back, where the fasteners attach to one or more of the massage subassemblies, fluid actuator subassemblies, and ventilation subassemblies, where the fasteners allow movement of one or more of the substrate, massage subassemblies, fluid actuator subassemblies, and ventilation subassemblies relative to the fasteners. Here, one or more of the substrate, the massage subassembly, the fluid actuator subassembly, and the vent subassembly include a plurality of alignment apertures, the plurality of alignment apertures including notches formed in their peripheries.

[0053] In some embodiments, the fluid actuator subassemblies (eg, fluid actuator subassemblies 50, 58) include a fan assembly (eg, fan subassembly 50).

[0054] In some embodiments, the massage subassembly (eg, massage subassembly 46) further includes one or more massage bladders (eg, massage bladder 48).

[0055] In some embodiments, a vent subassembly (eg, vent subassembly 60) is formed on a substrate (eg, substrate 42).

[0056] In some embodiments, one or more of the substrate (e.g., substrate 42), the massage subassembly (e.g., massage subassembly 46), the fluid actuator subassembly (e.g., fluid actuator subassemblies 50, 58), and the vent subassembly (e.g., vent subassembly 60) are fastened together by welds (e.g., fasteners 36, 62).

[0057] In some embodiments, fasteners (e.g., fasteners 36, 62) attach an assembly (e.g., vehicle seat assembly 10, trim cover subassembly 15, cushion subassembly 20, fluid actuator subassemblies 25, 30, seat module subassembly 38, seat module subassembly 76) to a frame (e.g., frame subassembly 35) of a seat bottom (e.g., seat bottom 44) or seat back (e.g., seat back 40).

[0058] In some embodiments, a cushion (e.g., cushion subassembly 20) is assembled to a substrate (e.g., substrate 42) where a plurality of recesses are formed in the cushion (e.g., cushion subassembly 20), each sized to receive a bladder (e.g., massage bladder 48) of a massage subassembly (e.g., massage subassembly 46).

[0059] In some embodiments, the fluid actuator subassemblies (eg, fluid actuator subassemblies 50, 58) include valve subassemblies (eg, fluid actuator subassembly 58).

[0060] In some embodiments, the fluid actuator subassembly (eg, fluid actuator subassembly 50, 58) further includes a pump (eg, fluid actuator subassembly 58) in fluid communication with the valve subassembly (eg, fluid actuator subassembly 58).

[0061] In some embodiments, a trim cover (eg, trim cover assembly 15) is attached to a substrate (eg, substrate 42).

[0062] In some embodiments, elastic straps (e.g., fasteners 36, 62) are attached to an inner surface of the trim cover (e.g., trim cover subassembly 15) to cooperate with one or more of the substrate (e.g., substrate 42), massage subassembly (e.g., massage subassembly 46), fluid actuator subassemblies (e.g., fluid actuator subassemblies 50, 58), and vent subassembly (e.g., vent subassembly 60) for alignment purposes. Fasteners (e.g., fasteners 36, 62) are attached to distal ends of the elastic straps to attach the assembly (e.g., vehicle seat assembly 10, trim cover subassembly 15, cushion subassembly 20, fluid actuator subassemblies 25, 30, seat module subassembly 38, seat module subassembly 76) to a seat frame (e.g., seat frame assembly 35).

[0063] In some embodiments, a cushion (e.g., cushion subassembly 20) is provided, where the elastic strap is a pull-through line that extends through an aperture in the cushion (e.g., cushion subassembly 20) to align the cushion (e.g., cushion subassembly 20) with an assembly (e.g., vehicle seat assembly 10, trim cover subassembly 15, cushion subassembly 20, fluid actuator subassemblies 25, 30, seat module subassembly 38, seat module subassembly 76). For example, tensioning the pull-through line aligns the seat component or subassembly with the seat cushion material. In a further example, the pull-through line includes a toggle closure for fastening the subassembly.

[0064] In some embodiments, a cover (e.g., trim cover subassembly 15) is attached to a substrate (e.g., substrate 42) so as to provide a chamber between the cover (e.g., trim cover subassembly 15) and the substrate (e.g., substrate 42) that at least partially encloses a massage subassembly (e.g., massage subassembly 46), a fluid actuator subassembly (e.g., fluid actuator subassemblies 50, 58), or a vent subassembly (e.g., vent subassembly 60).

[0065] In some embodiments, a lumbar subassembly (eg, massage subassembly 46) is disposed within the chamber.

[0066] In some embodiments, a massage subassembly (eg, massage subassembly 46) is disposed within the chamber.

[0067] In some embodiments, a vent subassembly (eg, vent subassembly 60) is disposed within the chamber.

[0068] In some embodiments, a heat transfer subassembly (eg, heat transfer subassembly 68) is disposed within the chamber.

[0069] In some embodiments, a sensor (eg, sensor 70) is disposed within the chamber.

[0070] In some embodiments, a wire (eg, wire 72) is disposed within the chamber.

[0071] In some embodiments, the cover (eg, trim cover subassembly 15) and the substrate (eg, substrate 42) are integrally formed.

[0072] In some embodiments, the cover (eg, trim cover subassembly 15) and the substrate (eg, substrate 42) comprise a thermoplastic polyurethane.

[0073] In some embodiments, a massaging subassembly (eg, massaging subassembly 46) is disposed between the cover (eg, cover subassembly 15) and the substrate (eg, substrate 42).

[0074] In some embodiments, the massaging subassembly (eg, massaging subassembly 46) is disposed external to the cover (eg, cover subassembly 15) and the substrate (eg, substrate 42).

[0075] In some embodiments, a foldable sidewall (eg, sidewall 74) interconnects the cover (eg, cover subassembly 15) and the substrate (eg, substrate 42).

[0076] In some embodiments, the sidewalls (eg, sidewall 74) include corrugated bellows.

[0077] In some embodiments, a cushion (eg, cushion subassembly 20) is disposed within the chamber.

[0078] In some embodiments, the cushion (eg, cushion subassembly 20) includes a fluid-permeable spacer fabric.

[0079] In some embodiments, the substrate (e.g., substrate 42) includes a fluid-impermeable layer, which may be a thermoplastic polyurethane. The cover (e.g., trim cover subassembly 15) includes a fluid-impermeable layer, which may be a thermoplastic polyurethane. The cover (e.g., trim cover subassembly 15) is attached to the substrate (e.g., substrate 42) along the periphery of the substrate (e.g., substrate 42) for a fluid-tight chamber between the cover (e.g., cover subassembly 15) and the substrate (e.g., substrate 42).

[0080] In some embodiments, the cover (eg, cover subassembly 15) is sewn to the substrate (eg, substrate 42).

[0081] In some embodiments, fasteners (eg, fasteners 36, 62) interconnect the cover (eg, trim cover subassembly 15) and the substrate (eg, substrate 42).

[0082] In some embodiments, the fasteners (eg, fasteners 36, 62) include rivets (eg, rivet 62), which may be tag pins, barbed fasteners, or ribbed shank rivets.

[0083] In some embodiments, fasteners (eg, fasteners 36, 62) are attached to a substrate (eg, substrate 42).

[0084] In some embodiments, fasteners (eg, fasteners 36, 62) attach the massage subassembly and / or the fluid actuator subassembly to the substrate.

[0085] In some embodiments, the fasteners (e.g., fasteners 36, 62) are mounted to one or more of the massage subassembly (e.g., massage subassembly 48), the fluid actuator subassembly (e.g., fluid actuator subassemblies 50, 58), and the ventilation subassembly (e.g., ventilation subassembly 60).

[0086] In some embodiments, the fasteners (e.g., fasteners 36, 62) allow movement of one or more of the substrate (e.g., substrate 42), the massage subassembly (e.g., massage subassembly 46), the fluid actuator subassembly (e.g., fluid actuator subassembly 50, 58), and the vent subassembly (e.g., vent subassembly 60) relative to the fastener (e.g., fasteners 36, 62).

[0087] In some embodiments, one or more of the substrate (e.g., substrate 42), the massage subassembly (e.g., massage subassembly 46), the fluid actuator subassembly (e.g., fluid actuator subassemblies 50, 58), and the ventilation subassembly (e.g., ventilation subassembly 60) include a plurality of alignment apertures (e.g., aperture 64).

[0088] In some embodiments, the plurality of alignment apertures (eg, aperture 64) include notches formed in their peripheries.

