Assembly, machine and method

Abstract

A seat assembly and sub-assembly for attaching and holding components are provided. The sub-assembly may include a trim cover having a cushion layer, and various fasteners or holders. The fasteners may include tie-down strips. The holders may include a connector that translates through the seat cushion layer. The holders may also include an envelope that surrounds the cushion layer.

Description

Technical Field

[0001] Cross - reference to related applications This application is a partial continuation application of U.S. Patent Application No. 17 / 841,745, filed on June 16, 2022 (Attorney Docket No. LEAR20795PUS), claims the benefit of U.S. Provisional Patent Application No. 63 / 357,060, filed on June 30, 2022 (Attorney Docket No. LEAR21101PRV), claims the benefit of U.S. Provisional Patent Application No. 63 / 393,386, filed on July 29, 2022 (Attorney Docket No. LEAR21097PRV), claims the benefit of U.S. Provisional Patent Application No. 63 / 393,382, filed on July 29, 2022 (Attorney Docket No. LEAR21098PRV), claims the benefit of U.S. Provisional Patent Application No. 63 / 393,389, filed on July 29, 2022 (Attorney Docket No. LEAR21099PRV), claims the benefit of U.S. Provisional Patent Application No. 63 / 354,079, filed on June 21, 2022 (Attorney Docket No. LEAR20837PRV), claims the benefit of U.S. Provisional Patent Application No. 63 / 393,392, filed on July 29, 2022 (Attorney Docket No. LEAR21040PRV), claims the benefit of U.S. Provisional Patent Application No. 63 / 411,400, filed on September 29, 2022 (Attorney Docket No. LEAR21182PRV), is a partial continuation application of U.S. Patent Application No. 18 / 085,120, filed on December 20, 2022 (Attorney Docket No. LEAR21096PUS), claims the benefit of U.S. Provisional Patent Application No. 63 / 354,412, filed on June 22, 2022 (Attorney Docket No. LEAR20886PRV), claims the benefit of U.S. Provisional Patent Application No. 63 / 357,101, filed on June 30, 2022 (Attorney Docket No. LEAR20912PRV), is a partial continuation application of U.S. Patent Application No. 18 / 087,223, filed on December 22, 2022 (Attorney Docket No. LEAR21094PUS), claims the benefit of U.S. Provisional Patent Application No. 63 / 354,319, filed on June 22, 2022 (Attorney Docket No. LEAR21102PRV), claims the benefit of U.S. Provisional Patent Application No. 63 / 356, filed on June 28, 2022,Claims the benefit of Danish Patent Application No. PA 2023 70030 (Attorney Docket No. LEAR20831PDK), filed on January 19, 2023; claims the priority of US Provisional Patent Application No. 63 / 356,093 (Attorney Docket No. LEAR20905PRV), filed on June 28, 2022; claims the benefit of Danish Patent Application No. PA 2023 70027 (Attorney Docket No. LEAR20905PDK), filed on January 19, 2023; claims the priority of US Provisional Patent Application No. 63 / 354,977 (Attorney Docket No. LEAR20887PRV), filed on June 23, 2022; claims the benefit of US Provisional Patent Application No. 63 / 393,141 (Attorney Docket No. LEAR21086PRV), filed on July 28, 2022; claims the benefit of US Provisional Patent Application No. 63 / 392,914 (Attorney Docket No. LEAR21103PRV), filed on July 28, 2022; claims the benefit of US Provisional Patent Application No. 63 / 392,926 (Attorney Docket No. LEAR21104PRV), filed on July 28, 2022; is a continuation-in-part of US Patent Application No. 17 / 983,881 (Attorney Docket No. LEAR21042PUS), filed on November 9, 2022; claims the benefit of US Provisional Patent Application No. 63 / 433,599 (Attorney Docket No. LEAR21149PRV), filed on December 19, 2022; is a continuation-in-part of US Patent Application No. 18 / 087,850 (Attorney Docket No. LEAR21148PUS), filed on December 23, 2022, the disclosures of which are hereby incorporated by reference in their entirety.,

[0002] The present disclosure relates to a seat assembly and sub-assemblies thereof. Specifically, the present disclosure relates to vehicle seat assemblies and sub-assemblies such as fluid assemblies (e.g., ventilation and / or massage assemblies, valve assemblies), trim assemblies, cushion assemblies, and temperature control / transfer assemblies.,

Brief Description of the Drawings

[0003]

Figure 1

[0004]

Figure 2

[0005]

Figure 3A

[0006]

Figure 3B

[0007]

Figure 4

[0008]

Figure 5

[0009]

Figure 6

[0010]

Figure 7

[0011]

Figure 8

[0012]

Figure 9

[0013]

Figure 10

[0014]

Figure 11

[0015]

Figure 12

[0016]

Figure 13

[0017]

Figure 14

[0018]

Figure 15

[0019]

Figure 16

[0020]

Figure 17

[0021]

Figure 18

[0022]

Figure 19

[0023]

Figure 20

[0024]

Figure 21

[0025]

Figure 22

[0026]

Figure 23

[0027]

Figure 24

[0028]

Figure 25

[0029]

Figure 26

[0030]

Figure 27

[0031]

Figure 28

[0032]

Figure 29

[0033]

Figure 30

[0034]

Figure 31

[0035]

Figure 32

[0036]

Figure 33

[0037]

Figure 34

[0038]

Figure 35

[0039]

Figure 36

[0040]

Figure 37

[0041]

Figure 38

[0042]

Figure 39

[0043]

Figure 40

[0044]

Figure 41

[0045]

Figure 42

[0046]

Figure 43

[0047]

Figure 44

[0048]

Figure 45

[0049]

Figure 46

[0050]

Figure 47

[0051]

Figure 48

[0052]

Figure 49

[0053]

Figure 50

[0054]

Figure 51

[0055]

Figure 52

[0056]

Figure 53

[0057]

Figure 54

[0058]

Figure 55

[0059]

Figure 56

[0060]

Figure 57

[0061]

Figure 58

[0062]

Figure 59

[0063]

Figure 60

[0064]

Figure 61

[0065]

Figure 62

[0066]

Figure 63

[0067]

Figure 64

[0068]

Figure 65

[0069]

Figure 66

[0070]

Figure 67

[0071]

Figure 68

[0072]

Figure 69

[0073]

Figure 70

[0074]

Figure 71

[0075]

Figure 72

[0076]

Figure 73

[0077]

Figure 74

[0078]

Figure 75

[0079]

Figure 76

[0080]

Figure 77

[0081]

Figure 78

[0082]

Figure 79

[0083]

Figure 80

[0084]

Figure 81

[0085]

Figure 82

[0086]

Figure 83

[0087]

Figure 84

[0088]

Figure 85

[0089]

Figure 86

[0090]

Figure 86B

[0091]

Figure 87

[0092]

Figure 88

[0093]

Figure 89

[0094]

Figure 90

[0095]

Figure 91

[0096]

Figure 92

[0097]

Figure 93

[0098]

Figure 94

[0099]

Figure 95

[0100]

Figure 96

[0101]

Figure 96B

[0102]

Figure 97

[0103]

Figure 98

[0104]

Figure 99

[0105]

Figure 100

[0106]

Figure 101

[0107]

Figure 101B

[0108]

Figure 102

[0109]

Figure 103

[0110]

Figure 104

[0111]

Figure 105

[0112]

Figure 106

[0113]

Figure 107

[0114]

Figure 108

[0115]

Figure 109

[0116]

Figure 110

[0117]

Figure 110B

[0118]

Figure 111

[0119]

Figure 112

[0120]

Figure 113

[0121]

Figure 114

[0122]

Figure 115

[0123]

Figure 116

Figure 117

[0124]

Figure 118

[0125]

Figure 119

[0126]

Figure 120

[0127]

Figure 121

[0128]

Figure 122

[0129]

Figure 123

[0130]

Figure 124

[0131]

Figure 125

[0132]

Figure 126

[0133]

Figure 127

[0134]

Figure 128

[0135]

Figure 129

Figure 130

[0136]

Figure 131

Figure 132

[0137]

Figure 133

[0138]

Figure 134

[0139]

Figure 135

[0140]

Figure 136

[0141]

Figure 137

Figure 138

Figure 139

[0142]

Figure 140

[0143]

Figure 141

Figure 142

[0144]

Figure 143

[0145]

Figure 144

[0146]

Figure 145

[0147]

Figure 146

[0148]

Figure 147

[0149]

Figure 148

[0150]

Figure 149

[0151]

Figure 150

[0152]

Figure 151

[0153]

Figure 152

[0154]

Figure 153

[0155]

Figure 154

[0156]

Figure 155

[0157]

Figure 156

[0158]

Figure 157

[0159]

Figure 158

[0160]

Figure 159

[0161]

Figure 160

[0162]

Figure 161

[0163]

Figure 162

[0164]

Figure 163

[0165]

Figure 164

[0166]

Figure 165

[0167]

Figure 166

[0168]

Figure 167

[0169]

Figure 168

[0170]

Figure 169

[0171]

Figure 170

[0172]

Figure 171

[0173]

Figure 172

[0174]

Figure 173

[0175]

Figure 174

[0176]

Figure 175

[0177]

Figure 176

[0178]

Figure 177

[0179]

Figure 178

[0180]

Figure 179

[0181]

Figure 180

[0182]

Figure 181

[0183]

Figure 182

[0184]

Figure 183

[0185]

Figure 184

[0186]

Figure 185

[0187]

Figure 186

[0188]

Figure 187

[0189]

Figure 188

[0190]

Figure 189

[0191]

Figure 190

[0192]

Figure 191

[0193]

Figure 192

[0194]

Figure 193

[0195]

Figure 194

[0196]

Figure 195

[0197]

Figure 196

[0198]

Figure 197

[0199]

Figure 198

[0200]

Figure 199

[0201]

Figure 200

[0202]

Figure 201

[0203]

Figure 202

[0204]

Figure 203

[0205]

Figure 204

Best Mode for Carrying Out the Invention

[0206] Here, embodiments will be referred to in detail and examples thereof are shown in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments described. However, it will be apparent to those skilled in the art that the various embodiments described 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.

[0207] It is understood that the disclosed embodiments are merely exemplary and that various alternatives are possible. The drawings are not necessarily to scale. Some features may be exaggerated or minimized to show details of particular components. Accordingly, the specific structural and functional details disclosed herein should not be construed as limiting, but rather as a merely representative basis for teaching one skilled in the art how to variously employ the embodiments of the present invention.

[0208] "One or more" includes functions performed by one element, functions performed by more than one element, for example, in a distributed manner, some functions performed by one element, some functions performed by some elements, or any combination of the above.

[0209] Also, in this specification, it is understood that although the terms first, second, etc. are used in some instances to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the various embodiments described, the first surface may be referred to as the second surface, and similarly, the second surface may be referred to as the first surface. The first surface and the second surface are both surfaces, but not the same surface.

[0210] The terms used in the description of the various described embodiments in this specification are for the purpose of describing particular embodiments only and are not intended to be limiting. When used in the description of the various described embodiments and the appended claims, the singular forms "a", "one", "the", and "said" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It should further be understood that the terms "comprising", "including", and / or "containing", when used herein, specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0211] As used herein, the term "when...ing" is optionally interpreted, depending on the context, to mean "when...", "at the time of...", or "in response to a determination" or "in response to a detection". Similarly, the expressions "when determined" or "when [stated condition or event] is detected" are interpreted, depending on the context, to mean "in a determination" or "in response to a determination" or "in a detection of [stated condition or event]" or "in response to a detection of [stated condition or event]".

[0212] Further, unless otherwise indicated, all numerical quantities in this disclosure are to be understood as being modified by the term "about" when describing a broader scope of the disclosure. Generally, implementation within the recited numerical ranges is desirable. Also, unless otherwise specified, percents, "parts of", and ratio values are by weight. The term "polymer" includes "oligomer", "copolymer", "terpolymer", etc. When a group or class of materials is described as being suitable or preferred for a given purpose, unless otherwise indicated, any mixture of two or more of that group or class is likewise suitable or preferred. The molecular weight given for any polymer refers to the number average molecular weight. The description of components in chemical terms means the components at the time of addition to the combination specified in the description and does not necessarily exclude chemical interactions between the components of a mixture once mixed. The initial definition of an acronym or other abbreviation applies to all subsequent uses of the same abbreviation in this specification and is applied mutatis mutandis to the normal grammatical variations of the initially defined abbreviation. Unless expressly stated to the contrary, measurements of properties are determined by the same technique as previously or later referenced for the same property.

[0213] Since specific components and / or conditions may vary, the disclosure is not necessarily limited to the specific embodiments and methods described below. Further, the terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting in any sense.

[0214] In this specification, the terms "substantially" or "generally" may be used 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 tolerances, or within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the value or relative property.

[0215] Also, it should be understood that an integer range explicitly includes all intervening integers. For example, the integer range from 1 to 10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range from 1 to 100 includes 1, 2, 3, 4, … 97, 98, 99, 100. Similarly, when any range is required, the intervening numerical values that are the increment of the difference between the upper and lower limits divided by 10 can be used as alternative upper or lower limits. For example, when the range is from 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 the lower limit value or the upper limit value.

[0216] The term controller can be provided as one or more controllers or control modules for various components and systems. The controller and the control system may include any number of controllers, may be integrated into a single controller, or may have various modules. Some or all of the controller may be connected by a controller area network (CAN) or other systems. 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. Further, any one or more of the electrical devices disclosed herein may be configured to execute a computer program embodied on a non-transitory computer-readable medium programmed to perform any number of functions as disclosed herein.

[0217] Referring to FIG. 1, a seat assembly 10 is disclosed that includes one or more sub - assemblies 15 to 35. For example, seat assembly 10 includes a trim assembly 15 disposed over a cushion assembly 20 supported by a frame assembly 35. In some embodiments, trim assembly 15 includes a ventilation portion. In some embodiments, seat assembly 10 also includes a fluid assembly 20. In some embodiments, seat assembly 10 includes temperature control assemblies 25, 30. In various embodiments, fluid assembly 20 is a ventilation assembly and / or a massage assembly. In some embodiments, fluid assembly 20 cooperates with the ventilation portion of trim assembly 15, and in some embodiments, fluid assembly 20 includes the ventilation portion of trim assembly 15. Temperature control assemblies 25, 30 include, for example, a heat transfer assembly. In some embodiments, a valve assembly for controlling fluid flow is included. In some embodiments, retainers or fasteners may attach various components to the cushion.

[0218] According to some embodiments, assemblies 10, 15, 20, 25, 30, 35 and sub-assemblies 10, 15, 20, 25, 30, 35 may each be provided separately. According to some embodiments, assemblies 10, 15, 20, 25, 30, 35 and sub-assemblies 10, 15, 20, 25, 30, 35 may be provided as pre-assembled modules 10, 15, 20, 25, 30, 35. Assembly 10, 15, 20, 25, 30 or sub-assembly 10, 15, 20, 25, 30 may be pre-assembled to the frame assembly 35. Assembly 10, 15, 25, 30, 35 or sub-assembly 10, 15, 25, 30, 35 may be pre-assembled to the cushion assembly 20. Assembly 10, 15, 25, 30, 35 or sub-assembly 10, 15, 25, 30, 35 may also be integrated into the material of the seat cushion assembly 20, for example, integrated into a foam or an extruded thermoplastic plastic mesh. In some embodiments, the cushion assembly 20 may be formed from an additional manufacturing process such as the process disclosed in U.S. Patent Publication No. 11,440,791 to Migneco et al., issued to Lear Corporation on September 13, 2022, the entire disclosure of which is incorporated herein by reference. Various options are available for pre-assembling sub-assemblies 10, 15, 20, 25, 30, 35 or assemblies 10, 15, 20, 25, 30, 35 as modules, or to the frame assembly 35, or to the seat cushion assembly 20.

[0219] Referring to FIG. 2, a seat assembly 100 such as a vehicle seat assembly is disclosed. The seat assembly 100 includes a seat frame 102 and a sub-assembly 104 such as a ventilation sub-assembly. The sub-assembly 104 may be supported by the seat frame 102. Referring to FIGS. 2-3, the sub-assembly 200 includes a trim cover 210 fixed to a membrane 220, one or more additional layers 240 such as a cushion, and / or a substrate 250.

[0220] The trim cover 210 is configured to be adjacent to the seat occupant. That is, the trim cover may include an outermost layer or may include a surface that is the outermost surface. The trim cover 210 covers the remaining components of the seat assembly 100 and can be the main contact surface with the occupant. The trim cover 210 may be configured to provide ventilation to the occupant during seating and driving. For example, the trim cover 210 may include one or more perforations 211 and / or may be permeable to fluids such as air. The trim cover 210 may include a first surface 212 (e.g., an exposed surface) and a second surface 213 (e.g., a non-exposed surface) that faces the first surface 212. The first surface 212 may be a surface of cloth, synthetic leather, or leather. For example, the cloth or synthetic leather may be cotton, polyester, polyurethane, nylon, or other suitable cloth. As a variant, the cloth or synthetic leather may be polyester or polyurethane. The trim cover 210 may also include one or more layers such as an outer layer 214 and an inner layer 215. For example, the outer layer 214 may be polyurethane synthetic leather or polyester cloth, and the inner layer 215 may be a spacer cloth or a thin polyurethane foam cushion (e.g., 0.05 to 5 mm, more preferably 0.1 to 3 mm, even more preferably 0.25 to 1.25 mm). The inner layer 215 may be permeable to the flow of fluids such as air, but the outer layer 214 may be made of an impermeable material such as synthetic leather or leather. When the outer layer 214 is an impermeable material, it may be perforated so as to provide ventilation to the adjacent occupant when receiving the fluid flow from the inner layer 215.