[0089] FIG. 8 illustrates a vehicle seat assembly 110 according to some embodiments. The vehicle seat assembly 110 includes a seat bottom 112 adapted to be mounted to a vehicle floor. The vehicle seat assembly 110 may be installed in any row of a vehicle. The vehicle seat assembly 110 includes a seat back 114 extending upright from the seat bottom 112. The vehicle seat assembly 110 also includes a headrest 116 extending above the seat back 114. The vehicle seat assembly 110 may be employed in any type of vehicle, including land vehicles, watercraft, aircraft, etc. The vehicle seat assembly 110 may be any seat assembly, such as an office chair, furniture, etc.

[0090] The vehicle seat assembly 110 is provided with a trim cover 118 that covers the seat bottom 112, seat back 114, and headrest 116 to hide the frame, cushion, and functional components. The seat bottom 112 is provided with a seat cushion material 120. The seat cushion material 120 may be made of twisted mesh as described above, or may be made of foam. The vehicle seat assembly 110 is also provided with a controller and pump 144. The controller and pump 144 may be provided in a module below the seat cushion 120, and may be a multi-function controller that also controls other functions in the vehicle.

[0091] FIG. 9 illustrates a seat subassembly 122 according to some embodiments. The seat subassembly 122 includes a first fluid-impermeable layer 124 and a second fluid-impermeable layer 128 sized to be placed over the seat cushion material 120. The first fluid-impermeable layer 124 may be constructed of a cushioning material such as foam. The second fluid-impermeable layer 128 may be formed from an impermeable polymer material such as thermoplastic polyurethane (TPU) film, polyvinyl chloride (PVC) film, polyethylene, or the like. The first fluid-impermeable layer 124, according to some embodiments, includes a plurality of vents 126 formed therethrough. Although multiple vents 126 are shown and described, any number of vents 126 may be utilized. The vents 126 direct airflow through the seat subassembly 122. According to some embodiments, the first fluid-impermeable layer 124 and the vents 126 may be optional if the trim cover 118 has a plurality of holes formed therethrough. Additionally, the first fluid impermeable layer 124 may be insulating. The first fluid impermeable layer 124 and the second fluid impermeable layer 128 may be joined together by a seam that is sewn, glued, welded, etc. around the peripheral edges of the layers 124, 128.

[0092] The second fluid impermeable layer 128 is provided to cooperate with the first fluid impermeable layer 124 to provide a fluid chamber 130 therebetween. The seat subassembly 122 is further provided with an inflatable bladder assembly 132. The inflatable bladder assembly 132, according to some embodiments, is supported by the first fluid impermeable layer 124 and disposed within the fluid chamber 130. According to some embodiments, the inflatable bladder assembly 132 may be displaced outside the fluid chamber 130, such as between the second fluid impermeable layer 128 and the seat cushion 120.

[0093] The controller 144 is in electrical communication with the pump 144, which is in fluid communication with the inflatable bladder assembly 132 to inflate the assembly 132. The controller 144 is programmed to receive input indicative of a manual adjustment and to adjust the inflatable bladder assembly 132 to apply pressure to the occupant. Similarly, the controller 144 may also be programmed to receive input indicative of a massage program to operate the inflatable bladder assembly 132 to apply a pressurized massage effect to the occupant.

[0094] The seat subassembly 122 further includes a fluid-permeable layer 134. The fluid-permeable layer 134 is formed from a resilient, porous material, such as a porous foam or the extruded thermoplastic mesh described above. The fluid-permeable layer 134 is sized to be received within the fluid chamber 130 of the inflatable bladder assembly 132. The fluid-permeable layer 134 and the inflatable bladder assembly 132 are disposed between the first fluid-impermeable layer 124 and the second fluid-impermeable layer 128. Although multiple inflatable air bladder assemblies 132 are shown, any number of air bladder assemblies 132 may be used.

[0095] The fluid-permeable layer 134 ensures that the first and second fluid-impermeable layers 124, 128 are not compressed together by the weight of an occupant. Without the permeable layers 934, 936, the impermeable layers 924, 928 would compress when subjected to weight from an occupant, which could block airflow when using the fan 140. If the seat subassembly 122 utilizes a compressor as opposed to a fan 140, the permeable layer 134 may be omitted.

[0096] The seat subassembly 122 also includes a heat transfer layer 138 that is displaced along the first fluid-impermeable layer 124 and spaced apart from the second fluid-impermeable layer 128. In some embodiments, the heat transfer layer 138 may be positioned along the trim layer 118, or alternatively, may be positioned between the second fluid-permeable layer 128 and the fan 140. In some embodiments, the heat transfer layer 138 may be positioned between the first fluid-impermeable layer 124 and the first fluid-permeable layer 134. The heat transfer layer 138 includes a conductive heater mat.

[0097] According to some embodiments, the seat subassembly 122 may be provided as a pre-assembled module that is subsequently assembled to the seat cushion material 120 and / or the seat trim cover 118. According to some embodiments, the seat subassembly 122 further includes an outer trim layer 118 disposed on the first fluid impermeable layer 124 and the second fluid impermeable layer 128. The trim layer 118 is perforated to allow fluid to pass through the outer trim layer 118. According to some embodiments, the trim layer 118 is adhered to the first fluid impermeable layer 124.

[0098] Continuing with reference to FIG. 9 , the seat subassembly 122 is provided with a fluid actuator 140, such as a fan 140. The fluid actuator 140 is welded directly to the second fluid-impermeable layer 128 to seal the connection around the fan 140. The fan 140 is connected to the second fluid-impermeable layer 128 by a retaining ring, according to some embodiments. The fan 140 is located between the trim cover 118 and the seat cushion 120. The seat cushion material 120 includes a receptacle cavity sized to receive the fan 140. For example, the fan 140 has a fan outline, and the cavity has a similar cavity geometry to the fan outline to provide a snug fit for the fan 140. Conventional fans are located under the vehicle seat cushion and outside the trim cover assembly. The fan 140 can be located within the seat subassembly 122 by installing the fan 140 above the seat cushion material 120.

[0099] Prior art seat assemblies with heating and cooling capabilities often place the fan and massage bladder under the cushion. Fluid ducts are then assembled through the cushion and trim cover of the conventional seat assembly. The fluid impermeable layers 124, 128, the permeable layer 134, the heat transfer layer 138, the air bladder assembly 132, and the fluid actuator 140 are all pre-assembled within the seat subassembly 122 so that the seat subassembly 122 is installed as a whole in the seat frame. This pre-assembly facilitates reduced manufacturing costs and time compared to the prior art.

[0100] The seat subassembly 122 is operable with a permeable, non-foam seat cushion material 120 formed from a twisted mesh, as described above. The second fluid-impermeable layer 128 provides a barrier between the fluid chamber 130 and the seat cushion 120. When utilized with a foam cushion 120, the second fluid-impermeable layer 128 may be omitted if the cushion 120 is air-impermeable. In this case, the fluid actuator 140 may be welded directly to the first fluid-impermeable layer 124 to transport fluid through the vent 126 in the fluid-impermeable layer 124. Alternatively, the fluid actuator 140 may be separate from the trim cover.

[0101] 10 shows a first fluid impermeable layer 124 and a second fluid impermeable layer 128 having a seam 142 along the perimeter. The seam 142 seals the layers 124, 128 together, preventing air from escaping from the fluid chamber 130. Alternatively, the layers 124, 128 may be attached together with an adhesive or welded.

[0102] FIG. 11 illustrates the second fluid-impermeable layer 128 according to some embodiments. The second fluid-impermeable layer 128 includes a first portion 146 and a second portion 148. The first portion 146 further includes a first flap 166. In some embodiments, the first flap 166 is perforated to allow airflow between zones or seams within the subassembly 122. In some embodiments, the first flap 166 may be segmented to allow airflow between zones and / or within the fluid chamber 130. The second portion 148 further includes a second flap 168 extending in the opposite direction from the first flap 166. The flaps 166, 168 may be used to attach the subassembly 122 to other seat components or subassemblies. For example, in some embodiments, the second flap 168 may be connected to the seat cushion material 120. The first and second portions 146, 148 may be sewn, welded, glued, or otherwise fastened together. The first and second portions 146, 148 may be ultrasonically or high frequency friction welded together.