[0221] The trim cover 210 may be fixed and / or sealed to the membrane 220. Thereby, the membrane 220 cannot be removed without damaging the trim cover 210, the membrane 220, or the fixing / sealing medium (e.g., sewing or welding). In a variant, the trim cover 210 and the membrane 220 may be fixed and / or sealed at least partially, for example, along or adjacent to the outer periphery of the sheet surface 218. In a variant, the trim cover 210 may be fixed / sealed to the membrane 220 so as to be impermeable or not to leak fluid flow such as air at the connection interface. Specifically, the fixation may refer to an immutable connection except for an adhesive that can be peeled off or attached so that it can be easily disconnected without damaging the material. The membrane 220 may be disposed between the trim cover 210 and the substrate 250. In a variant, the membrane 220 may be adjacent to the trim cover 210. The membrane 220 may also be disposed adjacent to one or more additional layers 240. One or more additional layers 240 may be disposed between the membrane 220 and the substrate 250. In other words, the assembly may include a trim cover 210 connected to and adjacent to the membrane 220, and this trim cover 210 is adjacent to one or more additional layers facing the trim cover 210.

[0222] Specifically, as shown in FIGS. 3A to 3B, the membrane 220 may form a ventilation bag 222 that defines a cavity. In yet another improvement, as shown in FIGS. 3A to 3B, the membrane 220 and the trim cover 210 may cooperate to form a cavity. The cavity may include a channel. Alternatively, the membrane 220 or the ventilation bag may further define a flow path in fluid communication with the cavity. Thus, the channel is disposed opposite the trim cover, extends from the trim cover toward the outlet of the blower 260, and is close to the outlet of the blower 260. The channel is configured to receive fluid flow from the blower 260. For example, in a variant, the channel may be disposed around the outlet of the blower 260 and sealed by, for example, a ring gasket or a ring snap. Alternatively, the channel may be disposed at the outlet or may engage the substrate 250.

[0223] The membrane 220 is made of an impermeable fabric that does not allow fluid flow such as air to pass through. For example, the membrane 220 may be a plastic and / or fabric sheet such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt such as Tyvek®. The ventilation bag may have a spacer 230 disposed within the cavity defined by the ventilation bag. The spacer 230 may be any suitable structure that resists crushing so as to impede fluid flow therethrough. For example, the spacer 230 may be a spacer fabric that allows air to pass through. The ventilation bag may be formed from one or more sheets.

[0224] For example, the membrane 220 may be formed from a first sheet 224 and a second sheet 225 that are fixed to each other to define a cavity. The first and second sheets 224, 225 may be fixed to form a seal. For example, the first and second sheets 224, 225 may be fixed to each other by stitching, heat staking, ultrasonic staking, hot plate welding, heat swaging, cold pressing, etc. so as not to allow fluid flow to escape unless it passes through one or more designated apertures. In a variant, the first sheet 224 may be permeable to fluid flow such as air. That is, the ventilation bag 222 may be configured to provide fluid communication with the trim cover 210. Specifically, the first sheet 224 may be disposed adjacent to the trim cover 210 and the second sheet 225 may be disposed opposite the trim cover 210 such that the first sheet 224 is disposed between the trim cover 210 and the second sheet 225.

[0225] One or more additional layers 240 may include a cushioning material or a comfort material 241. The cushioning material or comfort material 241 may provide comfort to a seated occupant. For example, the cushioning material or comfort material may be a foam. In a variant, the cushioning material or comfort material 241 may be a non-foamed mesh. Specifically, the ventilation assembly 200 and / or the seat assembly 100 may be non-foamed. Specifically, the ventilation assembly may be non-foamed and not include a foam cushion. In other words, the seat assembly may be non-foamed.

[0226] Non-foamed may refer to one or more layers of non-foamed materials laminated together. Each layer may be formed from a woven monofilament fiber material. An example of the material is a polyester such as polyethylene terephthalate. The material may also be formed from recycled materials to reduce material costs and waste. The material may be a non-woven fabric, a woven fabric, and / or a knit that provides a structure while also providing porosity, breathability, and compliance. The non-foamed material may be made from a woven fabric of monofilaments. For example, additional details of non-foamed materials or non-foamed materials can be found in the application identified in Application No. 17 / 218,663, filed on March 31, 2021. The entire application is incorporated herein by reference.

[0227] In a variant, the non-foamed or non-bubbled material may be a non-woven mesh of a thermoplastic resin. The mesh can be formed by extruding a pressurized molten thermoplastic resin from an extruder through an extrusion die. The extrusion die may include a plurality of outlet ports or nozzles that discharge a plurality of strands of the molten thermoplastic resin. The strands are discharged into a fluid chamber having a fluid (e.g., water) that cools against the flow of the strands. The fluid causes buckling, looping, and / or intersection of the strands with adjacent strands against the flow of the strands. The solidified and intertwined strands form an integral thermoplastic non-woven mesh cushion. For example, additional details of this process are disclosed in the application identified in Application No. 17 / 741,639, filed on May 11, 2022. The entirety of which is incorporated herein by reference.

[0228] By defining an orifice with one or more additional layers 240, the membrane 220 can pass from the trim cover 210 through the one or more additional layers 240 to the blower 260 and receive fluid flow from the blower 260 during operation.

[0229] The one or more additional layers 240 may also support a plurality of components such as the blower 260, pump, electrical circuit, ventilation assembly 200, and / or massage / bladder assembly, etc. by the substrate 250. In this case, it may be referred to as a carrier. The substrate 250 may be suspended by a suspension system (e.g., suspension wires) etc. to the seat frame 102 of the seat assembly 100. The substrate 250 may be a rigid board such as a plastic board. The substrate 250 or carrier may define an orifice so as to receive fluid flow from the blower 260 through the orifice during operation. Alternatively, the blower 260 may be directly connected to the ventilation bag.

[0230] The blower 260 may include a motor that mechanically communicates with a fan configured to provide a fluid flow during operation. The blower 260 may include an inlet for receiving a fluid such as air and an outlet for delivering the fluid flow during operation. Thus, in one or more embodiments, the ventilation assembly 200 may be configured to receive a fluid flow from the blower 260 or deliver a fluid flow to the blower 260. As a result, the fluid flow may proceed along the membrane 220 or through the ventilation bag formed by the membrane 220 to the trim cover 210 and through the trim cover 210 or vice versa, providing ventilation to the seated occupant during operation and when assembled to the seat assembly. In other words, the blower may be configured to provide an air flow to the occupant or draw an air flow from the occupant to provide ventilation (i.e., the blower may be configured to pull air or push air).

[0231] In some embodiments, a ventilation assembly (e.g., 200) for a seat (e.g., 100) for a vehicle (e.g., motorcycle, automobile, locomotive, personal watercraft, aircraft) etc. is provided, which includes a trim cover (e.g., 210), a sub - assembly (e.g., 200) (e.g., ventilation bag 222), and a spacer (e.g., 230) such as a spacer fabric. The trim cover (e.g., 210) is configured to contact an occupant when assembled to the seat (e.g., 100) during operation and provide ventilation by a fluid flow such as an air flow. The ventilation bag (e.g., 222) defines a cavity and a channel that is in fluid communication with the cavity and is disposed opposite the trim cover (e.g., 210). The channel is configured to communicate with a blower (e.g., 260) through one or more additional layers (e.g., 240) such as a cushion material / comfort material (e.g., 241 which may be a non - foamed mesh) or through a substrate (e.g., 250) such as a carrier board, rigid board, plastic board. The ventilation bag (e.g., 222) is fixed to the trim cover (e.g., 210) such that a fluid flow (e.g., air flow) travels from the ventilation bag (e.g., 222) to the trim cover (e.g., 210) or vice versa. A spacer 230 such as a spacer fabric is disposed in the cavity.

[0232] In various embodiments, the ventilation bag (e.g., 222) is sewn or welded to the trim cover (e.g., 210).

[0233] In one or more embodiments, the ventilation bag (e.g., 222) is at least partially fixed to the trim cover (e.g., 210) along its outer periphery.

[0234] In some embodiments, the one or more additional layers (e.g., 240) include a substrate (e.g., 250) such as a carrier board, rigid board, plastic board configured to support the blower (e.g., 260).

[0235] In various embodiments, one or more additional layers (e.g., 240) include a non-foamed mesh such as a non-foamed mesh cushion (e.g., 241). A sub-assembly (e.g., 200) such as a ventilation assembly further includes a blower (e.g., 260) supported by a substrate (e.g., 250) such as a carrier board, a rigid board, or a plastic board.

[0236] In one or more embodiments, a ventilation bag (e.g., 222) includes a first sheet (e.g., 224) (e.g., a plastic sheet and / or a cloth sheet such as felt like polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®) adjacent to a trim cover (e.g., 210), and a second sheet (e.g., 225) (e.g., a plastic sheet and / or a cloth sheet such as felt like polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®) that cooperates with the first sheet (e.g., 224) (e.g., is fixedly sealed by stitching, heat staking, ultrasonic staking, hot plate welding, heat swaging, cold pressing, etc. so as not to allow fluid flow to escape unless through one or more designated apertures). The second sheet is disposed on the opposite side of the trim cover (e.g., 210) such that the first and second sheets (e.g., 224, 225) (e.g., a plastic sheet and / or a cloth sheet such as felt like polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®) define cavities and channels.

[0237] In some embodiments, one or more additional layers (e.g., 240) do not include a foam cushion.

[0238] In one or more embodiments, the outer peripheral portion is the outer peripheral portion of the surface (e.g., 218) of the sheet assembly.

[0239] In one or more embodiments, a vehicle seat (e.g., 100) is provided that includes a sub-assembly (e.g., 200) such as a ventilation assembly, and a seat frame (e.g., 102) that supports the sub-assembly (e.g., the ventilation assembly).

[0240] The seat sub-assembly (e.g., 100) includes a trim cover (e.g., 210), a carrier (e.g., 250) (e.g., a rigid plastic board), a first sheet (e.g., 224) (e.g., a plastic sheet and / or a cloth sheet such as felt like polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®), a second sheet (e.g., 225) (e.g., a plastic sheet and / or a cloth sheet such as polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®), a spacer (e.g., 230) such as a spacer cloth, and one or more additional layers (e.g., 240).

[0241] In one or more embodiments, the trim cover (e.g., 210) has a first surface (e.g., 212) (e.g., an exposed surface) and a second surface (e.g., 213) (e.g., an unexposed surface) that faces the first surface (e.g., 212) (e.g., the exposed surface).

[0242] In various embodiments, the trim cover (e.g., 210) is configured to provide ventilation to an occupant adjacent to the first surface (e.g., 212) (e.g., the exposed surface) when a fluid flow (e.g., an air flow) is received at the second surface (e.g., 213) (e.g., the unexposed surface).

[0243] In some embodiments, the carrier (e.g., 250) is configured to support a blower (e.g., 260).

[0244] In various embodiments, a carrier (e.g., 250) defines an orifice that receives a fluid flow (e.g., an air flow) from a blower (e.g., 260). A first sheet (e.g., 224) (e.g., a plastic sheet and / or a cloth sheet such as felt like polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®) cooperates with a trim cover (e.g., 210) (secured by stitching, heat staking, ultrasonic staking, hot plate welding, thermal swaging, cold pressing, etc. to prevent fluid flow from escaping except through one or more specified apertures) and is disposed between the trim cover (e.g., 210) and the carrier (e.g., 250) (e.g., a rigid plastic board). There is a second sheet (e.g., 225) (e.g., a plastic sheet and / or a cloth sheet such as felt like polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®) between the first sheet (e.g., 224) and the carrier (e.g., 250) (e.g., a rigid plastic board).

[0245] In various embodiments, a second sheet (e.g., 225) (e.g., a plastic sheet and / or a cloth sheet such as felt like polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®) cooperates with a first sheet (e.g., 224) (e.g., a plastic sheet and / or a cloth sheet such as felt like polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®) (sealed, for example, by stitching, heat staking, ultrasonic staking, hot plate welding, heat swaging, cold pressing, etc., to prevent fluid flow (e.g., air flow) from leaking except through one or more specified apertures), and the first and second sheets (e.g., 224, 225) (e.g., a plastic sheet and / or a cloth sheet such as felt like polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®) define a cavity that includes channels.

[0246] In various embodiments, the channels are configured to receive a fluid flow (e.g., an air flow) from a blower (e.g., 260) through an orifice. In some embodiments, a spacer (e.g., 230) (e.g., a spacer cloth) is disposed in the cavity.

[0247] In various embodiments, one or more additional layers (e.g., 240) are disposed between the second sheet (e.g., 225) (e.g., a plastic sheet and / or a cloth sheet such as felt like polyethylene, polyurethane, thermoplastic polyurethane, and / or Tyvek®) and a carrier (e.g., 250) (e.g., a rigid plastic board), and the channels provide a passage through the one or more additional layers (e.g., 240) (e.g., a cushioning / comfort material (e.g., 241) such as a non-foamed mesh), and ventilation is provided through the cavity to and from the blower (e.g., 260) and to and from an occupant adjacent to the trim cover (e.g., 210).

[0248] In one or more embodiments, the first sheet (e.g., 224) is secured to the trim cover (e.g., 210) by stitching or welding.

[0249] In some embodiments, a spacer (e.g., 230) (e.g., a spacer fabric) is disposed between the first and second sheets (e.g., 224, 225) (e.g., plastic sheets and / or fabric sheets such as polyethylene, polyurethane, thermoplastic polyurethane, and / or felt such as Tyvek®).

[0250] In some embodiments, a sheet frame (e.g., 102) supports one of the subassemblies described herein.

[0251] In one or more embodiments, a subassembly (e.g., 200) such as a ventilation assembly for a sheet includes a trim cover (e.g., 210), a carrier (e.g., 250), a cushion (e.g., 241), and a membrane (e.g., 220).

[0252] In various embodiments, a carrier (e.g., 250) (e.g., a rigid plastic board) is configured to support a blower (e.g., 260).

[0253] In some embodiments, the carrier (e.g., 250) defines a first orifice configured to receive a fluid flow (e.g., an air flow) from the blower (e.g., 260) during operation.

[0254] In one or more embodiments, a cushion (e.g., 241) (such as a non-foamed fibrous nonwoven mesh cushion) is disposed between the trim cover (e.g., 210) and the carrier (e.g., 250).

[0255] In some embodiments, the cushion (e.g., 241) is adjacent to the carrier (e.g., 250) and defines a second orifice.

[0256] In various embodiments, a membrane (e.g., 220) is disposed between a cushion (e.g., 241) and a trim cover (e.g., 210) and extends through a second orifice.

[0257] In one or more embodiments, a membrane (e.g., 220) fixed to a trim cover (e.g., 210) causes a fluid flow (e.g., an air flow) to be received or delivered to the trim cover (e.g., 210) through a first orifice, and to provide ventilation through the trim cover (e.g., 210) to an occupant adjacent to the trim cover (e.g., 210) during operation.

[0258] In some embodiments, the membrane (e.g., 220) is fixed to the trim cover (e.g., 210) along an outer periphery.

[0259] In various embodiments, the membrane (e.g., 220) is sewn or welded to the trim cover (e.g., 210).

[0260] In some embodiments, the membrane (e.g., 220) may be sewn to the trim cover (e.g., 210). In other embodiments, the membrane (e.g., 220) is welded to the trim cover (e.g., 210).

[0261] In one or more embodiments, a vehicle seat (e.g., 100) includes a seat frame (e.g., 102) and a sub-assembly (e.g., 200) such as a ventilation assembly supported by the seat frame (e.g., 102).

[0262] Referring to FIG. 4, a seat assembly 320 such as a vehicle seat assembly 320 is shown. In other examples, the seat assembly 320 can be in the shape and size of a driver's or passenger's seat in the front row, a second row, a third row, or other rear row seats, and can include a bench-style seat, a bucket seat, or other seat styles as shown. Further, the seat assembly may be a non-stowable seat, or may be a stowable seat that is foldable and stowable in a cavity of the vehicle floor. Additionally, the seat assembly 320 may be configured for other non-vehicle applications.

[0263] The seat assembly 320 has a support structure 322 provided by one or more support members. The support members may be provided by a frame and / or a substrate. The seat assembly has a plurality of seat components, which include at least a seat bottom 324 and a seat back 326. The seat bottom 324 may be sized to receive a seated occupant and support the occupant's pelvis and thighs. The seat back 326 may extend upright from the seat bottom 324 and be sized to support the occupant's back. The seat assembly may additionally have a headrest (not shown). The seat bottom 324 has a seat bottom cushion 328. The seat back 326 has a seat back cushion 330. The frame 322 may include a wire suspension mat or other structure for supporting the cushions 328, 330.

[0264] The support structure 322 provides a rigid structural support for the seat components, such as the seat bottom 324 and the seat back 326, and may be provided as a plurality of frame members and / or substrates or panels that are movable relative to each other to provide adjustment of the seat assembly. The support structure 322 may be formed from a stamped steel alloy, a fiber-reinforced polymer, or any suitable structural material.

[0265] One or more trim assemblies 332 are used to cover the seat bottom cushion 328 and / or the seat back cushion 330, and a seating surface is provided to the seat assembly 320. The vehicle seat assembly 320 is shown with the trim cover assembly 332 partially cut away. In one example, the trim cover assembly 332 covers both cushions 328, 330. In other examples, multiple trim cover assemblies are provided to cover the seat bottom cushion and the seat back cushion. The trim cover assembly 332 according to various embodiments will be described in further detail below. The trim assembly 332 provides the trim surface, i.e., the visible surface or A-surface, of the seat assembly 320. The trim assembly 332 also incorporates additional material layers as described below and can further provide breathability to the seat. The seat assembly 332 may be provided as a modular component for assembly to the seat assembly 320.

[0266] In one example, as shown, one or more trim assemblies 332 are in fluid communication with a fluid system 350, such as an air system, to provide an air flow through the trim assembly for ventilation. The air system 350 includes a fan 352 and / or an air pump 352 and supplies a pressurized air flow to the trim assembly 332.

[0267] The seat cushion 340 will be described in further detail below, and this description may equally apply to the seat bottom cushion 328 or the seat back cushion 330. According to various examples, the seat cushion 340 can be formed from a foam material, such as molded polyurethane foam, or a non-foam material, or a combination thereof. As an alternative, the seat assembly 320 may be provided without the cushion 340 such that the trim assembly is supported directly on the support member 322, e.g., as a panel or substrate.

[0268] In a non-limiting example, the non-foamed parts or members of the seat cushion 340 are formed of a twisted yarn mesh material, also known as an intertwined three-dimensional filament structure. The twisted yarn mesh material is made from a polymer mesh having a plurality of integrated polymer strands (twisted yarns). The twisted yarn mesh material can be made from, for example, a linear low density polyethylene (LLPDE) material, although other polymers and materials effective in providing the desired properties and functionality are also contemplated. The twisted yarn mesh material may be formed using extruded filaments of linearly oriented low density polyethylene (LLDPE) that are randomly intertwined, bent, looped, or otherwise positioned and oriented, and are directly bonded to each other to provide a porous mesh structure.

[0269] Referring to FIGS. 5-6, a trim assembly 400 according to various embodiments of the present disclosure is shown. The trim assembly 400 can be formed from multiple layers of materials as described below. The trim assembly 400 may be used as a trim assembly 332 with the vehicle seat assembly 320 of FIG. 4, or with other seats as described above, or with other vehicles or other applications.

[0270] The trim assembly 400 has a perforated trim cover layer 402. The trim cover layer 402 can provide the A surface of the trim assembly 400, or the seat surface visible to the seat occupant. The perforated trim cover layer 402 can be formed from one or more panels 404 of leather, leatherette, vinyl, woven fabric, knitted fabric, or other materials. The perforations in the panels 404 of the trim cover layer 402 allow an air flow across the trim cover layer 402. The perforations may be provided as small holes or apertures formed through the trim cover layer. The knit or weave pattern of a fabric trim cover layer can function as perforations and provide an air flow throughout the fabric layer.

[0271] The various panels 404 of the trim cover layer 402 are connected to each other via joints 406. The joints 406 can be provided by sewing, welding, adhesively bonding, laminating, or other processes to connect two adjacent trim panels 404 to form the trim cover layer. In the illustrated example, the trim panels 404 are connected to each other via seams formed by sewing so as to provide the joints 406. A hem 408 is provided in the trim cover layer 402, and the hem 408 is the region between the edges of two panels connected together and the joint region or the stitching line.

[0272] The trim assembly 400 has a barrier layer 410 connected to the trim cover layer 402. The barrier layer 410 is impermeable to air. In one example, the barrier layer 410 is formed from a continuous plastic layer such as a thermoplastic polyurethane sheet or film. The ventilation port 412 may be connected to the barrier layer 410 or formed in the barrier layer 410 using, for example, one or more of the techniques described above with respect to the joints, and may be connected to the air system 350 described above with respect to FIG. 4 via a hose or tube.

[0273] One or more porous spacer material layers 420 are disposed between the trim cover layer 402 and the barrier layer 410. Each spacer layer 420 is formed from a breathable material or includes perforations or other features to allow air to pass through and across the layer. In the illustrated example, first and second spacer material layers 422, 424 are provided. In other examples, three or more spacer material layers 420 are provided. The spacer material layers 420 may be formed from the same material or different materials.

[0274] In the illustrated example, the first spacer layer 422 is formed from a reticulated foam layer, such as a urethane or other foam material, and may further be known as a soft-touch material that provides a cushioned feel to the seat occupant. In a non-limiting example, the reticulated foam has 25 to 45 holes per inch, although other ranges of holes per inch are contemplated. The second spacer layer 424 is formed from a spacer fabric, such as a knit or mesh spacer fabric. The spacer fabric may be a fabric layer formed by knitting or other means that forms a mesh structure that allows air to pass through and provides a firm support surface. In other examples, the first and second spacer material layers 422, 424 may be formed from other materials that allow an air flow therethrough.

[0275] The first spacer layer 422 is in contact with the trim cover layer 402, and the second spacer layer 424 is disposed between the first spacer layer 422 and the barrier layer 410. The first spacer layer 422 has a trench 426 or trough formed therein. As used herein, the trench 426 may refer to an open channel or groove formed in the spacer layer 420 that intersects one of the surfaces. In one example, the trench 426 has a floor 428. As shown, the trench 426 may be formed in the surface that engages or contacts the B surface of the trim cover layer 402. The butt joint 408 between two adjacent panels of the trim cover layer is received in the trench, and the joint 406 may additionally be received in the trench 426.

[0276] In a further example, a perforated heating pad or mat (not shown) may be disposed between the trim cover layer 402 and the barrier layer 410 and laminated with the spacer layer 420. The heating pad may be selectively operated to supply heat from the trim assembly 400 to the seat occupant.

[0277] As shown in FIG. 4, the trim cover layer 402 is connected to the barrier layer 410 around the outer periphery of the trim assembly, and the spacer material layer 420 is enclosed by the trim cover layer and the barrier layer. The trim cover layer 420 can be connected around the outer periphery of the barrier layer by sewing, adhesion, welding, laminating, or other methods. Additional trim panels may be connected to the trim assembly, for example adjacent to the outer periphery, to cover other portions or the periphery of the sheet, as shown with respect to FIGS. 3-5 below by way of example. Further, the additional trim panels may be provided as described with respect to the trim assembly 400, or may be provided without a barrier layer or other layer. Additional tie-downs used to connect the trim assembly to the sheet 320 may be provided around or adjacent to the outer periphery of the trim assembly 400.

[0278] The trim assembly 400 has a tie-down film 430 that can function as a reinforcing layer or reinforcing material 430 connected to the trim cover layer 402. Note that in FIG. 9, the film 430 is shown partially transparent under the spacer layer 420 for illustrative purposes. In one example, the tie-down film 430 is formed from a non-woven fabric. A porous spacer material layer, such as a first spacer layer 422, is disposed between at least a portion of the trim cover layer 402 and the tie-down film 430. The tie-down film 430 is laminated between the first and second spacer material layers 422, 424 as shown, such that the tie-down film 430 is separated from the trim cover layer 402 by the first porous spacer material layer 422. The tie-down film 430 may contact the first spacer layer 422 on the side opposite the trench 426.

[0279] The tie-down film 430 is connected to the trim cover layer 402 and is connected to the joint 406 and / or the overlap 408 of the first and second panels 404. In the illustrated example, the overlap 408 is sewn to the tie-down film 430 through the first spacer material layer 422, for example through a seam 432, through the floor 428 of the trench 426 in the first spacer layer.

[0280] The tension at the seam 432 connecting the overlap 408 to the tie-down film 430, like the depth of the trench 426 and the thickness of the layer 422, helps to define the shape of the trim cover layer 402 and the appearance of the trim assembly 400. This is because the joint 406 between the plurality of panels 404 of the trim assembly or the tie-down effect or visual appearance of the seam is formed.

[0281] In various examples, the first spacer material layer 422 and / or the tie-down film 430 are each connected to the second spacer material layer 424. For example, the first spacer material layer 422 and the tie-down film 430 are each connected to the second spacer material layer 424 via adhesion and / or lamination.

[0282] The trim assembly 400 may be formed or assembled before being connected to the cushion 340 or the seat assembly 320. In a further example, the trim cover assembly 400 may be shipped or moved to a location or assembly line for the vehicle seat assembly 320 after being assembled at a first facility or a first manufacturing line. Since the trim assembly 400 may include components for functions such as ventilation and / or heating that are pre-assembled within the assembly 400, the seat 320 can be more easily assembled with fewer steps.

[0283] Referring to FIGS. 7 through 9, a trim assembly 500 according to various examples of the present disclosure is shown. The trim assembly 500 can be formed from multiple layers of materials as described below. The trim assembly 500 may be used as a trim assembly 332 with the vehicle seat assembly 320 of FIG. 4, or with other seats, or other vehicles or other applications as described above. Elements that are the same or similar to those described above with respect to FIGS. 2 through 3 are given the same reference numbers for simplicity, and the description of these elements can be found above according to various embodiments.

[0284] As described above, the trim assembly 500 has a perforated trim cover layer 402 and is formed from one or more panels 404. In one example, two panels 404 are connected via a joint 406 with a butt joint 408. In other examples, a single panel 404 may be provided.

[0285] The trim assembly 500 has a barrier layer 410 connected to the trim cover layer 402. The barrier layer 410 has a ventilation port 412 and may be connected to the air system 350 described above with respect to FIG. 4 via a hose or tube.

[0286] One or more porous and breathable spacer material layers 420 are disposed between the trim cover layer 402 and the barrier layer 410. In the illustrated example, first and second spacer material layers 422, 424 are provided. In other examples, three or more spacer material layers 420 are provided. In the illustrated non-limiting example, the first spacer layer 422 is formed from a reticulated foam layer and the second spacer layer 424 is formed from a spacer fabric such as a knit or mesh spacer fabric.

[0287] The first spacer layer 422 is provided with a first portion and a second portion. Similarly, the second spacer layer is provided with a first portion and a second portion. The first portions of these layers form a first stack 502 and the second portions of these layers form a second stack 504. The first and second stacks 502, 504 may be arranged adjacent to each other and without overlap. In other examples, additional stacks of spacer layers may be provided. The butt joint 408 between the plurality of panels 404 of the trim cover layer may be disposed between adjacent stacks, for example, in a gap 506 therebetween.

[0288] As shown in FIGS. 7 to 9, the trim cover layer 402 is connected to the barrier layer 410 around the outer periphery of the trim assembly, and the spacer material layer 420 is enclosed by the trim cover layer and the barrier layer. The trim cover layer 420 can be connected around the outer periphery of the barrier layer by sewing, adhesion, welding, lamination, or other methods. An additional trim panel 510 can be connected to the trim assembly 500 adjacent thereto around the periphery, for example, to cover other portions or the surroundings of the sheet. Further, an additional trim panel may be provided as described for the trim assembly 400, or may be provided without a barrier layer or other layer as shown in the figures. Additional tie-downs may be provided around or adjacent to the outer periphery of the trim assembly 400 to connect the trim assembly to the sheet 320, for example, along a seam or other joint 512, or at other positions along the outer periphery.

[0289] The trim assembly 500 has a tie-down membrane 520 connected to the trim cover layer 402. In one example, the tie-down membrane 520 is formed from a breathable or porous material, and in the example shown, is formed from a screen or coated mesh. In a non-limiting example, the coated mesh is a glass fiber screen covered with vinyl. In other examples, the tie-down membrane 520 may be formed from a plastic material such as a thermoplastic polyurethane sheet or film, and is perforated or otherwise formed to provide an air flow therethrough.

[0290] The tie-down membrane 520 is connected to the trim cover layer 402. In one example, the tie-down membrane 520 is connected to the joint 406 and / or the overlap 408 of the first and second panels 404. In other examples, the tie-down membrane 520 is connected to a single panel 404 through decorative stitching, adhesion, and / or lamination, for example, in the central region of the panel away from the edge or joint.

[0291] The tie-down film 520 extends outwardly from the B surface of the trim cover layer 402 to the distal end 522. The tie-down film 520 extends between the first and second portions of each porous spacer material layer or through the gap 506 between the stacks 502, 504 to the barrier layer. The tie-down film 520 is disposed between adjacent stacks 502, 504 of the spacer layer 420. Thus, the tie-down film 520 extends to the distal end 522 so as to cross the spacer material layer 420. In one example, and as shown in the figure, the tie-down film 520 extends through the barrier layer 410 to the distal end 522, so that its distal end is located outside the barrier layer, and the barrier layer is located between the distal end and the spacer layer. In other examples, the distal end 522 of the tie-down film may remain inside the barrier layer.

[0292] The tie-down film 520 is connected to the barrier layer 410, for example, adjacent to the distal end 522. The tie-down film 520 may be connected to the barrier layer 410 via any of the techniques described above with respect to joining.

[0293] The distal end 522 of the tie-down film 520 can be used as a tie-down to the cushion and / or frame of the sheet 320, for example, using clips, hog rings, surface fasteners, etc. Beads or apertures for using these attachment functions can be further provided at the distal end of the tie-down film.

[0294] Since the distance between the connection points of the trim cover layer 402 and the barrier layer 410 to the tie-down film 520 forms a tie-down effect or visual appearance with respect to the joint or seam between the panels of the trim assembly, it helps to define the shape of the trim cover layer 402 and the appearance of the trim assembly 500.

[0295] Figure 7 shows a method 600 of forming a trim cover assembly 332 and also provides a method of assembling a trim cover assembly 332 with a seat assembly such as a vehicle seat assembly 320. In various examples, the steps may be performed in other orders, sequentially or simultaneously. Additionally, additional steps may be added and steps may be omitted. Method 600 may be used to form a trim assembly 400 or a trim assembly 500 according to various embodiments.

[0296] In step 602, a port 412 is inserted or formed in a barrier layer 410.

[0297] In step 604, one or more layers 420 of porous spacer material are disposed between a perforated trim cover layer 402 and the barrier layer 410.

[0298] In one example, a first spacer material layer 422 and a second spacer material layer 424 are disposed between the perforated trim cover layer 402 and the barrier layer 410. In a further step, a trench 426 may be formed in the first spacer layer 422 on a face engaging the trim cover layer 402 or on a face facing the trim cover layer 402. The trim cover layer may be formed with a joint 406 between two panels 404. In one example, the joint 406 is a seam, weld, or lamination and there is a butt joint 408 formed by the two panels. The butt joint 408 is disposed in the trench 426 of the spacer layer.

[0299] In another example, a first portion and a second portion of each spacer material layer 420 are disposed between the perforated trim cover layer 402 and the barrier layer 410. The first portions of the spacer layers may be stacked on top of each other in a first stack 502 and the second portions of the spacer layers may be offset from the first stack and stacked on top of each other in a second stack 504 that is non - overlapping with the first stack.

[0300] In step 606, the perforated trim cover layer 402 is connected to the tie-down films 430, 520 with the spacer layer 422 positioned between the trim cover layer 402 and at least a portion of the tie-down film.

[0301] In one example, the tie-down film 430 is laminated under the first spacer material layer 422 and on the side opposite the trench 426. In a further example, the tie-down film 430 is disposed between the first and second spacer material layers 422, 424. The overlap 408 of the trim cover panel is stitched to the tie-down film 430 through the spacer material layer 422 along the trench 426. Thereafter, the first spacer layer 422 and the tie-down film 430 can be connected to the second spacer layer 424 using, for example, adhesion, welding, lamination, or other techniques.

[0302] In another example, the tie-down film 520 extends laterally to the trim cover layer 402 and is disposed to extend between the first and second portions of each spacer material layer or between the stacks 502, 504 to the distal end 522. The tie-down film 520 is connected to the trim cover layer 402 or can be connected, for example, by stitching or other means and through the joint 406 between two panels such as a seam. Alternatively, the tie-down film 520 may be connected through a decorative stitch or seam or through lamination, adhesion, or welding. The tie-down film 520 is also connected to the barrier layer 410. In one example, the distal end 522 of the tie-down film extends outward from the barrier layer 410 such that the barrier layer is positioned between the distal end 522 and the spacer layer 420. The distal end 522 of the tie-down film may then be additionally used as a tie-down for securing the trim assembly to a cushion of a sheet such as a frame and / or sheet 320.

[0303] In step 608, the perforated trim cover layer 402 is connected to the barrier layer 410 to assemble the trim assemblies 400, 500. In one example, the trim cover layer 402 is sewn to the barrier layer 410. The single or plural spacer layers 420 are encapsulated by the trim cover layer and the barrier layer.

[0304] In step 610, the trim assemblies 400, 500 are connected to the frame 322 of the seat assembly. In one example, the trim assemblies 400, 500 may be directly connected to the frame 322 and / or the cushion 340. To connect the trim assembly 332 to the seat 320, various tie-downs such as single or plural tie-downs for the trim assembly 332 may be used, and an additional trim panel 510 may be connected to the seat 320.

[0305] In step 612, the trim assembly is connected to the air system 350 by connecting a fan and / or a pump to the inlet port 412 of the barrier layer 410.

[0306] In step 614, the trim assembly 332 of the seat 320 is ventilated by providing an air flow from the air system 350 to the port 412 of the barrier layer 410, from a fan and / or an air pump of the air system. The air flow is schematically shown by arrows in FIGS. 2 and 5. Since the barrier layer 410 is air-impermeable, air can only exit the trim assembly 332 through the perforated trim cover layer 402. Air flows into the trim assembly 332 and rises through the second and first spacer layers 422, 424 because each layer is porous and breathable. In the case of the trim assembly 400 having the tie-down 430, air generally flows around the tie-down, although there may also be air passing through the tie-down. In the case of the trim assembly 500 having the tie-down 520, air flows laterally within the trim assembly 500 such that air flows into various portions of the spacer layer and through the stacks 502, 504 and into various regions of the trim assembly 500 and may cross the tie-down 520. Note that in either trim assembly, the structure of the porous spacer layer 420 is such that air is dispersed and diffused throughout the trim assemblies 400, 500 and different areas of the trim cover layer 402. The air then flows through the perforated trim cover layer 402 to the seat occupant.

[0307] In other examples, elements such as a heating layer within the trim assembly 332 may be actuated to supply heat from the trim assembly to the seat occupant.

[0308] In one or more embodiments, an assembly (e.g., 400) includes a perforated trim cover layer (e.g., 402), a tie-down film (e.g., 430) (e.g., a reinforcing layer) connected to the trim cover layer (e.g., 402), a barrier layer (e.g., 410) (e.g., a non-permeable layer such as a continuous plastic layer that is non-permeable to air (e.g., a thermoplastic polyurethane sheet or film)) connected to the trim cover layer (e.g., 402), and a porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., a urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) disposed between the trim cover layer (e.g., 402) and the barrier layer (e.g., 410) (e.g., a non-permeable layer such as a continuous plastic layer that is non-permeable to air (e.g., a thermoplastic polyurethane sheet or film)).