[0103] 12 illustrates the second fluid-impermeable layer 128 as a continuous sheet according to some embodiments. The second fluid-impermeable layer 128 is provided with a first flap 160 and a second flap 162. The first flap 160 may be perforated to allow air to pass therethrough within the fluid chamber 130. The second flap 162 may extend in the opposite direction from the first flap 160 and be attached to the seat cushion material 120. The first and second flaps 160, 162 may be sewn, welded, glued, or otherwise fastened to the second fluid-impermeable layer 128. The first and second flaps 160, 162 may be ultrasonically or high-frequency friction welded to the second fluid-impermeable layer 128.

[0104] 13 illustrates a method 170 according to some embodiments. Method 170 may be provided and used to install at least one inflatable bladder assembly 132 and to install first fluid impermeable layer 124. Method 170 may have more or fewer steps than those described below, and the various steps may be performed in a different order, sequentially, or simultaneously.

[0105] The method 170 includes placing (172) at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132) supported by a first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) to apply pressure to an occupant, and placing (174) the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) over seat cushion material.

[0106] The vehicle seat assembly may include a seat bottom adapted to be mounted to the vehicle floor. The vehicle seat assembly may be installed in any row of the vehicle. The vehicle seat assembly may include a seat back extending upright from the seat bottom. The vehicle seat assembly may also include a headrest extending above the seat back. The vehicle seat assembly may be employed in any type of vehicle, including land vehicles, watercraft, aircraft, etc. The vehicle seat assembly may be any seat assembly, such as an office chair, furniture, etc. The vehicle seat assembly may be provided with trim covers that cover the seat bottom, seat back, and headrest, respectively, to hide the frame, cushion, and functional components.

[0107] The seat bottom may be provided with a seat cushioning material. The seat cushioning material may be constructed from the twisted thermoplastic mesh described above or may be constructed from foam. The vehicle seat assembly may also be provided with a controller and a pump. The controller and pump may be provided in a module below the seat cushioning material and may be a multi-function controller that also controls other functions in the vehicle.

[0108] The seat subassembly may include a second fluid-impermeable layer sized to be placed over the seat cushioning. The first fluid-impermeable layer may be comprised of a cushioning material such as foam. The second fluid-impermeable layer may be formed from an impermeable polymeric material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, or polyethylene. The first fluid-impermeable layer may include a plurality of vents formed therethrough. Any number of vents may be utilized. The multiple vents may direct airflow through the seat subassembly. The first fluid-impermeable layer and vents may be optional if the trim cover has multiple holes therethrough. The first fluid-impermeable layer may be insulating. The first and second fluid-impermeable layers may be joined together by a sewn, glued, welded, or other seam around the peripheral edges of the layers.

[0109] The inflatable bladder assembly may be supported by the first fluid-impermeable layer and positioned within the fluid chamber. The inflatable bladder assembly may be positioned outside the fluid chamber, such as between the second fluid-impermeable layer and the seat cushion material.

[0110] The controller may be in electrical communication with the pump, which may be in fluid communication with the inflatable bladder assembly to inflate the assembly. The controller may be programmed to receive input indicative of a manual adjustment to adjust the inflatable bladder assembly to apply pressure to the occupant. The controller may be programmed to receive input indicative of a massage program to operate the inflatable bladder assembly to apply a pressurized massage effect to the occupant.

[0111] The seat subassembly may further include a fluid-permeable layer. The fluid-permeable layer may be formed from a resilient porous material, such as a porous foam or an extruded thermoplastic mesh. The fluid-permeable layer may be sized to be received within a fluid chamber disposed in an inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly may be disposed between a first fluid-impermeable layer and a second fluid-impermeable layer. Any number of air bladders may be used.

[0112] The fluid-permeable layer may ensure that the first and second fluid-impermeable layers are not compressed together by the weight of an occupant. Without the permeable layer, the weight from the occupant could compress the impermeable layers and block airflow when the fan is in use. If the seat subassembly utilizes a compressor as opposed to a fan, the permeable layer may be omitted.

[0113] The seat subassembly may also include a heat transfer layer disposed along the first fluid-impermeable layer. The heat transfer layer is spaced apart from the second fluid-impermeable layer. The heat transfer layer may be disposed along the trim layer, or alternatively, may be disposed between the second fluid-impermeable layer and the fan. The heat transfer layer may be disposed between the first fluid-impermeable layer and the first fluid-permeable layer. The heat transfer layer may include a conductive heater mat.

[0114] The seat subassembly may be provided as a pre-assembled module that is stacked together and subsequently secured to the seat cushion material and / or the seat trim cover. For example, "secured" means secured so as not to open or separate. The seat subassembly may further include an outer trim layer disposed over the first and second fluid-impermeable layers. The trim layer may be perforated to allow fluid to pass through the outer trim layer. The trim layer may be bonded to the first fluid-impermeable layer. The fluid actuator may be welded directly to the second fluid-impermeable layer to seal the connection around the fan. The fan may be connected to the second fluid-impermeable layer by a retaining ring. The fan may be located between the trim cover and the seat cushion material. The seat cushion material may include a receptacle sized to receive the fan. Positioning the fan above the seat cushion material may allow the fan to be positioned within the seat subassembly.

[0115] The fluid impermeable layer, permeable layer, heat transfer layer, air bladder assembly, and fluid actuator may all be pre-assembled within the seat subassembly, with the seat subassembly attached to the seat frame as a whole. The seat subassembly may be operable with an air-permeable, non-foam seat cushion material formed from a thermoplastic mesh. The second fluid impermeable layer may provide a barrier between the fluid chamber and the seat cushion material. When used with a foam cushion, the second fluid impermeable layer may be omitted if the cushion is air impermeable. In this case, the fluid actuator may be welded directly to the first fluid impermeable layer 924 to transport fluid through vents in the fluid impermeable layer. The fluid actuator may be separate from the trim cover.

[0116] The first and second fluid-impermeable layers may be seamed along their peripheries. The seams may seal the layers to prevent air from escaping from the fluid chamber. The layers may be attached with an adhesive or welded together, as opposed to using seams.

[0117] The second fluid-impermeable layer may have a first portion and a second portion. The first portion may further include a first flap. The first flap may be perforated to allow airflow between zones or seams within the subassembly. The first flap may be segmented to allow airflow between zones and / or within fluid chambers. The second portion may further include a second flap extending in an opposite direction from the first flap. These flaps may be used to attach the subassembly to other seat components or subassemblies. The second flap may be connected to the seat cushion material. The first and second portions may be sewn, welded, glued, or otherwise fastened together. The first and second portions may be ultrasonically or high-frequency friction welded together.

[0118] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may have a first flap and a second flap. The first flap may be perforated to allow air to pass through the first flap within the fluid chamber. The second flap may extend in the opposite direction from the first flap and may be attached to the seat cushion material. The first and second flaps may be sewn, welded, glued, or otherwise fastened to the second fluid-impermeable layer. The first and second flaps may be ultrasonically or high-frequency friction welded to the second fluid-impermeable layer.

[0119] In some embodiments, the method 170 includes attaching, such as by welding, a second portion (e.g., the second portion 148, the first flap 160, the second flap 162) as a retainer (e.g., the first flap 160, the second flap 162, the first flap 166, the second flap 168) to the first fluid-impermeable layer (e.g., the first fluid-impermeable layer 124, the second fluid-impermeable layer 128, the first portion 146). The second fluid-impermeable layer may be provided with a first portion and a second portion. The first portion may further be provided with a first flap. The first flap may be perforated to allow air flow between zones or seams within the subassembly. The first flap may be segmented to allow air flow between zones and / or within the fluid chamber. The second portion may further be provided with a second flap extending in an opposite direction from the first flap. These flaps may be used to attach the subassembly to other seat components or subassemblies. The second flap may be connected to the seat cushion material. The first and second portions may be sewn, welded, glued, or otherwise fastened together. The first and second portions may be ultrasonically or high frequency friction welded together.

[0120] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may have a first flap and a second flap. The first flap may be perforated to allow air to pass through the first flap within the fluid chamber. The second flap may extend in the opposite direction from the first flap and may be attached to the seat cushion material. The first and second flaps may be sewn, welded, glued, or otherwise fastened to the second fluid-impermeable layer. The first and second flaps may be ultrasonically or high-frequency friction welded to the second fluid-impermeable layer.