[0309] In some embodiments, the porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., a urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) is disposed between the trim cover layer (e.g., 402) and at least a portion of the tie-down film (e.g., 430) (e.g., a reinforcing layer).

[0310] In various embodiments, the assembly (e.g., 400) further includes a ventilation port (e.g., 412) connected to the barrier layer (e.g., 410) (e.g., a non-permeable layer such as a continuous plastic layer that is non-permeable to air (e.g., a thermoplastic polyurethane sheet or film)).

[0311] In one or more embodiments, a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) is surrounded by a trim cover layer (e.g., 402) and a barrier layer (e.g., 410) (e.g., a non-permeable layer such as non-permeable to air (e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film)).

[0312] In various embodiments, the assembly (e.g., 400) includes a second porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer).

[0313] In some embodiments, a second porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) is disposed between a first porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) and a barrier layer (e.g., 410) (e.g., a non-permeable layer such as non-permeable to air (e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film)).

[0314] In one or more embodiments, the first porous spacer material layer (e.g., 420) includes a reticulated foam.

[0315] In various embodiments, the second porous spacer material layer (e.g., 420) includes a spacer fabric.

[0316] In some embodiments, the trim cover layer (e.g., 402) is connected to a barrier layer (e.g., 410) (e.g., a non-permeable layer such as non-permeable to air, e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film) around the outer periphery of the assembly (e.g., 400).

[0317] In one or more embodiments, the assembly (e.g., 400) further includes one or more trim panels (e.g., 404) connected to the assembly (e.g., 400) adjacent to its outer periphery.

[0318] In one or more embodiments, the assembly (e.g., 400) further includes one or more tie-downs (e.g., 400) connected to the assembly (e.g., 400) adjacent to its outer periphery.

[0319] In various embodiments, the assembly (e.g., 400) further includes a perforated heating pad disposed between the trim cover layer (e.g., 401) and the barrier layer (e.g., 410) (e.g., a non-permeable layer such as non-permeable to air, e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film).

[0320] In some embodiments, the perforated trim cover layer (e.g., 402) includes a first panel (e.g., 404) connected to a second panel (e.g., 404) along a joint (e.g., 406) (e.g., a seam) by a lap (e.g., 408) (e.g., the region between the edge and the joint region or seam line in two panels connected together).

[0321] In one or more embodiments, the joint (e.g., 406) includes a seam (e.g., 432).

[0322] In various embodiments, the tie-down membrane (e.g., 430) (e.g., a reinforcing layer) is connected to the joint (e.g., 406) (e.g., a seam) of the first and second panels (e.g., 404) and / or the splice (e.g., 408) (e.g., the region between the edge and the joint area or the stitching line in two panels connected together).

[0323] In some embodiments, a porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric, etc.))) defines a trench (e.g., 426), and the splice (e.g., 408) (e.g., the region between the edge and the joint area or the stitching line in two panels connected together) is received within the trench (e.g., 426).

[0324] In one or more embodiments, the splice (e.g., 408) (e.g., the region between the edge and the joint area or the stitching line in two panels connected together) is sewn to the tie-down membrane (e.g., 430) through a porous spacer material (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric, etc., having other features that allow air to pass through and across the layer))).

[0325] In various embodiments, the tie-down membrane (e.g., 430) (e.g., a reinforcing layer) is connected to the trim cover layer (e.g., 402) via decorative stitching, adhesion, and / or lamination in the central region of the panel, e.g., 404.

[0326] In some embodiments, the perforated trim cover layer (e.g., 402) includes leather, leatherette, vinyl, and / or fabric.

[0327] In one or more embodiments, the barrier layer (e.g., 410) (e.g., a non-permeable layer such as non-permeable to air (e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film)) includes a non-permeable layer.

[0328] In various embodiments, the barrier layer (e.g., 410) includes plastic.

[0329] In some embodiments, a tie-down film (e.g., 430) (e.g., a reinforcing layer) is laminated between a first porous spacer material layer and a second porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer), so that the tie-down film (e.g., 430) (e.g., a reinforcing layer) is separated from the trim cover layer by the first porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer).

[0330] In one or more embodiments, the first spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) and the tie-down film e.g., 430 (e.g., a reinforcing layer) are each connected to a second spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer).

[0331] In various embodiments, a first spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) such as a layer having other features that allow air to pass through and across the layer) and a tie-down membrane (e.g., 430) (e.g., a reinforcing layer) are each connected to a second spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) such as a layer having other features that allow air to pass through and across the layer) via adhesion and / or lamination.

[0332] In some embodiments, the tie-down membrane (e.g., 430) (e.g., a reinforcing layer) includes a non-woven fabric.

[0333] In one or more embodiments, a porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) such as a layer having other features that allow air to pass through and across the layer) includes a first portion and a second portion, and the tie-down membrane (e.g., 430) (e.g., a reinforcing layer) extends to a barrier layer (e.g., 410) (e.g., a non-permeable layer such as non-permeable to air (e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film)) between the first portion and the second portion of the porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) such as a layer having other features that allow air to pass through and across the layer).

[0334] In various embodiments, a second porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) includes a first portion and a second portion, and a tie-down membrane (e.g., 430) (e.g., a reinforcing layer) extends to a barrier layer (e.g., 410) (e.g., a non-permeable layer such as air-impermeable (e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film)) between the first portion and the second portion of the second porous spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer).

[0335] In some embodiments, the tie-down membrane (e.g., 430) (e.g., a reinforcing layer) extends laterally through the spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) and the barrier layer (e.g., 410) (e.g., a non-permeable layer such as air-impermeable (e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film)) to a distal end.

[0336] In one or more embodiments, a barrier layer (e.g., 410) (e.g., a non-permeable layer such as air-impermeable, e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film) is disposed between the distal end of the tie-down membrane 430 (e.g., a reinforcing layer) and a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam such as urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer, such that the distal end of the tie-down membrane (e.g., 430) (e.g., a reinforcing layer) is present outside of the barrier layer (e.g., 410) (e.g., a non-permeable layer such as air-impermeable, e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film).

[0337] In various embodiments, a barrier layer (e.g., 410) (e.g., a non-permeable layer such as a non-permeable layer to air, e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film) is connected to the tie-down membrane (e.g., 430) (e.g., a reinforcing layer).

[0338] In some embodiments, the tie-down membrane (e.g., 430) (e.g., a reinforcing layer) is perforated.

[0339] In one or more embodiments, the tie-down membrane (e.g., 430) (e.g., a reinforcing layer) includes a screen.

[0340] In one or more embodiments, the sheet assembly (e.g., 320) includes a support structure (e.g., 322) such as a frame and an assembly (e.g., 400) supported by the support structure (e.g., 322) (e.g., a frame).

[0341] In various embodiments, the sheet assembly (e.g., 320) further includes a cushion member covered by the assembly (e.g., 400).

[0342] In some embodiments, the assembly (e.g., 400) is connected to the frame and / or cushion members (e.g., 328, 330).

[0343] In various embodiments, the seat assembly (e.g., 400) further includes an air pump (e.g., 352) and / or a fan (e.g., 352) connected to a barrier layer (e.g., 410) (e.g., a non-permeable layer such as air-impermeable, e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film).

[0344] In one or more embodiments, the method (e.g., 460) includes placing one or more layers of porous spacer material (e.g., 420) (e.g., a breathable or perforated layer, or a reticulated foam such as urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric) having other features that allow air to pass through and across the layer) between a perforated trim cover layer (e.g., 402) and a barrier layer (e.g., 410) (e.g., a non-permeable layer such as air-impermeable, e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film) (i.e., step 461), connecting the perforated trim cover layer (e.g., 402) to a tie-down membrane (e.g., 430) (e.g., a reinforcing layer) such that a spacer layer (e.g., 420) (e.g., a breathable or perforated layer, or a reticulated foam such as urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric) having other features that allow air to pass through and across the layer) is disposed between the trim cover layer (e.g., 402) and at least a portion of the tie-down membrane (e.g., 430) (i.e., step 466), and connecting the perforated trim cover layer (e.g., 402) to the barrier layer (e.g., 410) (e.g., a non-permeable layer such as air-impermeable, e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film) to assemble the trim assembly (i.e., step 468).

[0345] In various embodiments, the placing step 461 (i.e., placing one or more spacer layers (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) between a perforated trim cover layer (e.g., 402) and a barrier layer (e.g., 410) (e.g., an impermeable layer such as impermeable to air (e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film)) further includes placing a first spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) and a second spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer) between a perforated trim cover layer (e.g., 402) and a barrier layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer).

[0346] In some embodiments, the method (e.g., 460) further includes forming trenches (e.g., 426) in a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam such as urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric), or other layers having other features that allow air to pass through and across the layer) (i.e., step 462), and placing the overlap (e.g., 408) (e.g., the area between the edges and the joint area or seam line in two panels connected together) of a joint (e.g., 406) (e.g., a seam) between two panels (e.g., 404) of a trim cover layer (e.g., 402) in the trenches (e.g., 426) (i.e., step 463).

[0347] In one or more embodiments, the method (e.g., 460) further includes laminating a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam such as urethane or other foam material or a spacer fabric, such as a knit or mesh spacer fabric, or other layers having other features that allow air to pass through and across the layer) between a tie-down membrane (e.g., 430) (e.g., a reinforcing layer) and the trim cover layer 402 (i.e., step 464), and sewing the overlap (e.g., 408) (e.g., the area between the edges and the joint area or seam line in two panels connected together) to the tie-down membrane 430 (e.g., a reinforcing layer) through the spacer material layer (e.g., 420) (a breathable layer or a perforated layer, or a reticulated foam, such as urethane or other foam material, or a spacer fabric, such as a knit or mesh spacer fabric, or other layers having other features for allowing air to pass through and across the layer) along the trenches (e.g., 426) (e.g., step 466).

[0348] In various embodiments, the placing step 461 (i.e., placing one or more layers of porous spacer material (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that permit air to pass through and across the layer) between a perforated trim cover layer (e.g., 402) and a barrier layer (e.g., 410) (e.g., a non-permeable layer such as air-impermeable (e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film)) further includes placing a first portion and a second portion of the spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that permit air to pass through and across the layer), and placing a tie-down membrane (e.g., 430) (e.g., a reinforcing layer) to extend laterally with respect to the trim cover layer 402 and between the first portion and the second portion of the spacer material layer 420 (e.g., a breathable layer or a perforated layer, or a reticulated foam (e.g., urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that permit air to pass through and across the layer) (i.e., step 465).

[0349] In some embodiments, the method (e.g., 460) further includes connecting a distal end (e.g., 522) to the barrier layer (e.g., 410) (e.g., a non-permeable layer such as air-impermeable (e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film)) (i.e., step 467).

[0350] In one or more embodiments, the method (e.g., 460) further includes connecting a trim assembly (e.g., 500) to the frame of the sheet assembly 320 (i.e., step 469).

[0351] In various embodiments, the method (e.g., 460) further includes placing an inlet port (e.g., 412) in a barrier layer (e.g., 410) (e.g., a non-permeable layer such as non-permeable to air, e.g., a continuous plastic layer such as a thermoplastic polyurethane sheet or film) (i.e., step 470).

[0352] In some embodiments, the method (e.g., 460) further includes connecting a fan and / or a pump (e.g., 352) to the inlet port (e.g., 412) (i.e., step 472).

[0353] In one or more embodiments, the method (e.g., 460) further includes passing an air flow through a spacer material layer (e.g., 420) (e.g., a breathable layer or a perforated layer, or a reticulated foam such as a urethane or other foam material or a spacer fabric (e.g., a knit or mesh spacer fabric)) having other features that allow air to pass through and across the layer, and through a perforated trim cover layer (e.g., 402), to vent the trim assembly (e.g., 400) to the inlet port (e.g., 412) (i.e., step 474).

[0354] In various embodiments, the method (e.g., 460) further includes passing an air flow across a tie-down membrane (e.g., 430) (e.g., a reinforcing layer) (i.e., step 474).

[0355] FIG. 11 shows a vehicle seat assembly 720 according to some embodiments. The vehicle seat assembly 720 is provided with a seat bottom 722 adapted to be mounted to a vehicle floor. The vehicle seat assembly 720 may be provided in any row of the vehicle. The vehicle seat assembly 720 includes a seat back 724 extending upright from the seat bottom 722. The vehicle seat assembly 720 also includes a headrest 726 extending above the seat back 724. The vehicle seat assembly 720 may be employed in any type of vehicle, including land vehicles, water vehicles, aircraft, etc. The vehicle seat assembly 720 may be any seat assembly, such as an office chair, furniture, etc.

[0356] The vehicle seat assembly 720 includes a plurality of adjacent trim cover segments 728, 729 that cover the seat bottom 722, the seat back 724, and the headrest 726 to hide the frame, cushion, and functional components. A seat cushion 730 is provided on the seat bottom 722. The seat cushion 730 may be configured by twisting a thermoplastic plastic mesh or foam.

[0357] FIG. 12 shows a trim cover assembly 731 according to some embodiments. The trim cover assembly 731 is provided with a first trim cover layer 732 and a second fluid-impermeable layer 742 sized to be disposed on the seat cushion 730. The first fluid-impermeable layer 732 may be composed of a cushioning material such as foam. The first fluid-impermeable layer 732 may also be composed of any airtight material or an impermeable polymer material such as polyethylene. According to one embodiment, the first fluid-impermeable layer 732 is sewn to the plurality of adjacent trim cover segments 728, 729. According to some embodiments, the first fluid-impermeable layer 732 is adhered or welded to the plurality of adjacent trim cover segments 728, 729.

[0358] In addition, a seam 736 extending through the first impermeable layer 732 is provided in a plurality of adjacent trim cover segments 728, thereby defining a first zone 738 and a second zone 740. The second fluid impermeable layer 742 can be formed from an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene, etc. According to some embodiments, the first fluid impermeable layer 732 is provided with a plurality of ventilation openings 734 formed to penetrate therethrough. Despite the plurality of ventilation openings 734 being illustrated and described, any number of ventilation openings 734 may be utilized. The ventilation openings 734 direct an air flow through the trim cover assembly 731. The plurality of ventilation openings 734 are optional if the plurality of adjacent trim cover segments 738, 729 are impermeable with through holes formed therein. In addition, the first fluid impermeable layer 732 is thermally insulating.

[0359] The second fluid impermeable layer 742 cooperates with the first fluid impermeable layer 732 to provide a fluid chamber 744 therebetween. The second fluid impermeable layer 742 is provided with a first portion 746 and a second portion 748. The first portion 746 extends through the first zone 738, and the second portion 748 extends through the second zone 740. A first flap 766 is provided in the first portion 746 of the second fluid impermeable layer 742, which extends between the first zone 738 and the second zone 740 and is sewn to form the seam 736. A second flap 768 extending in a direction opposite to the first flap 766 is further provided in the second portion 748 of the second fluid impermeable layer 742 for connection to the seat cushion 730. The second fluid impermeable layer 742 is perforated, for example, along the first flap 766, to allow air to pass through the first zone 738 and the second zone 740.

[0360] Continuing to refer to FIG. 12, the trim cover assembly 731 is further provided with first fluid permeable layers 754, 755 and second fluid permeable layers 756, 757. The fluid permeable layers 754, 755, 756, 757 are formed of an elastic and porous material such as a porous foam, an extruded thermoplastic resin mesh, a woven three-dimensional spacer material. The first fluid permeable layers 754, 755 are displaced along the first fluid impermeable layer 732. The first fluid permeable layers 754, 755 extend through the first zone 38 and the second zone 740 and are separated at the seam 736, and each becomes a first fluid permeable layer portion 754, 755 within one of the zones 738, 740. According to some embodiments, the first fluid permeable layers 754, 755 are sewn to the seam 736. According to some embodiments, the first fluid permeable layers 754, 755 may be laminated and not sewn to the seam 736.

[0361] The second fluid permeable layers 756, 757 are spacer fabrics sized to be received within the fluid chamber 44 and are spaced apart from the first fluid permeable layers 754, 755. The second fluid permeable layers 756, 757 extend through the first zone 738 and the second zone 740 and are separated at the seam 736, and each becomes a second fluid permeable layer portion 756, 757 within one of the zones 738, 740. The second fluid permeable layers 756, 757 are also displaced along the perforated second fluid impermeable layer 742, allowing air to flow through the first zone 738 and the second zone 740. Without the permeable layers 754, 755, 756, 757, the impermeable layers 732, 742 may be compressed when the weight of the occupant is applied, and the air flow may be blocked when using the fan 752. If the trim cover assembly 731 utilizes a compressor as opposed to the fan 752, the permeable layers 754, 755, 756, 757 may be omitted.

[0362] The trim cover assembly 731 is also provided with a heat transfer layer 758 that is displaced along the first fluid-impermeable layer 732 and spaced apart from the second fluid-impermeable layer 742. In some embodiments, the heat transfer layer 758 may be displaced along the trim cover segments 728, 729, or alternatively, may be displaced between the second fluid-permeable layers 756, 757 and the fan 752. In some embodiments, the heat transfer layer 758 may be displaced between the first fluid-permeable layers 754, 755 and the first fluid-impermeable layer 732. A conductive heater mat is provided on the heat transfer layer 758. The trim cover assembly 731 is further provided with outer trim cover segments 728, 729 disposed on the first fluid-impermeable layer 732 and the second fluid-impermeable layer 742. The trim cover segments 728, 729 are perforated so that liquid can pass through the outer trim cover 728. The trim cover segments 728, 729 are also provided with apertures 764 along the seam 736 so that air can pass through the first zone 738 and the second zone 740. Further, the trim cover segments 728, 729 are sewn to the first fluid-impermeable layer 732 without an adhesive. According to some embodiments, the trim layer segments 728, 729 are adhered to the first fluid-impermeable layer 732.

[0363] Referring to FIG. 12, the trim cover assembly 731 is provided with a fluid actuator 750 such as a fan 752. The fluid actuator 750 is directly welded to the second fluid-impermeable layer 742 to seal the connection around the fluid actuator 750 according to some embodiments. The fan 752 is connected to the second fluid-impermeable layer 742 by a retaining ring according to some embodiments. The fan 752 is installed between the trim cover 728 and the seat cushion 730. The seat cushion 730 includes a receptacle sized to receive the fan 752. Conventional fans are installed under the vehicle seat cushion and outside the trim cover assembly. By installing the fan 752 on the seat cushion 730, the fan 752 can be displaced within the trim cover assembly 731.

[0364] Prior art seat assemblies with heating and cooling capabilities often have a fan oriented under the cushion. At this time, fluid ducts are assembled to pass through the cushion and trim cover of a conventional seat assembly. Since the fluid-impermeable layers 732, 742, the permeable layers 754, 755, 756, 757, the heat transfer layer 758, and the fluid actuator 750 are all pre-assembled within the trim cover assembly 731, the trim cover assembly 731 as a whole can be installed on the seat frame. Thereby, the manufacturing cost and time are reduced compared to the prior art.

[0365] The trim cover assembly 731 is operable with a permeable non-foamed sheet cushion 730 formed from a thermoplastic mesh. The second fluid-impermeable layer 742 provides a barrier between the fluid chamber 744 and the sheet cushion 730. When used with the foam cushion 730, the second fluid-impermeable layer 742 may be omitted if the cushion 730 is air-impermeable. In this case, the fluid actuator 750 can be directly welded to the first fluid-impermeable layer 732 to convey fluid through the plurality of vents 734 of the fluid-impermeable layer 732. Alternatively, the fluid actuator 750 may be separated from the trim cover 728.

[0366] FIG. 13 shows a second fluid-impermeable layer 742 according to some embodiments. The second fluid-impermeable layer 742 is provided with a first portion 746 and a second portion 748. The first portion 746 extends through a first zone 738 of the trim cover assembly 731. The second portion 748 extends through a second zone 740 of the trim cover assembly 731. The first portion 746 is further provided with a first flap 766 that extends between the first zone 738 and the second zone 740. In one embodiment, the first flap 766 is perforated to allow air flow between the first zone 738 and the second zone 740. In some embodiments, the first flap 766 may be segmented to allow air flow between the first zone 738 and the second zone 740. The second portion 748 is further provided with a second flap 768 that extends in a direction opposite to the first flap 766, and the second portion 748 is connected to the seat cushion 730. The first portion 746 and the second portion 748 may be fixed by sewing, welding, adhesion, or other means.

[0367] FIG. 14 shows the second fluid-impermeable layer 742 according to some embodiments as a continuous sheet. The second fluid-impermeable layer 742 extends through the first zone 738 and the second zone 740. The second fluid-impermeable layer 742 is provided with a first flap 760 and a second flap 762. The first flap 760 extends between the first zone 738 and the second zone 740. In addition, the first flap 760 is perforated to allow air to pass through the first zone 738 and the second zone 740. The second flap 762 extends in a direction opposite to the first flap 760 and may be attached to the seat cushion 730. The first and second flaps 760, 762 may be sewn, welded, adhered, or otherwise fixed to the second fluid-impermeable layer 742.

[0368] In one or more embodiments, the assembly (e.g., 731) is sized to be disposed on a sheet cushion (e.g., 730) such as a foam or a plied thermoplastic mesh, a first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), a plurality of adjacent trim cover segments (e.g., 728, 729) sewn to the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) to conceal the frame, cushion, and other functional components, and a seam (e.g., 736) extending through the frame, cushion, and other functional components, and the plurality of adjacent trim cover segments (e.g., 728, 729) to conceal the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material such as polyethylene).

[0369] In various embodiments, the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material such as polyethylene) further includes a plurality of vents (e.g., 734) formed therethrough.

[0370] In some embodiments, the seam (e.g., 736) extends through the first impermeable layer (e.g., 732) (e.g., any air-impermeable material or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), thereby defining a first zone (e.g., 738) and a second zone (e.g., 740) of the trim cover segment (e.g., 728).

[0371] In one or more embodiments, the assembly (e.g., 731) further includes a second fluid-impermeable layer (e.g., 742) (e.g., any airtight or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) that cooperates with a first fluid-impermeable layer (e.g., 732), with a fluid chamber (e.g., 744) therebetween.

[0372] In various embodiments, the second fluid-impermeable layer (e.g., 742) (e.g., any airtight or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) further includes a first portion (e.g., 746) that extends through a first zone (e.g., 738) and a second zone (e.g., 740).

[0373] In some embodiments, the second fluid-impermeable layer (e.g., 742) (e.g., any airtight or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) further includes a second portion (e.g., 748) that extends in a direction opposite to the first portion (e.g., 746) for connecting to a sheet cushion (e.g., 730).

[0374] In one or more embodiments, the second fluid-impermeable layer (e.g., 742) (e.g., any airtight or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) is perforated to allow air to pass through the first zone (e.g., 738) and the second zone (e.g., 740).

[0375] In various embodiments, the assembly (e.g., 731) further includes a fluid actuator (e.g., 750) (e.g., a fan) attached to a second fluid-impermeable layer (e.g., 742) (e.g., any airtight or impermeable polymeric material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), and conveys fluid (e.g., air) through a fluid chamber (e.g., 744) and out of a first fluid-impermeable layer (e.g., 732) (e.g., any airtight or impermeable polymeric material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene).

[0376] In some embodiments, the fluid actuator (e.g., 750) (e.g., a fan) further includes a fan attached to one of a first zone (e.g., 738) or a second zone (e.g., 740) to provide fluid communication through the first zone (e.g., 738) and the second zone (e.g., 740).

[0377] In one or more embodiments, the fluid actuator (e.g., 750) (e.g., a fan) conveys air through a first portion (e.g., 746) of a second fluid-impermeable layer (e.g., 740) (e.g., any airtight or impermeable polymeric material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), a fluid chamber (e.g., 744), and a first fluid-impermeable layer (e.g., 733) (e.g., any airtight or impermeable polymeric material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), such that air passes through the second fluid-impermeable layer (e.g., 742) (e.g., any airtight or impermeable polymeric material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) from the first zone (e.g., 738) to the second zone (e.g., 740).

[0378] In various embodiments, the assembly (e.g., 731) further includes a first fluid permeable layer (e.g., 754, 755) (e.g., an elastic porous material such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material) displaced along a first fluid impermeable layer (e.g., 732) (e.g., any airtight or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene).

[0379] In some embodiments, the first fluid permeable layer (e.g., 754, 755) (e.g., an elastic porous material such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material) extends through a first zone (e.g., 738) and a second zone (e.g., 740), and the first fluid permeable layer (e.g., 754, 755) (e.g., an elastic porous material such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material) is sewn to a seam (e.g., 736).

[0380] In one or more embodiments, the assembly (e.g., 731) further includes a second fluid permeable layer (e.g., 756, 757) (e.g., an elastic porous material such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material) sized to be received within a fluid chamber (e.g., 744) and spaced apart from the first fluid permeable layer (e.g., 754, 755) (e.g., an elastic porous material such as a porous foam, an extruded thermoplastic resin mesh, a knitted three-dimensional spacer material).

[0381] In various embodiments, the single or plural fluid impermeable layers (e.g., 732 / 742) are insulating.

[0382] In some embodiments, a plurality of adjacent trim cover segments (e.g., 728, 729) are perforated to allow fluid (e.g., air) to pass through the trim cover segments (e.g., 728, 729).

[0383] In one or more embodiments, an assembly (e.g., 731), a second fluid-impermeable layer (e.g., 742) (e.g., any airtight or impermeable polymeric material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) extends through a first zone (e.g., 738) and a second zone (e.g., 740), and the second fluid-impermeable layer (e.g., 742) (e.g., any airtight or impermeable polymeric material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) further includes a first perforated portion (e.g., 746) that extends to a seam (e.g., 736) of a trim cover segment (e.g., 728, 729), and a second portion (e.g., 748) connected to a seat cushion (e.g., 730) (foam or non-foamed thermoplastic filament mesh).

[0384] In various embodiments, a seat assembly (e.g., 720) includes a seat bottom (e.g., 722), a seat back (e.g., 724) extending in an upright position from the seat bottom (e.g., 722), a seat cushion (e.g., 730) attached to the seat bottom (e.g., 722) or the seat back (e.g., 724), and a trim cover assembly (e.g., 731) disposed over the seat cushion (e.g., 730).

[0385] In some embodiments, the seat cushion (e.g., 730) is fluid-permeable.

[0386] In one or more embodiments, a method (e.g., 770) includes attaching a plurality of adjacent trim cover segments (e.g., 728, 729) to a first fluid-impermeable layer 732 (e.g., any air-impermeable material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene, or an impermeable polymeric material) (i.e., step 772), and sewing a seam (e.g., 736) through the adjacent trim cover segments (e.g., 728, 729) and the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene, or an impermeable polymeric material) to form a first zone (e.g., 738) and a second zone (e.g., 740) (i.e., step 774).

[0387] In various embodiments, the method (e.g., 770) further includes attaching a second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene, or an impermeable polymeric material) (i.e., step 776) (e.g., fixing the first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene, or an impermeable polymeric material) having a perforated first portion (e.g., 746) extending through the first zone (e.g., 738) and the second zone (e.g., 740) in cooperation with the second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene, or an impermeable polymeric material)) by sewing, welding, adhering, or other means.

[0388] In some embodiments, the method (e.g., 770) further includes attaching a fluid actuator (e.g., 750) (e.g., a fan) to the second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene, or an impermeable polymeric material) (i.e., step 778).

[0389] In one or more embodiments, the method (e.g., 770) further includes installing, e.g., at step 780, a first fluid-impermeable layer (e.g., 732) (e.g., any air-impermeable or impermeable polymeric material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), a second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable or impermeable polymeric material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene), and trim cover segments (e.g., 728, 729) onto a pre-assembled sheet assembly (e.g., 720) having a cushion (e.g., 730) (e.g., a foam or a mesh of polymeric yarns) and a frame (e.g., a rigid structure such as steel or aluminum that supports a sub-assembly of the sheet).

[0390] In various embodiments, an assembly (e.g., 731) includes a first fluid-impermeable layer (e.g., 732) sized to be received by a seat cushion (e.g., 730) (e.g., a foam or a non-foamed mesh of polymer yarns), the first fluid-impermeable layer (e.g., 732) being made of any air-impermeable or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), or polyethylene, and having at least one vent formed therethrough. A plurality of adjacent trim cover segments (e.g., 728, 729) are sewn to the first fluid-impermeable layer (e.g., 732) by a seam (e.g., 736) extending through the trim cover segments (e.g., 728, 729) and the first fluid-impermeable layer (e.g., 732) to form a first zone (e.g., 738) and a second zone (e.g., 740). A perforated second fluid-impermeable layer (e.g., 742) made of any air-impermeable or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), or polyethylene cooperates with (e.g., is secured by sewing, welding, adhesion, or other means to) the first fluid-impermeable layer (e.g., 732) to define a fluid chamber (e.g., 744 therebetween. The second fluid-impermeable layer (e.g., 742) has a first portion (e.g., 746) extending vertically therethrough through the first zone (e.g., 738) and the second zone (e.g., 740), and a first fluid-permeable layer (e.g., 754, 755) sized to be received by the first fluid-impermeable layer (e.g., 732) made of any airtight or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), or polyethylene, the first fluid-permeable layer being a porous foam, an extruded thermoplastic resin mesh,An elastic porous material such as a braided three-dimensional spacer material), and a first portion of a second fluid-impermeable layer (e.g., 742) (e.g., any air-impermeable material or impermeable polymer material such as thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) A fluid actuator (e.g., 750) (e.g., a fan) directly attached to (e.g., 746), and a second fluid-permeable layer (e.g., 756, 757) displaced along the first fluid-impermeable layer (e.g., 732) (e.g., thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene) An elastic porous material such as a porous foam, an extruded thermoplastic resin mesh, a braided three-dimensional spacer material), and a heat transfer layer (e.g., 758) (e.g., a conductive heater mat) along the second fluid-permeable layer (e.g., 756, 757) (e.g., a porous foam, an extruded thermoplastic resin mesh, a braided three-dimensional spacer material). A conductive heater mat is provided in the heat transfer layer (e.g., 758). The second fluid-permeable layer (e.g., 756, 757) (e.g., a porous foam, an extruded thermoplastic resin mesh, a braided three-dimensional spacer material) is separated from the first fluid-permeable layer (e.g., 754, 757) (e.g., a porous foam, an extruded thermoplastic resin mesh, a braided three-dimensional spacer material).

[0391] Figure 15 shows a vehicle seat assembly 810 according to some embodiments. The vehicle seat assembly 810 is provided with a seat bottom 812 adapted to be mounted to a vehicle floor. The vehicle seat assembly 810 may be provided in any row of the vehicle. The vehicle seat assembly 810 includes a seat back 814 extending upright from the seat bottom 812. The vehicle seat assembly 810 also includes a headrest 816 extending over the seat back 814. The vehicle seat assembly 810 may be employed in any type of vehicle including land vehicles, water vehicles, aircraft, etc. The vehicle seat assembly 810 may be any seat assembly such as an office chair, furniture, etc.

[0392] The vehicle seat assembly 810 is provided with a trim cover 818 that covers the seat bottom 812, the seat back 814, and the headrest 816 to hide the frame, cushion, and functional components. A seat cushion 820 is provided on the seat bottom 812. The seat cushion 820 may be configured by twisting a thermoplastic plastic mesh or foam.

[0393] FIG. 16 shows a trim cover assembly 822 according to some embodiments. The trim cover assembly 822 is provided with a first trim cover layer 824 and a second fluid-impermeable layer 826 sized to be disposed on the seat cushion 820. The first fluid-impermeable layer 824 may be composed of a cushioning material such as foam. The second fluid-impermeable layer 826 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 824 is provided with a plurality of ventilation openings 836 formed to penetrate therethrough. Despite the plurality of ventilation openings 836 being illustrated and described, any number of ventilation openings 836 may be utilized. The ventilation openings 836 direct an air flow through the trim cover assembly 822. Additionally, the first fluid-impermeable layer 824 is thermally insulating.

[0394] The second fluid-impermeable layer 826 cooperates with the first fluid-impermeable layer 824 to provide a fluid chamber 825 therebetween. The trim cover assembly 822 is further provided with a first fluid-permeable layer 828 and a second fluid-permeable layer 830. The fluid-permeable layers 828, 830 are formed of an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh. The first fluid-permeable layer 828 is sized to be received within the fluid chamber 825 between the first fluid-impermeable layer 824 and the second fluid-impermeable layer 826. The second fluid-permeable layer 830 is displaced along the first fluid-impermeable layer 824 so as to be spaced apart from the first fluid-permeable layer 828. The first fluid-permeable layer 828 and the second fluid-permeable layer 830 ensure that the first fluid-impermeable layer 824 and the second fluid-impermeable layer 826 are not compressed together by the weight of the occupant. Without the permeable layers 828, 830, the impermeable layers 824, 826 may be compressed when the weight of the occupant is applied, and the air flow may be blocked when using the fan 832. If the trim cover assembly 822 utilizes a compressor as opposed to a fan 832, the permeable layers 828, 830 may be omitted.

[0395] The trim cover assembly 822 is also provided with a heat transfer layer 834 that is displaced along the first fluid-impermeable layer 824 and spaced apart from the second fluid-impermeable layer 826. In some embodiments, the heat transfer layer 834 may be displaced along the trim layer 828 or alternatively may be displaced between the second fluid-permeable layer 830 and the fan 832. The heat transfer layer 834 is provided with an electrically conductive heater mat. The trim cover assembly 822 is further provided with an outer trim layer 818 disposed over the first fluid-impermeable layer 824 and the second fluid-impermeable layer 826. The trim layer 818 is perforated so that fluid can pass through the outer trim layer 818. Further, the trim layer 818 is stitched 838 to the first fluid-impermeable layer 824 without an adhesive in some embodiments. According to some embodiments, the trim layer 818 is adhered to the first fluid-impermeable layer 824.

[0396] Continuing to refer to FIG. 16, the trim cover assembly 822 is provided with a fluid actuator 832 such as a fan 832. According to some embodiments, the fluid actuator 832 is directly welded to the second fluid-impermeable layer 826 to seal the connection around the fan 832. The fan 832 is connected to the second fluid-impermeable layer 826 by a retaining ring according to some embodiments. The fan 832 is installed between the trim cover 818 and the seat cushion 820. The seat cushion 820 includes a receptacle sized to receive the fan 832. Conventional fans are installed under the vehicle seat cushion and outside the trim cover assembly. By installing the fan 832 on top of the seat cushion 820, displacement of the fan 832 within the trim cover assembly 822 is allowed.

[0397] Prior art seat assemblies with heating and cooling functions often orient the fan under the cushion. At this time, fluid ducts are assembled to pass through the cushion and trim cover of the conventional seat assembly. Since the fluid-impermeable layers 824, 826, permeable layers 828, 830, heat transfer layer 834, and fluid actuator 832 are all pre-assembled within the trim cover assembly 822, the trim cover assembly 822 as a whole can be installed on the seat frame. This reduces manufacturing costs and time compared to the prior art.