[0121] In some embodiments, the method 170 includes welding a second portion (e.g., second portion 148, first flap 160, second flap 162) to a first fluid-impermeable layer (e.g., first fluid-impermeable layer 124). The first portion may further include a first flap. The first flap may be perforated to allow airflow between zones or seams within the subassembly. The first flap may be segmented to allow airflow between zones and / or within fluid chambers. The second portion may further include a second flap extending in an opposite direction from the first flap. These flaps may be used to attach the subassembly to other seat components or subassemblies. The second flap may be connected to seat cushion material. The first and second portions may be sewn, welded, glued, or otherwise fastened together. The first and second portions may be ultrasonically or high-frequency friction welded together.

[0122] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may have a first flap and a second flap. The first flap may be perforated to allow air to pass through the first flap within the fluid chamber. The second flap may extend in the opposite direction from the first flap and may be attached to the seat cushion material. The first and second flaps may be sewn, welded, glued, or otherwise fastened to the second fluid-impermeable layer. The first and second flaps may be ultrasonically or high-frequency friction welded to the second fluid-impermeable layer.

[0123] In some embodiments, the method 170 includes attaching other seat components (e.g., the trim layer 118, the heat transfer layer 138, the fan 140) to the second portion (e.g., the second portion 148, the first flap 160, the second flap 162). The seat subassembly may also include a heat transfer layer disposed along the first fluid-impermeable layer. The heat transfer layer is spaced apart from the second fluid-impermeable layer. The heat transfer layer may be disposed along the trim layer, or alternatively, may be disposed between the second fluid-impermeable layer and the fan. The heat transfer layer may be disposed between the first fluid-impermeable layer and the first fluid-permeable layer. The heat transfer layer may include a conductive heater mat.

[0124] The seat subassembly may be provided as a pre-assembled module that is subsequently assembled to a seat cushion and / or a seat trim cover. The seat subassembly may further include an outer trim layer disposed on the first and second fluid-impermeable layers. The trim layer may be perforated to allow fluid to pass through the outer trim layer. The trim layer may be adhered to the first fluid-impermeable layer. The fluid actuator may be welded directly to the second fluid-impermeable layer to seal the connection around the fan. The fan may be connected to the second fluid-impermeable layer by a retaining ring. The fan may be located between the trim cover and the seat cushion. The seat cushion may include a receptacle sized to receive the fan. The fan may be located above the seat cushion, allowing the fan to displace within the seat subassembly.

[0125] The fluid impermeable layer, permeable layer, heat transfer layer, air bladder assembly, and fluid actuator may all be pre-assembled within the seat subassembly, with the seat subassembly attached to the seat frame as a whole. The seat subassembly may be operable with an air-permeable, non-foam seat cushion material formed from a thermoplastic mesh. The second fluid impermeable layer may provide a barrier between the fluid chamber and the seat cushion material. When used with a foam cushion, the second fluid impermeable layer may be omitted if the cushion is air impermeable. In this case, the fluid actuator may be welded directly to the first fluid impermeable layer 924 to transport fluid through vents in the fluid impermeable layer. The fluid actuator may be separate from the trim cover.

[0126] The first and second fluid-impermeable layers may be seamed along their peripheries. The seams may seal the layers to prevent air from escaping from the fluid chamber. The layers may be attached with an adhesive or welded together, as opposed to using seams.

[0127] The second fluid-impermeable layer may have a first portion and a second portion. The first portion may further include a first flap. The first flap may be perforated to allow airflow between zones or seams within the subassembly. The first flap may be segmented to allow airflow between zones and / or within fluid chambers. The second portion may further include a second flap extending in an opposite direction from the first flap. These flaps may be used to attach the subassembly to other seat components or subassemblies. The second flap may be connected to the seat cushion material. The first and second portions may be sewn, welded, glued, or otherwise fastened together. The first and second portions may be ultrasonically or high-frequency friction welded together.

[0128] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may have a first flap and a second flap. The first flap may be perforated to allow air to pass through the first flap within the fluid chamber. The second flap may extend in the opposite direction from the first flap and may be attached to the seat cushion material. The first and second flaps may be sewn, welded, glued, or otherwise fastened to the second fluid-impermeable layer. The first and second flaps may be ultrasonically or high-frequency friction welded to the second fluid-impermeable layer.

[0129] An assembly (e.g., a vehicle seat assembly 110, a seat subassembly 122) that may be a seat assembly or a subassembly thereof is described. The assembly (e.g., the vehicle seat assembly 110, the seat subassembly 122) includes a first fluid-impermeable layer (e.g., a first fluid-impermeable layer 124) sized to be placed over a seat cushion material and at least one inflatable bladder assembly (e.g., an inflatable bladder assembly 132) supported by the first fluid-impermeable layer (e.g., the first fluid-impermeable layer 124) to apply pressure to an occupant. The vehicle seat assembly may include a seat bottom adapted to be mounted to a vehicle floor. The vehicle seat assembly may be installed in any row of the vehicle. The vehicle seat assembly may include a seat back extending upright from the seat bottom. The vehicle seat assembly may also include a headrest extending above the seat back. The vehicle seat assembly may be employed in any type of vehicle, including land vehicles, watercraft, aircraft, etc. The vehicle seat assembly may be any seat assembly such as an office chair, furniture, etc.

[0130] The vehicle seat assembly may include trim covers that cover the seat bottom, seat back, and headrest, respectively, to hide the frame, cushion, and functional components. The seat bottom may include a seat cushion material. The seat cushion material may be made of the twisted thermoplastic mesh described above or may be made of foam. The vehicle seat assembly may also include a controller and a pump. The controller and pump may be provided in a module below the seat cushion material and may be a multi-function controller that also controls other functions in the vehicle.

[0131] The seat subassembly may include a second fluid-impermeable layer sized to be placed over the seat cushion material. The first fluid-impermeable layer may be comprised of a cushion material such as foam. The second fluid-impermeable layer may be formed from an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, or polyethylene. The first fluid-impermeable layer may include a plurality of vents formed therethrough. Any number of vents may be utilized. The multiple vents may direct airflow through the seat subassembly. The first fluid-impermeable layer and the vents may be optional if the trim cover has multiple holes therethrough. The first fluid-impermeable layer may be insulating.

[0132] The first and second fluid-impermeable layers may be joined together by a sewn, glued, welded, etc. seam around the peripheral edges of the layers. The second fluid-impermeable layer may be provided to cooperate with the first fluid-impermeable layer to provide a fluid chamber therebetween. An inflatable bladder assembly may be supported by the first fluid-impermeable layer and positioned within the fluid chamber. The inflatable bladder assembly may be positioned outside the fluid chamber, such as between the second fluid-impermeable layer and the seat cushion material.

[0133] The controller may be in electrical communication with the pump, which may be in fluid communication with the inflatable bladder assembly to inflate the assembly. The controller may be programmed to receive input indicative of a manual adjustment to adjust the inflatable bladder assembly to apply pressure to the occupant. The controller may be programmed to receive input indicative of a massage program to operate the inflatable bladder assembly to apply a pressurized massage effect to the occupant.

[0134] The seat subassembly may further include a fluid-permeable layer. The fluid-permeable layer may be formed from a resilient porous material, such as a porous foam or an extruded thermoplastic mesh. The fluid-permeable layer may be sized to be received within a fluid chamber disposed in the inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly may be disposed between a first fluid-impermeable layer and a second fluid-impermeable layer. Any number of air bladders may be used. The fluid-permeable layer may ensure that the first and second fluid-impermeable layers are not compressed together by the weight of an occupant. Without the permeable layer, the weight from the occupant could compress the impermeable layer, blocking airflow when the fan is in use. If the seat subassembly utilizes a compressor as opposed to a fan, the permeable layer may be omitted.

[0135] The seat subassembly may also include a heat transfer layer disposed along the first fluid-impermeable layer. The heat transfer layer is spaced apart from the second fluid-impermeable layer. The heat transfer layer may be disposed along the trim layer, or alternatively, may be disposed between the second fluid-impermeable layer and the fan. The heat transfer layer may be disposed between the first fluid-impermeable layer and the first fluid-permeable layer. The heat transfer layer may include a conductive heater mat.

[0136] The seat subassembly may be provided as a pre-assembled module that is subsequently assembled to a seat cushion material and / or a seat trim cover. The seat subassembly may further include an outer trim layer disposed on the first and second fluid-impermeable layers. The trim layer may be perforated to allow fluid to pass through the outer trim layer. The trim layer may be adhered to the first fluid-impermeable layer.

[0137] The seat subassembly may be provided with a fluid actuator, such as a fan. The fluid actuator may be welded directly to the second fluid-impermeable layer to seal the connection around the fan. The fan may be connected to the second fluid-impermeable layer by a retaining ring. The fan may be located between the trim cover and the seat cushion material. The seat cushion material may include a receptacle sized to receive the fan. Locating the fan above the seat cushion material may allow the fan to displace within the seat subassembly.

[0138] The fluid impermeable layer, permeable layer, heat transfer layer, air bladder assembly, and fluid actuator may all be pre-assembled within the seat subassembly, with the seat subassembly attached to the seat frame as a whole. The seat subassembly may be operable with an air-permeable, non-foam seat cushion material formed from a thermoplastic mesh. The second fluid impermeable layer may provide a barrier between the fluid chamber and the seat cushion material. When used with a foam cushion, the second fluid impermeable layer may be omitted if the cushion is air impermeable. In this case, the fluid actuator may be welded directly to the first fluid impermeable layer 924 to transport fluid through vents in the fluid impermeable layer. The fluid actuator may be separate from the trim cover.

[0139] The first and second fluid-impermeable layers may be seamed along their peripheries. The seams may seal the layers to prevent air from escaping from the fluid chamber. The layers may be attached with an adhesive or welded together, as opposed to using seams.

[0140] The second fluid-impermeable layer may have a first portion and a second portion. The first portion may further include a first flap. The first flap may be perforated to allow airflow between zones or seams within the subassembly. The first flap may be segmented to allow airflow between zones and / or within fluid chambers. The second portion may further include a second flap extending in an opposite direction from the first flap. These flaps may be used to attach the subassembly to other seat components or subassemblies. The second flap may be connected to the seat cushion material. The first and second portions may be sewn, welded, glued, or otherwise fastened together. The first and second portions may be ultrasonically or high-frequency friction welded together.

[0141] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may have a first flap and a second flap. The first flap may be perforated to allow air to pass through the first flap within the fluid chamber. The second flap may extend in the opposite direction from the first flap and may be attached to the seat cushion material. The first and second flaps may be sewn, welded, glued, or otherwise fastened to the second fluid-impermeable layer. The first and second flaps may be ultrasonically or high-frequency friction welded to the second fluid-impermeable layer.

[0142] In some embodiments, at least one vent (e.g., vent 126) is formed through the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146). Any number of vents may be utilized. Multiple vents may direct airflow through the seat subassembly. The first fluid-impermeable layer and vent may be optional if the trim cover has multiple holes therethrough.

[0143] In some embodiments, a second fluid-impermeable layer (e.g., second fluid-impermeable layer 128) is provided to cooperate with a first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) to provide a fluid chamber (e.g., fluid chamber 130) therebetween. The second fluid-impermeable layer may be sized to be placed over the seat cushion material. The second fluid-impermeable layer may be formed from an impermeable polymeric material, such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, or polyethylene. The first and second fluid-impermeable layers may be joined together by a sewn, glued, welded, or other seam around the peripheral edges of the layers. The fluid-impermeable layer, the permeable layer, the heat transfer layer, the air bladder assembly, and the fluid actuator may all be pre-assembled within the seat subassembly, with the seat subassembly as a whole being attached to the seat frame. The seat subassembly may be operable with an air-permeable, non-foam seat cushion formed from a twisted thermoplastic mesh, as described above. The second fluid-impermeable layer may provide a barrier between the fluid chamber and the seat cushion material. When used with a foam cushion, the second fluid-impermeable layer may be omitted if the cushion is air-impermeable. In this case, the fluid actuator may be welded directly to the first fluid-impermeable layer 924 to transport fluid through vents in the fluid-impermeable layer. The fluid actuator may be separate from the trim cover. The first and second fluid-impermeable layers may be stitched along their peripheries. The stitching may seal the layers to prevent air from escaping the fluid chamber. The layers may be attached with adhesive or welded together, as opposed to using stitching.

[0144] In some embodiments, the second fluid actuator (e.g., fan 140) is attached directly to the second fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146). The fluid-permeable layer may ensure that the first and second fluid-impermeable layers are not compressed together by the weight of an occupant. Without the permeable layer, the weight from the occupant could compress the impermeable layer and block airflow when the fan is in use. If the seat subassembly utilizes a compressor as opposed to a fan, the permeable layer may be omitted. The fluid actuator may be welded directly to the second fluid-impermeable layer to seal the connections around the fan. The fan may be connected to the second fluid-impermeable layer by a retaining ring. The fan may be installed between the trim cover and the seat cushion material. The seat cushion material may include a receptacle sized to receive the fan. The fan may be located above the seat cushion material, allowing the fan to displace within the seat subassembly. The seat subassembly may be operable with an air-permeable, non-foam seat cushion material formed from a twisted thermoplastic mesh. The second fluid-impermeable layer may provide a barrier between the fluid chamber and the seat cushion material. When utilized with a foam cushion, the second fluid-impermeable layer may be omitted if the cushion is air-impermeable. In this case, the fluid actuator may be welded directly to the first fluid-impermeable layer 924 to transport fluid through vents in the fluid-impermeable layer. The fluid actuator may be separate from the trim cover.

[0145] In some embodiments, the second fluid actuator (e.g., fan 140) is welded to the second fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146). The fluid-permeable layer may ensure that the first and second fluid-impermeable layers are not compressed together by the weight of an occupant. Without the permeable layer, the weight from the occupant could compress the impermeable layer and block airflow when the fan is in use. If the seat subassembly utilizes a compressor as opposed to a fan, the permeable layer may be omitted. The fan may be connected to the second fluid-impermeable layer by a retaining ring. The fan may be located between the trim cover and the seat cushion material. The seat cushion material may include a receptacle sized to receive the fan. Locating the fan above the seat cushion material may allow the fan to displace within the seat subassembly. The seat subassembly may be operable with an air-permeable, non-foam seat cushion material formed from a twisted thermoplastic mesh. The second fluid-impermeable layer may provide a barrier between the fluid chamber and the seat cushion material. When utilized with a foam cushion, the second fluid-impermeable layer may be omitted if the cushion is air-impermeable. In this case, the fluid actuator may be welded directly to the first fluid-impermeable layer 924 to transport fluid through vents in the fluid-impermeable layer. The fluid actuator may be separate from the trim cover.

[0146] In some embodiments, the second fluid actuator further includes a fan (e.g., fan 140). The fluid-permeable layer may ensure that the first and second fluid-impermeable layers are not compressed together by the weight of an occupant. Without the permeable layer, the weight from the occupant could compress the impermeable layer and block airflow when the fan is in use. If the seat subassembly utilizes a compressor rather than a fan, the permeable layer may be omitted. The fluid actuator may be welded directly to the second fluid-impermeable layer to seal the connection around the fan. The fan may be connected to the second fluid-impermeable layer by a retaining ring. The fan may be located between the trim cover and the seat cushion material. The seat cushion material may include a receptacle sized to receive the fan. The fan may be located above the seat cushion material to allow the fan to displace within the seat subassembly. The seat subassembly may be operable with an air-permeable, non-foam seat cushion material formed from a twisted thermoplastic mesh. The second fluid-impermeable layer can provide a barrier between the fluid chamber and the seat cushion material. When used with a foam cushion, the second fluid-impermeable layer can be omitted if the cushion is air-impermeable. In this case, the fluid actuator can be welded directly to the first fluid-impermeable layer 924 to transport fluid through vents in the fluid-impermeable layer. The fluid actuator can be separate from the trim cover.

[0147] In some embodiments, at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132) is disposed within the fluid chamber (e.g., fluid chamber 130). The inflatable bladder assembly may be supported by a first fluid-impermeable layer and disposed within the fluid chamber. The inflatable bladder assembly may be disposed outside the fluid chamber, such as between the second fluid-impermeable layer and the seat cushion material. The fluid-permeable layer may be formed from a resilient porous material, such as a porous foam or an extruded thermoplastic mesh. The fluid-permeable layer may be sized to be received within the fluid chamber disposed within the inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly may be disposed between the first fluid-impermeable layer and the second fluid-impermeable layer. Any number of air bladders may be used. The fluid-impermeable layer, the permeable layer, the heat transfer layer, the air bladder assembly, and the fluid actuator may all be pre-assembled within the seat subassembly, such that the seat subassembly as a whole is attached to the seat frame.