[0398] The trim cover assembly 822 is operable with a permeable non-foamed seat cushion 820 formed from a thermoplastic mesh. The second fluid-impermeable layer 826 provides a barrier between the fluid chamber 825 and the seat cushion 820. When used with a foamed cushion 820, the second fluid-impermeable layer 826 may be omitted if the cushion 820 is air-impermeable. In this case, the fluid actuator 832 may be directly welded to the first fluid-impermeable layer 824 to convey fluid through the vent 836 of the fluid-impermeable layer 824. Alternatively, the fluid actuator 832 may be separated from the trim cover 818.

[0399] Figure 17 shows an external trim layer 818 having a seam 838 along the outer periphery, a first fluid-impermeable layer 824, and a second fluid-impermeable layer 826. The seam 838 seals the layers 818, 824, 826 to prevent air from leaking out of the fluid chamber 825. Alternatively, the layers 818, 824, 826 may be attached or welded with an adhesive, as opposed to using the seam 838.

[0400] In one or more embodiments, the assembly (e.g., 822) is sized to be disposed on top of a sheet cushion (e.g., 820) (e.g., a foam or a non-woven mesh of polymer filaments), and includes a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, or polyethylene) having at least one vent (e.g., 836) formed therein, and a fluid actuator (e.g., 832) such as a fan attached to the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, or polyethylene) to convey fluid (e.g., air) through the vent (e.g., 836) of the first fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, or polyethylene).

[0401] In various embodiments, the assembly (e.g., 822) further includes a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, or polyethylene) that cooperates with the first fluid-impermeable layer (e.g., 824) (e.g., sewn, welded, adhered, or fixed by other means) to provide a fluid chamber (e.g., 825) therebetween.

[0402] In some embodiments, a fluid actuator (e.g., 832) such as a fan is directly attached to a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), and fluid (e.g., air) passes through a fluid chamber (e.g., 825) and then is conveyed out through a vent (e.g., 836) in a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0403] In one or more embodiments, the assembly (e.g., 822) further includes a first fluid-permeable layer (e.g., 828) sized to be received within the fluid chamber (e.g., 825) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh).

[0404] In various embodiments, the assembly (e.g., 822) further includes a second fluid-permeable layer (e.g., 830) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh) displaced along a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) spaced apart from the first fluid-permeable layer (e.g., 828).

[0405] In some embodiments, a fluid actuator (e.g., 832) (e.g., a fan) is directly attached to a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0406] In one or more embodiments, a fluid actuator (e.g., 832) (e.g., a fan) is welded to a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0407] In various embodiments, the assembly (e.g., 822) further includes a heat transfer layer 834 (e.g., a conductive heater mat) displaced along a first fluid-impermeable layer 826 (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) spaced apart from a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0408] In some embodiments, the heat transfer layer (e.g., 834) further includes a conductive heater mat.

[0409] In one or more embodiments, the assembly (e.g., 822) further includes an external trim layer (e.g., 818) disposed over a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0410] In various embodiments, the external trim layer (e.g., 818) is perforated to allow a fluid (e.g., air) to pass through the external trim layer (e.g., 818).

[0411] In some embodiments, the outer trim layer (e.g., 818) is sewn to the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) without an adhesive.

[0412] In one or more embodiments, the fluid actuator (e.g., 832) further includes a fan.

[0413] In various embodiments, the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) is insulating.

[0414] In some embodiments, a plurality of vents (e.g., 836) are formed through the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0415] In one or more embodiments, a seat assembly (e.g., 810) such as for a vehicle includes a seat bottom (e.g., 812), a seat back (e.g., 814) extending in an upright position from the seat bottom (e.g., 812), a seat cushion (e.g., 820) attached to the seat bottom (e.g., 812) or the seat back (e.g., 814), and a trim cover assembly (e.g., 822) disposed on the seat cushion (e.g., 820).

[0416] In various embodiments, the seat cushion (e.g., 820) is fluid-permeable.

[0417] In one or more embodiments, a method (e.g., 840) includes attaching a fluid actuator (e.g., 832) (e.g., a fan) to a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), i.e., step 844; attaching an external trim layer (e.g., 818) over the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), i.e., step 844; and installing the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and the external trim layer 818 over a pre-assembled sheet assembly (e.g., 810) having a cushion (e.g., 820) and a frame, i.e., step 844.

[0418] In various embodiments, the method (e.g., 840) further includes attaching a second fluid-impermeable layer to cooperate with the first fluid-impermeable layer to provide a fluid chamber therebetween, i.e., step 845.

[0419] In one or more embodiments, the assembly (e.g., 822) has a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) sized to be received by a seat cushion (e.g., 820) (e.g., a foam or a non-foam such as a non-woven mesh of polymer filaments). The first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) includes at least one vent (e.g., 836) formed therethrough, a second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) that cooperates with (e.g., is fastened by sewing, welding, adhesion, or other means) the first fluid-impermeable layer, a first fluid-permeable layer (e.g., 828) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh) sized to be received by the first fluid-impermeable layer, a fluid actuator (e.g., 832) (e.g., a fan) directly attached to the second fluid-impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), a second fluid-permeable layer (e.g., 830) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh) displaced along the first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), and a heat transfer layer (e.g., 834) (e.g.,A perforated outer trim layer (e.g., 818) is disposed on a conductive heater mat and a first fluid-impermeable layer (e.g., 824) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and a second impermeable layer (e.g., 826) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), the perforated outer trim layer (e.g., 818) allowing fluid to pass through the outer trim layer (e.g., 818). The conductive heater mat is provided on the heat transfer layer (e.g., 834). The second fluid-permeable layer (e.g., 830) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh) is spaced apart from the first fluid-permeable layer (e.g., 828) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh).

[0420] Figure 18 shows a vehicle seat assembly 910 according to some embodiments. The vehicle seat assembly 910 is provided with a seat bottom 912 adapted to be mounted to a vehicle floor. The vehicle seat assembly 910 may be provided in any row of the vehicle. The vehicle seat assembly 910 includes a seat back 914 extending upright from the seat bottom 912. The vehicle seat assembly 910 also includes a headrest 916 extending over the seat back 914. The vehicle seat assembly 910 may be employed in any type of vehicle including land vehicles, water vehicles, aircraft, etc. The vehicle seat assembly 910 may be any seat assembly such as an office chair, furniture, etc.

[0421] The vehicle seat assembly 910 is provided with a trim cover 918 that covers the seat bottom 912, the seat back 914, and the headrest 916 to conceal the frame, cushion, and functional components. A seat cushion 920 is provided on the seat bottom 912. The seat cushion 920 may be formed by twisting a thermoplastic plastic mesh or foam. The vehicle seat assembly 910 is also provided with a controller and a pump 944. The controller and the pump 944 may be provided in a module under the seat cushion 920 or may be a multifunctional controller that controls other functions within the vehicle.

[0422] FIG. 19 shows a trim cover assembly 922 according to some embodiments. The trim cover assembly 922 is provided with a first trim cover layer 924 and a second fluid-impermeable layer 928 sized to be disposed over the seat cushion 920. The first trim cover layer 924 is referred to as the first fluid-impermeable layer 924. The first fluid-impermeable layer 924 may be composed of a cushioning material such as foam. The second fluid-impermeable layer 928 may be formed from an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, or polyethylene. According to some embodiments, the first fluid-impermeable layer 924 is provided with a plurality of ventilation openings 926 formed therethrough. Despite the plurality of ventilation openings 926 being illustrated and described, any number of ventilation openings 926 may be utilized. The ventilation openings 926 direct an air flow through the trim cover assembly 922. According to some embodiments, if the trim cover 918 has a plurality of holes formed therethrough, the first fluid-impermeable layer 924 and the ventilation openings 926 may be optional. Additionally, the first fluid-impermeable layer 924 is insulating.

[0423] The second fluid-impermeable layer 928 cooperates with the first fluid-impermeable layer 924 to provide a fluid chamber 930 therebetween. The trim cover assembly 922 is further provided with an inflatable bladder assembly 932. The inflatable bladder assembly 932 is, according to some embodiments, supported on the first fluid-impermeable layer 924 and oriented within the fluid chamber 930. According to some embodiments, the inflatable bladder assembly 932 may be displaced outside the fluid chamber 930, such as between the second fluid-impermeable layer 928 and the seat cushion 920.

[0424] The controller 944 is in electrical communication with the pump 944, and the pump 944 is in fluid communication with the inflatable bladder assembly 932 to inflate the assembly 932. The controller 944 is configured to receive an input indicative of a manual adjustment and adjust the inflatable bladder assembly 932 to apply pressure to the occupant.

[0425] The trim cover assembly 922 is further provided with a first fluid-permeable layer 934 and a second fluid-permeable layer 936. The fluid-permeable layers 934, 936 are formed from an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh. The first fluid-permeable layer 934 is sized to be received within the fluid chamber 930 displaced over the inflatable bladder assembly 932. The first fluid-permeable layer and the inflatable bladder assembly 932 are oriented between the first fluid-impermeable layer 924 and the second fluid-impermeable layer 928. Although a plurality of inflatable air bladder assemblies 932 are shown, any number of air bladder assemblies 932 may be present.

[0426] The second fluid permeable layer 936 is displaced along the first fluid impermeable layer 924 so as to be spaced apart from the first fluid permeable layer 934. The first fluid permeable layer 934 and the second fluid permeable layer 936 ensure that the first fluid impermeable layer 924 and the second fluid impermeable layer 928 are not compressed together by the weight of the occupant. Without the permeable layers 934, 936, the impermeable layers 924, 928 may be compressed when the weight of the occupant is applied, and the air flow may be blocked when using the fan 942. When the trim cover assembly 922 utilizes a compressor as opposed to the fan 942, the permeable layers 934, 936 may be omitted.

[0427] The trim cover assembly 922 is also provided with a heat transfer layer 938 that is displaced along the first fluid impermeable layer 924 and spaced apart from the second fluid impermeable layer 928. In some embodiments, the heat transfer layer 938 may be displaced along the trim layer 918, or alternatively, may be displaced between the second fluid permeable layer 928 and the fan 942. In some embodiments, the heat transfer layer 938 may be displaced between the first fluid impermeable layer 924 and the first fluid permeable layer 934. A conductive heater mat is provided in the heat transfer layer 938. The trim cover assembly 922 is further provided with an outer trim layer 918 disposed over the first fluid impermeable layer 924 and the second fluid impermeable layer 928. The trim layer 918 is perforated so that fluid can pass through the outer trim layer 918. Further, the trim layer 918 is sewn to the first fluid impermeable layer 924 without an adhesive in some embodiments. According to some embodiments, the trim layer 918 is adhered to the first fluid impermeable layer 924.

[0428] Continuing to refer to FIG. 19, the trim cover assembly 922 is provided with a fluid actuator 942 such as a fan 940. The fluid actuator 940 is directly welded to the second fluid-impermeable layer 928 so as to seal the connection portion around the fan 942. The fan 942 is connected to the second fluid-impermeable layer 928 by a retaining ring according to some embodiments. The fan 942 is installed between the trim cover 918 and the seat cushion 920. The seat cushion 920 includes a receptacle sized to receive the fan 942. Conventional fans are installed under the vehicle seat cushion and outside the trim cover assembly. By installing the fan 942 on top of the seat cushion 920, the fan 942 can be displaced within the trim cover assembly 922.

[0429] Prior art seat assemblies with heating and cooling functions often orient the fan and massage bladder under the cushion. At this time, fluid ducts are assembled to pass through the cushion and trim cover of the conventional seat assembly. Since the fluid-impermeable layers 924, 928, the permeable layers 934, 936, the heat transfer layer 938, the air bladder assembly 932, and the fluid actuator 940 are all pre-assembled within the trim cover assembly 922, the trim cover assembly 922 as a whole can be attached to the seat frame. This pre-assembly reduces manufacturing costs and time compared to the prior art.

[0430] The trim cover assembly 922 is operable with a permeable non-foamed sheet cushion 920 formed from a thermoplastic mesh. A second fluid-impermeable layer 928 provides a barrier between the fluid chamber 930 and the sheet cushion 920. When utilized with the foam cushion 920, the second fluid-impermeable layer 928 may be omitted if the cushion 920 is air-impermeable. In this case, the fluid actuator 940 may be welded directly to the first fluid-impermeable layer 924 to convey fluid through the vent 926 of the fluid-impermeable layer 924. Alternatively, the fluid actuator 940 may be separated from the trim cover.

[0431] In one or more embodiments, the assembly (e.g., 922) includes a first trim cover layer (e.g., 924) sized to be disposed over the sheet cushion (e.g., 920) and at least one inflatable bladder assembly (e.g., 932) supported on the first trim cover layer (e.g., 924) to apply pressure to an occupant.

[0432] In various embodiments, the first trim cover layer (e.g., 924) is fluid-impermeable.

[0433] In some embodiments, the assembly (e.g., 922) further includes a first fluid-impermeable layer (e.g., 924) (e.g., a cushion material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene, or an impermeable polymer material) that includes at least one vent (e.g., 926) formed therein.

[0434] In one or more embodiments, the assembly (e.g., 922) further comprises a second fluid-impermeable layer (e.g., 928) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) that cooperates with (e.g., is secured by stitching, welding, adhesion, or other means) a first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) to provide a fluid chamber (e.g., 930) therebetween.

[0435] In various embodiments, the assembly (e.g., 922) further comprises a second fluid actuator (e.g., 940), such as a fan, that is directly attached to a second fluid-impermeable layer (e.g., 928) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0436] In some embodiments, the second fluid actuator (e.g., 940) (e.g., a fan) is welded to a second fluid-impermeable layer (e.g., 928) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0437] In one or more embodiments, the second fluid actuator (e.g., 940) further comprises a fan.

[0438] In various embodiments, at least one inflatable bladder assembly (e.g., 932) is oriented within the fluid chamber (e.g., 930).

[0439] In some embodiments, the assembly (e.g., 922) further includes a first fluid permeable layer (e.g., 934) sized to be received within a fluid chamber (e.g., 930) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh), and the first fluid permeable layer (e.g., 934) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh) is displaced over the inflatable bladder assembly (e.g., 932).

[0440] In one or more embodiments, the assembly (e.g., 922) further includes a second fluid permeable layer (e.g., 936) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh) displaced along a first fluid impermeable layer (e.g., 924) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and spaced apart from the first fluid permeable layer (e.g., 934) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh).

[0441] In various embodiments, the assembly (e.g., 922) further includes a heat transfer layer (e.g., 938) (e.g., a conductive heater mat) displaced along a first fluid impermeable layer spaced apart from a second fluid impermeable layer (e.g., 924) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0442] In some embodiments, the heat transfer layer (e.g., 938) further includes a conductive heater mat.

[0443] In one or more embodiments, the assembly (e.g., 922) includes an outer trim layer (e.g., 918) disposed over a first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and a second fluid-impermeable layer (e.g., 926) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), and the outer trim layer (e.g., 918) is perforated to allow fluid to pass through the outer trim layer (e.g., 918).

[0444] In one or more embodiments, the outer trim layer (e.g., 918) is sewn to the first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) without an adhesive.

[0445] In various embodiments, the assembly (e.g., 922) further includes a controller (e.g., 944) in electrical communication with at least one inflatable bladder assembly (e.g., 932) configured to receive an input indicative of a manual adjustment and adjust the at least one inflatable bladder assembly (e.g., 932) to apply pressure to an occupant.

[0446] In various embodiments, the first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) is insulating.

[0447] In some embodiments, a plurality of vents (e.g., 926) are formed through the first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymeric material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene).

[0448] In one or more embodiments, at least one inflatable air bladder assembly (e.g., 932) further includes a plurality of inflatable air bladder assemblies (e.g., 932) housed within a fluid chamber (e.g., 930).

[0449] In various embodiments, a seat assembly (e.g., 910) includes a seat bottom (e.g., 912), a seat back (e.g., 914) extending in an upright position from the seat bottom (e.g., 912), a seat cushion (e.g., 920) attached to the seat bottom (e.g., 912) or the seat back (e.g., 914), and an assembly (e.g., 922) disposed on the seat cushion (e.g., 920).

[0450] In some embodiments, the seat cushion (e.g., 920) is fluid permeable.

[0451] In one or more embodiments, a method (e.g., 950) includes installing (i.e., 952) a first trim cover layer (e.g., 918) sized to be disposed on a seat cushion (e.g., 920), and installing (i.e., 954) at least one inflatable bladder assembly (e.g., 932) supported on the first trim cover layer 918 to apply pressure to an occupant.