[0148] In some embodiments, a first fluid-permeable layer (e.g., first fluid-permeable layer 134) is sized to be received within a fluid chamber (e.g., fluid chamber 130), and the first fluid-permeable layer (e.g., first fluid-permeable layer 134) is displaced in an inflatable bladder assembly (e.g., inflatable bladder assembly 132). The inflatable bladder assembly may be supported by a first fluid-impermeable layer and disposed within the fluid chamber. The inflatable bladder assembly may be disposed outside the fluid chamber, such as between a second fluid-impermeable layer and the seat cushion material.

[0149] The fluid-permeable layer may be formed from a resilient porous material, such as a porous foam or an extruded thermoplastic mesh. The fluid-permeable layer may be sized to be received within a fluid chamber disposed in the inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly may be disposed between a first fluid-impermeable layer and a second fluid-impermeable layer. Any number of air bladders may be used. The fluid-permeable layer may ensure that the first and second fluid-impermeable layers are not compressed together by the weight of an occupant. Without the permeable layer, the weight from the occupant could compress the impermeable layer, blocking airflow when the fan is in use. If the seat subassembly utilizes a compressor as opposed to a fan, the permeable layer may be omitted.

[0150] The fluid impermeable layer, permeable layer, heat transfer layer, air bladder assembly, and fluid actuator may all be pre-assembled within the seat subassembly, with the seat subassembly as a whole being attached to the seat frame. The seat subassembly may be operable with an air-permeable, non-foam seat cushion material formed from a twisted thermoplastic mesh. The second fluid impermeable layer may provide a barrier between the fluid chamber and the seat cushion material. When used with a foam cushion, the second fluid impermeable layer may be omitted if the cushion is air impermeable. In this case, the fluid actuator may be welded directly to the first fluid impermeable layer 924 to transport fluid through vents in the fluid impermeable layer. The fluid actuator may be separate from the trim cover.

[0151] In some embodiments, a heat transfer layer (e.g., heat transfer layer 138) is disposed along a first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) spaced apart from a second fluid-impermeable layer (e.g., second fluid-impermeable layer 128). The seat subassembly may also include a heat transfer layer disposed along the first fluid-impermeable layer. The heat transfer layer is spaced apart from the second fluid-impermeable layer. The heat transfer layer may be disposed along the trim layer or, alternatively, between the second fluid-impermeable layer and the fan. The heat transfer layer may be disposed between the first fluid-impermeable layer and the first fluid-permeable layer. The heat transfer layer may include a conductive heater mat. The fluid-impermeable layer, the permeable layer, the heat transfer layer, the air bladder assembly, and the fluid actuator may all be pre-assembled within the seat subassembly, such that the seat subassembly as a whole is attached to the seat frame.

[0152] In some embodiments, the heat transfer layer (eg, heat transfer layer 138) further comprises an electrically conductive heater mat.

[0153] In some embodiments, a controller (e.g., controller and pump 144) is in electrical communication with at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132) and is programmed to receive input indicating a manual adjustment and to adjust at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132) to apply pressure to an occupant, for example, by inflating or deflating. The controller and pump may be provided in a module below the seat cushion and may be a multi-function controller that also controls other functions in the vehicle. The inflatable bladder assembly may be supported by a first fluid-impermeable layer and disposed within the fluid chamber. The inflatable bladder assembly may be disposed outside the fluid chamber, such as between a second fluid-impermeable layer and the seat cushion. The controller may be in electrical communication with the pump, and the pump may be in fluid communication with the inflatable bladder assembly to inflate the assembly. The controller may be programmed to receive an input indicating a manual adjustment and adjust the inflatable bladder assembly to apply pressure to the occupant. The controller may be programmed to receive an input indicating a massage program and operate the inflatable bladder assembly to apply a pressurized massage effect to the occupant. The fluid-permeable layer may be formed from a resilient porous material, such as a porous foam or an extruded thermoplastic mesh. The fluid-permeable layer may be sized to be received within a fluid chamber disposed in the inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly may be disposed between a first fluid-impermeable layer and a second fluid-impermeable layer. Any number of air bladders may be used.

[0154] In some embodiments, the first fluid impermeable layer (eg, first fluid impermeable layer 124, second fluid impermeable layer 128, first portion 146) is insulating.

[0155] In some embodiments, multiple vents (e.g., vent 126) are formed through the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146). Any number of vents may be utilized. Multiple vents may direct airflow through the seat subassembly. The first fluid-impermeable layer and vents may be optional if the trim cover has multiple holes therethrough.

[0156] In some embodiments, the at least one inflatable bladder assembly (e.g., inflatable bladder assembly 132) further includes a plurality of inflatable bladder assemblies (e.g., inflatable bladder assemblies 132) disposed within the fluid chamber (e.g., fluid chamber 130). The inflatable bladder assemblies may be supported by a first fluid-impermeable layer and disposed within the fluid chamber. The inflatable bladder assemblies may be disposed outside the fluid chamber, such as between a second fluid-impermeable layer and the seat cushion material.

[0157] The controller may be in electrical communication with the pump, and the pump may be in fluid communication with the inflatable bladder assembly to inflate the assembly. The controller may be programmed to receive input indicating a manual adjustment and adjust the inflatable bladder assembly to apply pressure to the occupant. The controller may be programmed to receive input indicating a massage program and operate the inflatable bladder assembly to apply a pressurized massage effect to the occupant. The fluid-permeable layer may be formed from a resilient porous material, such as a porous foam or an extruded thermoplastic mesh. The fluid-permeable layer may be sized to be received within a fluid chamber disposed in the inflatable bladder assembly. The fluid-permeable layer and the inflatable bladder assembly may be oriented between a first fluid-impermeable layer and a second fluid-impermeable layer. Any number of air bladders may be used.

[0158] In some embodiments, a seam (e.g., stitching 142) extends through the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146). The first and second fluid-impermeable layers may be stitched along their perimeters. The stitching may seal the layers to prevent air from escaping the fluid chamber. The layers may be attached with an adhesive or welded together, as opposed to utilizing stitching.

[0159] In some embodiments, the first fluid-impermeable layer (e.g., first fluid-impermeable layer 124, second fluid-impermeable layer 128, first portion 146) further includes a first portion (e.g., first portion 146, first flap 160) and a second portion (e.g., second portion 148, first flap 160, second flap 162) extending away from the first portion (e.g., first portion 146, first flap 160) to provide a retainer (e.g., first flap 160, second flap 162, first flap 166, second flap 168). The second fluid-impermeable layer may include a first portion and a second portion. The first portion may further include a first flap. The first flap may be perforated to allow air flow between zones or seams within the subassembly. The first flap may be segmented to allow airflow between zones and / or within the fluid chamber. The second portion may further include a second flap extending in an opposite direction from the first flap. These flaps may be used to attach the subassembly to other seat components or subassemblies. The second flap may be connected to the seat cushion material. The first and second portions may be sewn, welded, glued, or otherwise fastened together. The first and second portions may be ultrasonically or high-frequency friction welded together.

[0160] The second fluid-impermeable layer may be a continuous sheet. The second fluid-impermeable layer may have a first flap and a second flap. The first flap may be perforated to allow air to pass through the first flap within the fluid chamber. The second flap may extend in the opposite direction from the first flap and may be attached to the seat cushion material. The first and second flaps may be sewn, welded, glued, or otherwise fastened to the second fluid-impermeable layer. The first and second flaps may be ultrasonically or high-frequency friction welded to the second fluid-impermeable layer.

[0161] A seat assembly (e.g., vehicle seat assembly 110) is described that includes a seat bottom (e.g., seat bottom 112). A seat back (e.g., seat back 114) extends in an upright position from the seat bottom (e.g., seat bottom 112). Seat cushioning is attached to the seat bottom (e.g., seat bottom 112) or the seat back (e.g., seat back 114). An assembly (e.g., seat subassembly 122) is installed on top of the seat cushioning. The seat bottom may be provided with the seat cushioning. The seat cushioning may be constructed from the twisted thermoplastic mesh described above or may be constructed from foam.

[0162] 14 illustrates a seat assembly 220 according to some embodiments. In some embodiments, the seat assembly 220, as depicted, is a vehicle seat assembly 220. Although a seat assembly 220 is shown and described, any seat assembly 220 may be used. For example, the assembly 220 may be used in an office chair, a comfort chair, furniture, a mattress, or other cushion. The assembly 220 may be used in a vehicle seat, an aircraft seat, a marine seat, etc. The assembly 220 may also be used in a bed mattress, a camping mattress, a hospital bed, etc.

[0163] The assembly 220 includes a fluid assembly 222 having at least two sheets 224, 226 of air impermeable material. The first and second sheets 224, 226 of air impermeable material are overlapped and connected to form a fluid cavity 228 therebetween. The first and second sheets 224, 226 of air impermeable material may be connected via welding, adhesive bonding, solvent bonding, mechanical fastening, etc. The sheets 224, 226 may be formed from a polymeric material, including, but not limited to, a plastic such as thermoplastic polyurethane (TPU).

[0164] 14 , a first fitting 230 is connected to the first sheet 224 or the second sheet 226 within the periphery of the first sheet 224 or the second sheet 226. The fitting 230 is in fluid communication with the fluid cavity 228 and provides a fluid connection therewith. The fitting 230 may be formed from a polymeric material, including, but not limited to, a plastic such as thermoplastic polyurethane (TPU). The fitting 230 may also be formed from an elastomeric material. The fitting 230 may be annular, radially symmetric about a central axis passing through the fitting 230.

[0165] The assembly 220 may be used as a seat assembly including a seat frame 232 having a seat back 234 and a seat bottom 236. The fluid assembly 222 may be installed in the seat back 234 and / or the seat bottom 236.

[0166] Assembly 220 may further include a pump 238 connected to assembly 220. Pump 238 operates to inflate or deflate one or more fluid bladders during operation. Pump 238 may further include a valve assembly and a controller, wherein the controller is programmed to operate pump 238 and the valve assembly to inflate and deflate fluid assembly 220.

[0167] In additional embodiments, the fluid assembly 222 may include a plurality of fluid cavities 228 formed between overlapping first and second sheets of air impermeable material 224, 226. Each fluid cavity 228 has a fitting 230 in fluid communication with the fluid cavity 228. Figure 15 shows a fluid cavity 228 in fluid communication with a fitting 230.

[0168] FIG. 16 illustrates a fluid bladder 240. The fluid bladder 240 is formed from multiple sheets, such as a first sheet 242, a second sheet 244, a third sheet 246, and a fourth sheet 248, of air impermeable material. The first sheet 242, the second sheet 244, the third sheet 246, and the fourth sheet 248 may be made from a polymeric material, including, but not limited to, a plastic such as thermoplastic polyurethane. The first sheet 242, the second sheet 244, the third sheet 246, and the fourth sheet 248 may be sequentially connected around adjacent peripheries to provide the fluid bladder 240. The first sheet 242, the second sheet 244, the third sheet 246, and the fourth sheet 248 of air impermeable material may be joined around their peripheries via welding, adhesive bonding, solvent bonding, mechanical fastening, or the like. The sheets 242, 244, 246, 248 of the bladder 240 collectively provide the bellows-type bladder 240. Fluid flow into the fluid cavity 250 causes the bladder 240 to expand, and conversely, fluid flow out of the fluid cavity 250 causes the bladder 240 to collapse. The fluid bladder 240 is positioned in the seat assembly 220 such that the first sheet 242 faces the contact or seating surface of the occupant. Inflation of the bladder 240 provides a pressurized massaging effect to the occupant.

[0169] 16 and 17, the fluid bladder 240 may further include a second fitting 252 in fluid communication with the bladder cavity 250. The second fitting 252 is sized to couple to the first fitting 230 of the fluid assembly 222 to provide fluid communication between the first and second fittings 230, 252. The first and second fittings 230, 252 may be joined by a snap fit, such as an interference fit. The second fitting 252 may also be a snap ring 252 sized to be received within the first fitting 230. The second fitting 252 may be formed from a polymeric material, including, but not limited to, a plastic such as thermoplastic polyurethane (TPU). The first and second fittings 230, 252 form a fluid-tight seal to transfer fluid from the fluid chamber 228 of the fluid assembly 222 to the fluid chamber 250 of the fluid bladder 240.

[0170] 15 and 17, one of the fittings 230, 252, e.g., the first fitting 230, includes a cylindrical body 254 that allows fluid to pass through a port 256 in the body 254. A radial retainer 258 extends inwardly from the body 254 and provides a fastener for the fitting 230. The first fitting 230 may be joined to the first sheet 224 by welding, adhesive, or the like.

[0171] 16 and 17 , the other of the fittings 230, 252, e.g., the second fitting 252, includes a cylindrical body 260 sized to be received in the port 256 of the first fitting 230. The cylindrical body 260 also includes a central port 262 in fluid communication with the port 256 of the first fitting 230. The body 260 has a recess 264 formed therein. The recess 264 is sized to receive the retainer 258 of the first fitting 230. During assembly of the second fitting 252 to the first fitting 230, the body 260 of the second fitting 252 is inserted into the port 256 of the first fitting 230. The body 260 deforms the resiliently flexible retainer 258, allowing the body 260 of the second fitting 252 to pass through until the retainer 258 is aligned with the recess 264, thereby allowing the retainer 258 to spring back into the recess 264. The retainer 258 cooperates with the recess 264 to fasten the second fitting 252 to the first fitting 230 while maintaining a fluid seal between the fittings 230, 252. The second fitting 252 may be joined to the fluid bladder 240 by welding, such as friction welding, sonic welding, adhesives, etc. Although the first fitting 230 is depicted on the fluid assembly 222 and the second fitting 252 is shown and described on the fluid bladder 240, the fittings 230, 252 may be interchanged.

[0172] FIG. 18 illustrates a fluid bladder 266 with a fitting 268 according to some embodiments. The fluid bladder 266 may be similar to the fluid bladder 240 of the previous embodiment. The fitting 268 may be similar to the second fitting 252 of the previous embodiment. The fitting 268 may connect the fluid bladder 266 to the first fitting 230 of the fluid assembly 222 via a snap fit to provide a fluid-tight seal. Additionally, a protrusion 270 may be formed on the body 260 of the fitting 268. Upon compression and contraction of the fluid bladder 266, the protrusion 270 may contact the second seat 226 of the fluid assembly 222 and prevent the second seat 226 from closing the port 262 of the fitting 268 when pressure from the weight of an occupant is applied.

[0173] Figure 19 is an exploded view of the fitting 268 of Figure 18. The fitting 268 may include a radial retainer 272 as a separate part aligned with the first fitting 230. The first fitting 230 may be installed through the first seat 224. A retainer ring 272 is then installed on the first fitting 230 to hold the first fitting 230 to the first seat 224. The use of the retainer ring 272 can eliminate an additional welding step. The retainer ring 272 may be used as an alternative to welding.

[0174] FIG. 20 illustrates another embodiment of a fluid bladder assembly 240. The fluid bladder assembly includes interconnectable fluid bladders 241, 243. Fluid bladder 241 includes a first sheet 242 and a second sheet 244 of air-impermeable material. The sheets may be sequentially connected around their adjacent peripheries. First sheet 242 and second sheet 244 may be joined around their peripheries via welding, adhesive bonding, solvent bonding, mechanical fastening, or the like. Fluid bladder 243 includes a third sheet 246 and a fourth sheet 248 of air-impermeable material. The sheets may be sequentially connected around their adjacent peripheries via welding, adhesive bonding, solvent bonding, mechanical fastening, or the like. Second sheet 244 may include a third fitting 274. Third fitting 274 may connect the first and second sheets to a fourth fitting 276 of third sheet 246 via a snap fit or an interference fit. The snap fit may provide a fluid-tight seal between the second sheet and the third sheet.

[0175] Although third fitting 274 is depicted as being on second seat 244 and fourth fitting 276 is depicted as being on third seat 246, fittings 274, 276 may be interchanged. In some embodiments, fluid bladder 241 provides intermediate fluid bladder 241 with one pair of seats 246, 248 as a bellows. Fluid bladder 243 provides distal fluid bladder 243 with another pair of seats 242, 244 as a bellows. The number of bellows may be increased by adding multiple intermediate fluid bladders 241 between distal fluid bladder 243 and first fitting 230. Using this process, various fluid bladder assemblies 240 may be assembled depending on the bladder displacement to be applied.