[0452] In various embodiments, the assembly (e.g., 922) is sized to be received by the seat cushion (e.g., 920) and includes an insulating first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), the first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) having at least one vent (e.g., 926) formed therethrough, a second fluid-impermeable layer (e.g., 928) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) that cooperates with (e.g., is fastened by sewing, welding, adhesion, or other means) the first fluid-impermeable layer (e.g., 924), a fluid actuator (e.g., 940) (e.g., a fan) directly attached to the second fluid-impermeable layer (e.g., 928) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), at least one inflatable bladder assembly (e.g., 932) oriented within the fluid chamber (e.g., 930) to apply pressure to the occupant and supported on the first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), a first fluid-permeable layer (e.g., 934) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh) displaced over the inflatable bladder assembly (e.g., 932), a second fluid-permeable layer (e.g., 936) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh) displaced along the first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), the second fluid-permeable layer (e.g., 936) (e.g.,A heat transfer layer (e.g., 938) (e.g., a conductive heater mat) disposed along an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh, and a first fluid-impermeable layer (e.g., 924) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene) and a perforated outer trim layer (e.g., 918) disposed on a second impermeable layer (e.g., 926) (e.g., an impermeable polymer material such as a thermoplastic polyurethane (TPU) film, a polyvinyl chloride (PVC) film, polyethylene), the perforated outer trim layer (e.g., 918) being configured to allow fluid to pass through the outer trim layer (e.g., 918). A second fluid-permeable layer (e.g., 936) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh) is spaced apart from a first fluid-permeable layer (e.g., 934) (e.g., an elastic porous material such as a porous foam or an extruded thermoplastic resin mesh). The heat transfer layer (e.g., 938) is provided with a conductive heater mat.,

[0453] FIG. 20 shows a seat assembly 1020 according to some embodiments. The seat assembly 1020 is depicted as a vehicle seat assembly 1020. The seat assembly 1020 can be used in any vehicle, such as a land vehicle, an aircraft, a water bike, etc. Although a vehicle seat assembly 1020 is disclosed, any seat assembly 1020, such as an office chair, can be implemented.,

[0454] The seat assembly 1020 includes a seat bottom assembly 1022 adapted to be attached to a vehicle floor. The seat bottom assembly 1022 is sized to receive and support the pelvis and thighs of an occupant seated on the seat bottom assembly 1022. A seat back assembly 1024 extends in an upright direction from the seat bottom assembly 1022. The seat back assembly 1024 is sized to receive and support the back of a seated occupant. A headrest assembly 1026 extends above the seat back assembly 1024 and supports the head of a seated occupant.,

[0455] The seatback assembly 1024 includes a seat support member of cushion material such as a cushion 1028, and provides support adapted to the occupant. The cushion 1028 is formed from a cushion material such as polyurethane foam and is structured to be sufficient to support the occupant while also providing comfort to the occupant. The cushion 1028 includes a central region 1030 sized to support the occupant's lumbar and chest regions. A pair of bolsters 1032 each extend laterally outward from the central region 1030, forward from the central region 1030, and in the fore-aft direction so as to provide lateral support to the occupant's lumbar and chest. The cushion 1028 also includes a shoulder region 1034 that extends above and slightly forward of the central region 1030 to receive and support the occupant's shoulders. At the front surface of the cushion 1028, the central region 1030, the bolsters 1032, and the shoulder region 1034 collectively provide a support surface 1036 for occupant contact and support.

[0456] Referring now to FIGS. 20 and 21, the seat assembly 1020 includes a local pressure assembly such as a massage assembly 1038 for imparting a local pressure effect such as a massage effect to a seated occupant. To impart a massage effect to various regions or zones within the seat assembly 1020, the massage assembly 1038 includes a plurality of local pressure devices such as massage devices 1040 each disposed in one of a plurality of zones along the central region 1030 of the cushion 1028. The massage devices 1040 are oriented to the central region 1030, but the massage devices 1040 can be utilized in any region of the seat assembly 1020. Although massage devices are illustrated and described, any local pressure device such as a tactile device, lumbar adjustment, bolster adjustment, shoulder adjustment, etc. may be used.

[0457] As shown in FIG. 21, the massage device 1040 is oriented on the rear surface 1042 of the seat cushion 1028. The rear surface 1042 of the seat cushion 1028 is sized to be spaced from the support surface 1036 and mounted to the frame or other structural support of the seat assembly 1020. The seat cushion 1028 may also have a concave back surface 1042 to partially enclose and hide the massage device 1040 and other functional or structural components of the seat assembly 1020.

[0458] In the illustrated embodiment, the massage device 1040 is an inflatable air bladder 1040. For that purpose, the seat assembly 1020 includes a pump and valve bank 1044 that fluidly cooperates with each of the air bladders 1040 to inflate and deflate the air bladders 1040. The seat assembly 1020 or the vehicle includes a controller 1046 that communicates with the pump and valve 1044 to control the operation of the pump and valve 1044.

[0459] In the prior art, seat assemblies having massage assemblies have been provided. Prior art massage assemblies often include a massage device oriented on the support surface of the seat cushion. By placing the massage device on the front surface, the massage effect can be directly transmitted to the occupant. However, placing the massage device on the support surface often requires assembling the massage assembly through the seat cushion. For example, the massage device is drawn out from an aperture in the seat cushion to be connected to a pneumatic air source or a power source, and pneumatic tubes or wiring extend through the cushion to reach the rear surface of the seat cushion. Orienting the massage device on the support surface adds complexity, manufacturing time, and cost to prior art massage assemblies.

[0460] Typically, in the prior art, it is avoided to dispose the massage device 1040 on the rear surface 1042 of the seat cushion 1028. In the prior art seat cushion, due to the operation of the massage device, the foam of the seat cushion is compressed before applying a detectable pressure to the occupant, so the massage effect is essentially attenuated. In addition, the massage effect from the rear surface of the cushion is often dispersed over the entire support surface of the seat cushion. To displace the support surface of the prior art seat cushion, it is often necessary to displace the entire support surface, resulting in a "tent-like" effect of the cushion.

[0461] To effectively impart an effective massage effect from the rear surface 1042 of the seat cushion 1028, a plurality of movable parts or joint parts 1048 are formed in the seat cushion 1028. The movable part 1048 is translatable with respect to the rest of the seat cushion 1028 by a weakened area 1050 formed between the movable part 1048 and the seat cushion 1028. The weakened area 1050 partially separates the movable part 1048 from the central area 1030 so as to allow the translation of the movable part 1048 while maintaining the connection between the movable part 1048 and the seat cushion 1028. The movable part 1048 may be formed of a material different from that of the seat cushion 1028 so as to be suitable for the applied function. For example, while the seat cushion 1028 can be formed from a foam such as polyurethane, the movable part 1048 can include compression fibers or other materials for elasticity as a joint movement device. The additional material of the movable part 1048 may be insert-molded into the foam of the movable part 1048.

[0462] The seat assembly 1020 includes a trim cover 1060 that covers the seat cushion 1028 to conceal the cushion 1028 and the massage assembly 1038. According to various embodiments, a comfort layer, a spacer fabric, an open-cell foam, a dense material, or any suitable material may be provided between the trim cover 1060 and the seat cushion 1028.

[0463] One of the plurality of movable parts 1048 is shown in detail in FIGS. 22 through 24. FIGS. 23 and 24 show that the seat cushion 1028 is attached to the seat frame 1058. The seat frame 1058 may be formed from stamped steel, a polymer substrate, or any suitable material. The massage device 1040 is oriented between the movable part and the seat frame 1058. The massage device 1040 may be adhered to the rear surface of the movable part 1048 by an adhesive. Since the seat frame 1058 has sufficient elasticity to provide a reaction force to the actuator 1040, the massage effect is efficiently distributed to the movable part 1048 by the concentrated energy and displacement.

[0464] FIGS. 22 through 24 show that the overall shape of the movable part 1048 is defined by the weakened region 1050. The movable part 1048 is sized to correspond to the shape of an actuator such as the massage bladder 1040. The weakened region 1050 includes a pair of slots 1052 formed to penetrate the seat support surface 1036. The slots 1052 collectively extend to surround most of the outer periphery of the movable part 1048. The slots 1052 also define a pair of tethers 1054 between the movable part 1048 and the remaining portion of the seat support surface 1036 of the seat cushion 1028. The tethers 1054 are sized to connect the movable part 1048 to be relatively movable with respect to the seat support surface 1036. Although one tether 1054 is shown, the quantity and orientation of the tethers 1054 are arbitrary.

[0465] The weakened area 1050 also includes a recess 1056 formed in the rear surface 1042 of the seat cushion 1028. The recess 1056 is formed to a blind depth as shown in FIG. 24 such that the tether 1054 has a reduced thickness relative to the movable portion 1048 and the central region 1030. The recess 1056 extends around the outer periphery of the movable portion 1048 and intersects the slot 1052. According to some embodiments, the weakened area 1050 may be provided with a recess 1056 formed around the outer periphery of the movable portion 1048 without the slot 1052 such that the tether 1054 extends around the outer periphery of the movable portion 1048 as a web. The weakened area 1050 may be formed in the seat cushion 1028 by any forming operation of the seat cushion 1028 such as a molding operation.

[0466] According to some embodiments, the tether 1054 may be sized to be sheared after an initial operation of the massage device 1040. For example, the tether 1054 may be sized to maintain the position and orientation of the movable portion 1048 until the movable portion 1048 is adhered to the massage device 1040. Thereafter, after several cycles of the massage device 1040, the tether 1054 is torn and translational movement of the movable portion 1048 without the tether is allowed, so that the movement performance can be further improved.

[0467] As shown in FIG. 25, the movable portions 1048 are each individually translatable in the longitudinal direction of the vehicle seat assembly 1020. The movable portions 1048 enhance the massage effect by effectively distributing the pressure and energy from the massage device 1040 to the movable portions 1048 and the occupant in a state of enhanced strength compared to the prior art.

[0468] Referring now to FIGS. 20 through 25, the massage assembly 1038 simplifies the manufacturing process of the massage assembly while minimizing the overall number of parts. The massage assembly 1038 also minimizes energy loss by allowing the foam massage points 1048 to articulate back and forth with respect to a seated occupant. The massage device 1040 and associated components such as tubes and connectors are installed on the rear surface 1042 of the seat cushion 1028 without being connected through the foam of the seat cushion 1028. By disposing the massage device 1040 on the rear surface 1042, the massage assembly 1038 can be pre-assembled by installation onto the frame 1058.

[0469] FIG. 26 shows a seat cushion 1062 according to some embodiments. The seat cushion 1062 is similar to the previous embodiments. The seat cushion 1062 also includes a reinforcement portion 1064 on the front surface of each movable portion 1048. The reinforcement portion 1064 can embody the entire movable portion 1048. The reinforcement portion 1064 can even embody the tether 1054 according to the displacement specifications of a particular application. The reinforcement portion 1064 is hard to enhance the efficiency of transmitting energy from the massage device 1040 to the occupant during massage operation by alleviating the attenuation and dissipation of the massage effect, and as a result, may be formed from a foam having a higher hardness than the remaining portion of the seat cushion 1028 to provide a hard surface.

[0470] The reinforcement portion 1064 may be formed from a high density or durometer foam that is molded separately from the remaining portion of the seat cushion 1028. The reinforcement portion 1064 may be molded separately as a unit and then insert molded with a soft foam with respect to the remaining portion of the seat cushion 1028. Alternatively, the reinforcement portion 1064 and the seat cushion 1028 may be molded together in a common mold in a multi-step process.

[0471] A vehicle seat assembly (e.g., 1020) is provided that includes a support member (e.g., a panel, substrate, or frame) for supporting a cushion (e.g., 1028) that includes a cushioning material such as a polyurethane foam. The support member defines a support surface (e.g., 1036) sized to support an occupant and includes a weakened region (e.g., 1050), such as a pair of slots 1052 formed through the support surface 1036. The weakened portion (e.g., 1050) provides a movable portion (e.g., 1048). The movable portion (e.g., 1048) may be formed from a material different from the cushioning material and translate relative to the seat support surface (e.g., 1036) (e.g., the movable portion 1048 is formed from compressed fibers while the cushioning material is a polyurethane foam). In various embodiments, the translation is due to a local pressure effect such as a massage effect from a pressurized bladder or the like applied to the rear surface of the movable portion (e.g., 1048) from a local pressure device (e.g., massage device 1040). The local pressure device (e.g., massage device 1040) is provided on the rear surface of the support of the cushioning material. In one or more embodiments, the rear surface (e.g., 1042) of the cushion (e.g., 1028) is spaced from the seat support surface (e.g., 1036).

[0472] In a variant, the weakened region (e.g., 1050), such as a pair of slots 1052 formed through the support surface 1036, extends around the outer periphery of the movable portion (e.g., 1048) (e.g., around most of the outer periphery). In various embodiments, the weakened region (e.g., 1050) is defined as a recess (e.g., 1056) formed in the support member to partially separate the movable portion (e.g., 1048) from the support surface (e.g., 1036). In some embodiments, the recess (e.g., 1056) is formed to pass through the support member. In one or more embodiments, the recess (e.g., 1056) is formed to a blind depth having a tether (e.g., 1054) in the weakened region (e.g., 1050). In various embodiments, the weakened region (e.g., 1050) is defined as a plurality of recesses formed in the support member to partially separate the movable portion (e.g., 1048) from the rest of the support member.

[0473] In one or more embodiments, the support member includes at least one tether (e.g., 1054) that connects a movable portion (e.g., 1048) and a seat support surface (e.g., 1036). In a variant, the seat support surface (e.g., 1036) has a first thickness and the tether has a second thickness that is less than the first thickness. In some embodiments, at least one tether (e.g., 1054) is sized to tear during initial operation to allow translation of the movable portion (e.g., 1048) without a tether.

[0474] In one or more embodiments, the movable portion (e.g., 1048) is reinforced relative to the seat support surface (e.g., 1036) by being formed from compression fibers, instead of polyurethane foam, or instead of a foam with high hardness, high density, or high resiliency, to disperse the local pressure effect imparted from a local pressure device (e.g., a massage device such as a fluid bladder (e.g., an air bladder)) to a reinforcement portion (e.g., 1064). For example, the support member is formed with a first hardness and the movable portion (e.g., 1048) is formed with a second hardness that is greater than the first hardness.

[0475] A local pressure assembly (e.g., massage assembly 1038) is provided for imparting a local pressure effect, such as a massage effect, to a seated occupant. The local pressure assembly (e.g., massage assembly 1038) includes a local pressure device (e.g., massage device 1040) and the support member described herein that includes a weakening region (e.g., 1050), a movable portion (e.g., 1048), a tether (e.g., 1054), and / or a reinforcement portion (e.g., 1064).

[0476] In various embodiments, the local pressure device (e.g., massage device 1040) includes an inflatable air bladder.

[0477] A seat assembly (e.g., 1020) will be described. The seat assembly (e.g., 1020) includes a seat frame (e.g., 1058) (such as a rigid material (e.g., metal, plastic, wood, or a combination thereof)), a local pressure device (e.g., massage device 1040) provided on the seat frame (e.g., 1058), and a support member (e.g., including weakened region 1050, movable part 1048, tether 1054, and / or reinforcement part 1064 in this specification) provided on the seat frame (e.g., 1058), and the support member on which the local pressure device (e.g., massage device 1040) is installed on the seat frame (e.g., 1058) in a state aligned with the movable part 1048.

[0478] A support member (e.g., a panel, substrate, or frame) of a cushion (e.g., 1028) including a cushioning material (e.g., polyurethane foam) is provided. The support member provides a seat support surface (e.g., 1036) sized to support an occupant, and includes a reinforcement part (e.g., 1064) (e.g., compressed fibers, or a foam with a greater hardness, stiffness, and / or density) within the seat support surface (e.g., 1036) to disperse the local pressure effect (e.g., massage effect) applied from the local pressure device (e.g., massage device 1040) to the reinforcement part (e.g., 1064).

[0479] In one or more embodiments, the support member is formed with a first hardness, and the reinforcement part (e.g., 1064) is formed with a second hardness greater than the first hardness.

[0480] A local pressure assembly (e.g., massage assembly 1038) is provided, which includes a local pressure device (e.g., massage device 1040) and the support member described herein.

[0481] A seat assembly is also provided that includes a seat frame (e.g., 1058 (e.g., a rigid material such as metal, plastic, wood, or a combination thereof)), a local pressure device (e.g., massage device 1040) provided on the seat frame (e.g., 1058), and the support member described herein installed on the seat frame (e.g., 1058) with the local pressure device (e.g., massage device 1040) aligned with a reinforcing portion (e.g., 1064).

[0482] In one or more embodiments, a seat support member of cushioning material (e.g., polyurethane foam) is provided. The seat support member includes a seat support surface (e.g., 1036) sized to support an occupant. The seat support surface (e.g., 1036) also includes a plurality of recesses formed through the seat support surface (e.g., 1036) and extending partially around the outer periphery of a movable portion (e.g., 1048 (e.g., compressed fibers or a foam with high hardness, stiffness, and / or density)). The plurality of recesses permit translation resulting from a local pressure effect (e.g., a massage effect) applied from the local pressure device (e.g., massage device 1040) to the movable portion (e.g., 1048). The support member is formed with a first hardness and the movable portion (e.g., 1048) is formed with a second hardness greater than the first hardness. Specifically, the seat support surface (e.g., 1036) has a first thickness. In some embodiments, the seat support member of cushioning material includes at least one tether connecting the movable portion and the seat support surface, and the tether has a second thickness smaller than the first thickness. The support member is formed with a first hardness and the movable portion is formed with a second hardness greater than the first hardness.

[0483] FIG. 27 shows a seat system 1120 according to some embodiments. The seat system 1120 is a vehicle seat system 1120 for a land vehicle, a water bike, an aircraft, etc. The seat system 1120 may also be a seat system 1120 such as a comfort chair, an office chair, etc. In a vehicle environment, the seat system 1120 may be a front row seat system 1120, or a subsequent middle row or rear row seat system 1120.

[0484] The seat system 1120 includes a seat bottom 1122 sized to support the occupant's pelvis and thighs. The seat bottom 1122 is adapted to be mounted to the vehicle floor. The seat back 1124 extends in an upright direction from the seat bottom 1122. The seat back 1124 is sized to receive and support the occupant's back. The seat back 1124 may be supported by the seat bottom 1122 or a support surface thereunder. A headrest 1126 for supporting the occupant's head is also provided on the seat back 1124.

[0485] The seat system 1120 provides contact surfaces 1128, 1130 for receiving and comfortably supporting the occupant. The seat system 1120 includes at least one actuator assembly 1132 provided within the seat system 1120 within the contact surfaces 1128, 1130. Although one actuator assembly 1132 is shown and described, any number or location of actuator assemblies 1132 may be used. The actuator assembly 1132 may be utilized to impart tactile effects to the occupant such as vibrations to convey an alert, vibrations to impart a massage, pressure to impart a pressure massage effect, support to the occupant, etc.

[0486] In the depicted embodiment, the actuator assembly 1132 is a fluid bladder 1132 such as an air bladder 1132. The fluid bladder 1132 is for imparting a pressure massage effect to the occupant. The fluid bladder 1132 is also disposed in the side bolster 1134 of the seat back 1124 and can provide adjustable support to the occupant.