[0176] FIG. 21 illustrates a fluid bladder 278 according to another embodiment. The fluid bladder 278 may be similar to the fluid bladder 240 of the previous embodiment. The second fitting 252 of the fluid bladder 278 may include an extension tube 280. The extension tube 280 allows the second fitting 252 of the fluid bladder 278 to be routed through a material, including but not limited to, foam, and connected to the first fitting 230 of the other assembly. The foam may include a seat cushion material or a mattress. The extension tube 280 may be formed from the same material as the second fitting 252. The central port 262 extends axially through the extension tube 280 to fluidly communicate with the port 256 of the first fitting 230.

[0177] 22 illustrates a fluid bladder 282 according to some embodiments. The fluid bladder 282 may include a fifth sheet 284 of air-impermeable material. The fifth sheet 284 may be formed from the same material as the first, second, third, and fourth sheets 242, 244, 246, and 248. The fifth sheet 284 may be connected to the fourth sheet 248 around its adjacent periphery via welding, adhesive bonding, solvent bonding, mechanical fastening, or the like. The fifth sheet 284 may be in physical contact with the second fitting 252. The fifth sheet 284 allows the second fitting 252 of the fluid bladder 282 to be routed through a cushion-like material.

[0178] FIG. 23 illustrates a method for connecting multiple fluid bladders 240 to the assembly 220 in a single step. Multiple fluid bladders 240 may be manufactured and physically connected by gang strips 286 for installation alignment of the fluid bladders 240. The gang strips 286 may be in physical contact with each of the multiple fluid bladders 240. The fluid bladders 240 may be connected to one another at specific distances 288 corresponding to the distances between the multiple first fittings 230 in the assembly 220. The fluid bladders 240 may be arranged in a specific pattern corresponding to the pattern in which the multiple first fittings 230 are arranged in the assembly 220. While the fluid bladders 240 are depicted in a linear pattern, other patterns are also contemplated, including, but not limited to, linear or radial arrays, or zigzag patterns. The second fittings 252 of each fluid bladder 240 may then be connected to each first fitting 230 of the assembly 220 in a single step. The strip of material 286 may be formed from a polymeric material, including but not limited to plastic.

[0179] The various embodiments of the air bladder assembly 220 provide flexibility and modularity in the design and assembly of the air bladder assembly 220 for a particular application. The joints 230, 252 allow for installation flexibility without requiring welding at every seam, which is difficult to automate for large air bladder assemblies. The joints 230, 252 also reduce the manufacturing time required to set up, weld, and cool the various sheets.

[0180] In another embodiment, a method is provided. The method comprises laminating first and second sheets of air impermeable material and bonding the first sheet to the second sheet to form a fluid cavity therebetween. Next, the method includes forming an aperture through one of the first and second sheets into the fluid cavity. Finally, the method includes installing a fitting in the aperture in fluid communication with the fluid cavity.

[0181] In some embodiments, the method may be used to manufacture a fluid bladder. At least two sheets may be connected around adjacent peripheries. The sheets may be connected around adjacent peripheries via welding, adhesive bonding, solvent bonding, mechanical fastening, etc. Collectively, the sheets may provide an interior fluid cavity within the bellows-type bladder. An aperture may be formed through one of the sheets to enter the fluid cavity. A fitting may be attached to the aperture in fluid communication with the fluid cavity. The fitting may be formed to be attached to a corresponding fitting in an assembly. For example, the fitting corresponds to a fitting in a fluid assembly.

[0182] In other embodiments, the method may be used to manufacture a fluid assembly. At least two sheets of air-impermeable material may be joined together to provide at least one fluid line therethrough. The sheets may be joined via welding, adhesive bonding, solvent bonding, mechanical fastening, or the like. Alternatively, the sheets may be joined together to provide multiple fluid lines therethrough. The multiple fluid lines may be arranged in parallel. An aperture through one of the sheets may be located at one end of each fluid line. A fitting may be located at each aperture for fluid communication with the fluid line. The fittings may be configured to correspond to other fittings, including, for example, fittings on a fluid bladder.

[0183] In other embodiments, the method may be used to manufacture an assembly. For example, the method may be used to manufacture a massage assembly. A fluid assembly with multiple fluid lines may be manufactured according to the method. The fluid lines may be arranged in parallel, although other patterns are also contemplated. Multiple fittings may be installed at apertures in each fluid line. Multiple fluid bladders may be manufactured with fittings corresponding to those of the fluid assembly. The fluid bladders may be manufactured as a single bladder or as a unit including multiple bladders. If a unit, the multiple bladders may be arranged in a pattern that allows the fittings of the fluid bladders to align with corresponding fittings of the fluid assembly. The multiple fluid bladders may then be attached to multiple fittings in the fluid assembly. The multiple fluid bladders may be attached to the multiple fittings in the fluid assembly either separately or as a unit. A pump, a valve assembly, and a controller may be connected to the assembly. The controller may be programmed to operate the pump and valve assembly to inflate and deflate the multiple fluid bladders. The fluid bladder may be repeatedly inflated and deflated for massage purposes.

[0184] While various embodiments have been described above, these embodiments are not intended to describe all possible forms of the present disclosure. In that regard, it is understood that the words used herein are words of description rather than limitation, and that various changes may be made without departing from the spirit and scope of the present disclosure. In addition, features of the embodiments from various implementations may be combined to form further embodiments of the present disclosure.

Claims

1. 1. A seat system comprising: a plurality of seat components including at least a fan, an inflatable bladder, a heat mat, a foam layer, and an air distribution layer; Seat cushion material, a trim cover disposed on the seat cushion material; Including, The plurality of seat components are disposed between the seat cushion material and the trim cover and secured together by at least one fastener.

2. The seating system of claim 1 further comprising a corrugated joint between the trim cover and the seat cushion material.

3. The seat system of claim 1 , wherein the fan is embedded in the seat cushion material.

4. 2. The seating system of claim 1, wherein the foam layer has one or more cavities (e.g., bulk spaces recessed into the surface rather than hollow cells in the foam), and the inflatable bladder is disposed in the one or more cavities.

5. 10. The seating system of claim 1, wherein the at least one fastener is selected from the group consisting of an interlocking key and tab, a plurality of tag pins, a sewn seam, a snap lock, a fir tree push-in fastener, a cable tie, a metal ring, a push pin, a toggle closure, and combinations thereof.

6. 2. The seating system of claim 1, wherein the plurality of seat components together provide a seat component subassembly, and the at least one fastener secures the seat component subassembly and the trim cover together.

7. The seating system of claim 6 wherein the seat subassembly is hermetically sealed.

8. The seating system of claim 6 , wherein the seat component subassembly includes a pocket, and the fan is disposed in the pocket.

9. The seat assembly of claim 1 , wherein the trim cover includes a pocket, and at least one of the plurality of seat components is disposed in the pocket.

10. 2. The seat assembly of claim 1, wherein the seat cushion material has a first side and a second side opposite the first side, the first side including one or more cavities.

11. The seat assembly of claim 10 , wherein at least one of the plurality of seat components is nested within one or more of the cavities.

12. 11. The seat assembly of claim 10, wherein the seat cushion material is multi-layered.

13. The seat assembly of claim 10 , wherein the seat cushion material and / or the plurality of seat components include alignment features.

14. 14. The seat assembly of claim 13, wherein the alignment features include pull-through lines connected to the plurality of seat components and extending through the seat cushion material, tension in the pull-through lines aligning the plurality of seat components with the seat cushion material.

15. The seat assembly of claim 14, wherein the pull-through line is elastic.

16. The seat assembly of claim 14 , wherein the pull-through line includes a toggle closure.

17. 11. The seat assembly of claim 10, wherein the fan defines a fan contour, and the one or more cavities have a cavity geometry similar to the fan contour.

18. 1. A method comprising: laminating at least the fan, the inflatable bladder, the heat mat, the foam layer, and the air distribution layer together to form a seat component subassembly; fastening the sheet component subassemblies together with at least one fastener; fastening the seat component subassembly together with a trim cover; fixing the trim cover with the seat component subassembly to a seat cushion material; Including, The seat component subassembly is disposed between the seat cushion material and the trim cover.

19. 20. The method of claim 18, further comprising dimensionally inspecting the sheeting system using at least one of a camera or a laser.

20. the seat cushion material has a first side and a second side opposite the first side, the first side including one or more cavities; and combining the seat component subassembly with the seat cushion material; 20. The method of claim 18, wherein combining the seat component subassembly and the seat cushion material includes nesting one or more portions of the seat component subassembly into one or more cavities in the seat cushion material.

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