[0487] Seat system 1120 includes a valve assembly 1136 that is in fluid communication with a fluid bladder 1132. A pump 1138, such as a compressor, is in fluid communication with the valve assembly 1136 to provide a source of pressurized fluid, such as compressed air, to the valve assembly 1136. Any number of pumps 1138 and electric valves 1136 may be used. Alternatively, a plurality of pumps 1138 may be used without using any electric valves 1136.

[0488] Controller 1140 is in electrical communication with pump 1138 and operates pump 1138 to generate a source of pressurized air. Controller 1140 is also in electrical communication with valve assembly 1136 to control valve assembly 1136 and regulate the flow of pressurized air to valve assembly 1136. Valve assembly 1136 is housed within seat back 1124 or seat bottom 1122 of seat system 1120. Controller 1140 is housed within the vehicle and, in some embodiments, is housed within seat back 1124 or seat bottom 1122.

[0489] System 1120 also includes an interface 1142 that is in electrical communication with controller 1140. Interface 1142 receives a manual selection of a massage effect. Interface 1142 communicates a massage request to controller 1140. Interface 1142 may be a mechanical selector switch or a plurality of switches. Interface 1142 may also be another human machine interface, such as a graphical user interface, for a passenger to select a massage effect. Interface 1142 may be incorporated into seat system 1120 or may be provided at another location within the vehicle. Interface 1142 may be integrated with controller 1140.

[0490] The controller 1140 is programmed such that the massage assembly 1132 is initially deactivated. Thus, the massage assembly 1132 is initially inoperable without being activated. The operation of the massage assembly 1132 can be activated as a service, incentive, subscription, promotion, or other marketing or retail effort. For example, the hardware of the massage assembly 1132 is installed in the seat system 1120, but it will not become operable until after activation of the operation.

[0491] The activation code may be provided by a software application accessible by a personal digital assistant (PDA) 1144 such as a smartphone. The PDA 1144 can be any controller configured to receive the activation code and transmit the code to the controller 1140. The PDA 1144 communicates wirelessly with a receiver 1146 in the vehicle or seat system 1120, and the receiver 1146 communicates with the controller 1140. For example, the occupant may install an application configured with the activation code on the PDA 1144. The occupant may subscribe to the service or access the activation code. The activation code is transmitted to the controller 1140 to activate or unlock the operation of the massage assembly 1132. The interface 42 may be provided in the software application along with the activation code of the PDA 1144.

[0492] Alternatively, the massage operation may be an option of the vehicle package. For example, a manufacturer, dealer, or other retailer may activate the massage operation based on the purchased vehicle package.

[0493] FIG. 28 shows a massage assembly 1148 that can be installed as a massage assembly 1132 in a seat system 1120. The massage assembly 1148 includes a pair of lumbar bladders 1150 that are oriented in the lumbar region of the seat surface 1130 and impart a pressure massage effect to the occupant. A valve assembly 1152 is in fluid communication with the lumbar bladders 1150 and a pump 1154, and sends pressurized air from the pump 1154 through the valve assembly 1152 to the lumbar bladders 1150. According to some embodiments, the massage assembly 1148 provides one massage effect, such as inflation and contraction of the lumbar bladders 1150. Alternatively, the massage assembly 1148 can provide multiple massage effects by means of additional valves or additional massage programs.

[0494] FIG. 29 shows an example of how the massage assembly 1148 in the seat system 1120 operates. At block 1156, the controller determines whether the massage is approved, such as when receiving an activation code from the PDA 1144. If the massage operation is not approved, block 1156 is repeated. If the massage is approved, block 1158 determines whether the massage operation was requested by a selection at the interface 42. If the massage effect is not requested, block 1158 is repeated. If the massage effect is requested, the massage operation is executed at block 1160.

[0495] Figure 30 shows a massage assembly 1162 according to some embodiments. The massage assembly 1162 is shown to be mounted to a suspension 1164 that supports the massage assembly 1162 for installation to a seat frame. The massage assembly 1162 includes a plurality of inflatable air bladders. These inflatable air bladders include a lumbar bladder 1166, an array of increasingly spaced air bladders 1168, a neck bladder 1170, and a pair of side bolster air bladders 1172. Each of these air bladders 1166, 1168, 1170, 1172 may be individually inflatable to support an occupant. Each of the air bladders 1166, 1168, 1170, 1172 may also be individually inflatable or may be inflatable in groups to perform a plurality of massage effects.

[0496] With various massage options, the massage assembly 1162 can provide a plurality of massage effects by the operation of the air bladders 1166, 1168, 1170, 1172, and / or various combinations of their various patterns. By providing a plurality of massage effects, various subscriptions or trim level options can be provided to an end user to obtain various authorization codes.

[0497] Figure 31 shows a method of operating a massage assembly, such as massage assembly 1162, that provides at least two massage effects. At block 1174, the controller determines whether the first massage is approved. If not, the determination at block 1174 is repeated. When the first massage is approved, the controller determines at block 1176 whether the second massage effect is approved. If the second massage effect is not approved, at block 1178, the controller determines whether the first massage effect is requested. If not, block 1176 is repeated. If the first massage effect is requested at block 1178, the first massage operation is executed at block 1180. The next block 1176 is repeated.

[0498] At step 1176, if the second massage is approved, block 1182 determines whether the first massage effect is requested. If the first massage effect is requested, the first massage operation is executed at step 1184. The next block 1182 is repeated. If the first massage effect is not requested at block 1182, step 1186 is executed to determine whether the second massage effect is requested. If the second massage effect is requested at block 1186, the second massage operation is executed at step 1188.

[0499] In one or more embodiments, an assembly (e.g., 1132 / 1134) (e.g., including a pair of lumbar bladders 1150) is described. The assembly (e.g., 1132 / 1134) includes a massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including, but not limited to, a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154) operable to impart a massage effect (e.g., a pressure massage effect or a vibration massage effect) to a seat assembly, and a controller (e.g., 1140) in communication with the massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including, but not limited to, a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154). In various embodiments, the controller (e.g., 1140) is provided as one or more controllers or control modules for various components and systems. The controller (e.g., 1140) and control system may include any number of controllers and may be integrated into a single controller or may have various modules. Some or all of the controller may be connected by 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. Further, any one or more of the electrical devices disclosed herein may be configured to execute a computer program embodied on a non-transitory computer-readable medium programmed to perform any number of functions as disclosed herein.In various embodiments, a controller (e.g., 1140) receives an input indicating approval, such as an approval code, to operate a massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including, but not limited to, a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and a pump 1138 / 1154), receives an input indicating a massage request (e.g., a manual selection of a massage effect such as on an interface), and in response to the approval (e.g., approval code) and the massage request (e.g., a manual selection of a massage effect such as on an interface), is programmed to output a signal to operate the massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including, but not limited to, a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and a pump 1138 / 1154).

[0500] Specifically, a massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including but not limited to a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154) is operable to provide at least two massage effects (e.g., a pressurized tactile effect and a vibrating tactile effect), and a controller 1140 is configured to provide a first massage effect (e.g., a pressurized massage or a vibrating massage) in response to an approval of the first massage effect (e.g., an approval code) and a request for the first massage effect (e.g., a manual selection of an interface). The controller 1140 receives an input (e.g., an approval code) indicating approval to operate a first massage effect (e.g., a pressurized massage) of the massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including but not limited to a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154), receives an input indicating a request for the first massage effect (e.g., a manual selection in an interface), and is programmed to output a first massage effect signal to operate the massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including but not limited to a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154).

[0501] In some embodiments, the controller (e.g., 1140) is configured to operate a second massage effect (e.g., a pressurized massage or a vibrating massage) of a massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including, but not limited to, a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154) in response to an approval of the second massage effect (e.g., an approval code) and a request for the second massage effect (e.g., a manual selection at an interface) by receiving an input (e.g., an approval code) indicating approval to operate the second massage effect (e.g., a pressurized massage) of the massage actuator (e.g., 1148), receiving an input indicating a request for the second massage effect (e.g., a pressurized massage or a vibrating massage) (e.g., a manual selection at an interface), and outputting a second massage effect signal to operate the massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including, but not limited to, a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154).

[0502] In some embodiments, the massage actuator (e.g., 1148) includes at least one air bladder. In various embodiments, the massage actuator (e.g., 1148) includes a valve assembly (e.g., 1136 / 1152) in fluid communication with a pump (e.g., 1138 / 1154) and at least one air bladder assembly (e.g., 1150). Specifically, the valve assembly (e.g., 1136 / 1152) is in electrical communication with the controller (e.g., 1140) and conveys pressurized air from the pump (e.g., 1138 / 1154) to the at least one air bladder assembly (e.g., 1150) in response to a signal from the controller (e.g., 1140).

[0503] A seat assembly (e.g., 1120) is described. The seat assembly (e.g., 1120) includes a seat bottom (e.g., 1122), a seat back (e.g., 1124) extending upright from the seat bottom (e.g., 1122), and an assembly (e.g., 1148 / 1162) described herein. The assembly (e.g., 1148 / 1162) includes a massage actuator (e.g., 1148 / 1162) (e.g., a fluid bladder 1150 such as an air bladder including, but not limited to, a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154) oriented in the seat bottom (e.g., 1122) or the seat back (e.g., 1124).

[0504] A system (e.g., 1120) includes an assembly (e.g., 1148) described herein and an interface (e.g., 1142) that communicates electrically with a controller (e.g., 1140) to output an input indicating a massage request (e.g., a manual selection of a massage effect) to the controller (e.g., 1140).

[0505] In some embodiments, the system (e.g., 1120) includes a second controller that communicates with the controller to output an input indicating approval.

[0506] A method is also provided. The method includes installing a massage actuator (e.g., 1148) (e.g., a fluid bladder 1150 such as an air bladder including but not limited to a lumbar bladder, a bolster bladder, and / or a shoulder bladder, a valve assembly 1136 / 1152, and / or a pump 1138 / 1154) in a seat assembly (e.g., 1120) to provide a massage effect (e.g., a pressure massage or a vibration massage) (i.e., step 1190), and deactivating the massage actuator 1148 to prevent the operation of the massage actuator 1148 (i.e., step 1196). In various embodiments, the method further includes connecting the massage actuator (e.g., 1148) to a controller (e.g., 1140) that controls the operation of the massage actuator (e.g., step 1192), programming the controller (e.g., 1140) to deactivate the operation of the massage actuator (e.g., 1148) (e.g., step 1194), retailing an activation code for activating the massage actuator (e.g., 1148) (i.e., step 1197), inputting an activation code for activating the massage actuator (e.g., 1148, and / or by retailing a software application having an activation code for activating the massage actuator) (i.e., step 1198), and / or inputting a massage request (e.g., a manual selection of a massage effect) to the massage actuator 1148 to provide a massage effect (e.g., a pressure massage or a vibration massage) from the activated massage actuator 1148 (i.e., step 1199). In various embodiments, the massage actuator (e.g., 1148) is activated using a wireless device (e.g., 1144). Specifically, the method includes activating the massage actuator (e.g., 1148) to execute a first massage effect with a first activation code.In some embodiments, the method may further include activating a massage actuator (e.g., 1148) with a second activation code to effect a second massage effect. In one or more embodiments, the method includes disposing at least one air bladder assembly (e.g., 1150) and at least one valve assembly (e.g., 1153) within a seat assembly (e.g., 1120).

[0507] A seat assembly (e.g., 1120) is also provided that includes a seat bottom (e.g., 1122), a seat back (e.g., 1134) extending upright from the seat bottom (e.g., 1122), a massage assembly, and a controller (e.g., 1140) that communicates with a massage actuator. The massage assembly includes a massage actuator (e.g., 1148) that is oriented in the seat bottom (e.g., 1122) or the seat back (e.g., 1124) and is operable to provide a massage effect (e.g., a pressure massage or a vibration massage). The controller (e.g., 1140) is programmed to receive an input indicating approval (e.g., an approval code) to operate the massage actuator, receive an input indicating a massage request (e.g., a manual selection of a massage effect), and output a signal to operate the massage actuator (e.g., 1148) in response to the approval (e.g., the approval code) and the massage request (e.g., the manual selection of a massage effect). In various embodiments, the massage actuator (e.g., 1148) is operable to provide at least two massage effects (e.g., a pressure massage effect and a vibration massage effect).In some embodiments, the controller receives an input indicating approval (e.g., an approval code) to operate a first massage effect (e.g., a pressure massage or a vibration massage) of a massage actuator (e.g., 1148), receives an input indicating a request for the first massage effect (e.g., a manual selection of a massage effect), and outputs a first massage effect signal to operate the massage actuator (e.g., 1148) to provide the first massage effect (e.g., a pressure massage or a vibration massage) in response to the first massage effect approval (e.g., an approval code) and the first massage effect request (e.g., a manual selection of a massage effect). The controller is programmed to receive an input indicating approval (e.g., an approval code) to operate a second massage effect (e.g., pressure or vibration) of the massage actuator (e.g., 1148), receive an input indicating a request for the second massage effect (e.g., a manual selection of a massage effect), and output a second massage effect signal to operate the massage actuator (e.g., 1148) to provide the second massage effect (e.g., a pressure or a vibration massage effect) in response to the second massage effect approval (e.g., an approval code) and the second massage effect request (e.g., a manual selection of a massage effect).

[0508] Referring to FIGS. 32 to 33, a massage bladder 1200 having a round portion 1210 is disclosed. Specifically, the bladder 1200 includes a first sheet 1220 that cooperates with a second sheet 1230 to define a bladder chamber having a circular shape that can be filled with a fluid. Specifically, the first and second sheets 1220, 1230 can cooperate by means of an adhesive, heat staking, and / or ultrasonic welding, hot plate welding, hot swaging, cold pressing, etc. For example, heat staking can form a local joint between two sheets 1220, 1230 to form a seal. Specifically, the sheets 1220, 1230 can be fixed by heat staking along the outer periphery of the round portion and / or the fluid passage to form a continuous heat staking line. The seal allows the passage to expand when a fluid such as an air flow passes through at a pressure above a threshold value.

[0509] In a variant, the chamber is spherical, hemispherical, spherical, cylindrical, ellipsoidal. In one or more embodiments, the round / curved shape can be formed on the first and / or second sheets 1220, 1230 so that the first and / or second sheets 1220, 1230 do not flatten under environmental conditions. For example, the first sheet 120 can be flat and the second sheet 1230 can be formed with half of a round shape (e.g., hemispherical) as shown in FIGS. 32 to 33, or vice versa. The bladder 1200 also includes a fluid passage 1240 to allow fluid to enter and exit the chamber.

[0510] Sheets 1202 and 1204 are generally made of a material that is impermeable to fluids such as air. In a variant, the sheet is an organic polymer material (i.e., plastic) such as polyethylene, polypropylene, polyvinyl chloride, polyurethane, acrylic, polycarbonate, or a combination thereof. The sheet may be thermoplastic or thermosetting. For example, the sheet may be thermoplastic polyurethane. Specifically, the shape and size of sheets 1202 and 1204 may be any suitable size that fits a seat such as a vehicle seat. In a variant, the shape and size may be suitable for providing a massage effect to a human body such as the back and / or neck of a person. In other details, the shape and size of the first sheet and the second sheet are substantially similar or the same. In one or more embodiments, the plastic sheet has a thickness of less than 5 mm, more preferably less than 1 mm, and even more preferably less than 0.5 mm. In a variant, the thickness is from 0.01 to 5 mm, more preferably from 0.1 to 1 mm, and even more preferably from 0.2 to 0.5 mm.

[0511] In one or more embodiments, as shown in FIG. 33, the rounded portion projects sharply from the plane X-X defined by the sheet. In a variant, the rounded portion of the sheet defines a cavity that is at least 30%, more preferably at least 50%, and even more preferably at least 60% of the rounded shape. For example, the rounded portion defines a chamber having a shape that is at least 30%, more preferably at least 50%, and even more preferably at least 60% of a sphere. Specifically, the chamber has the shape of a hemisphere (i.e., 50% of a sphere).

[0512] In some further embodiments, as shown in FIG. 36, the bladder 1600 includes a first sheet 1620 and a second sheet 1630, each having a rounded shape 1610 (e.g., a hemisphere) formed thereon. In a variant, a plurality of rounded shapes formed thereon are aligned such that the chambers they form have a shape different from the shape formed in any one of them. By aligning the formed portions of the sheets, a chamber embodying at least 60% of the rounded shapes, more preferably at least 75% of the rounded shapes, and even more preferably at least 90% of the rounded shapes can be obtained. For example, hemispheres are formed on each of the first sheet 1620 and the second sheet 1630, and when combined, a spherical chamber is defined. Specifically, the hemisphere or sphere has a radius of 5 to 35 mm, more preferably 10 to 30 mm, and even more preferably 15 to 25 mm. For example, the radius is 21.335 mm.

[0513] Flat structures such as conventional accordion or bellows-shaped bladders are inefficient and costly. In many cases, these bladders are formed by a plurality of flat (unformed) sheets. For example, a conventional bladder 1400 as shown in FIGS. 34 to 35 requires at least four sheets to cooperate to define a chamber, which requires additional material and processing. In other words, the bladder 1200 described herein requires less material to be used because the ratio of volume to surface area is large. Further, while the flat shape has a large contact area so that the pressure felt or experienced by the occupant is small, a rounded shape or a pointed shape (i.e., a shape having the apex of the shaper) has a small contact area at the apex that exerts a large finger pressure effect or a large pressure that provides a massage, as shown in FIGS. 37 to 42.

[0514] Figures 37 through 42 are diagrams showing the body pressure distribution when the maximum pressure is applied. These charts are obtained by placing a pressure-sensitive mat between the occupant and the bladder assembly and measuring the pressure when the bladder is filled and released. A group of occupants are tested to obtain pressure data such as the average maximum pressure applied. The red areas indicate the regions with the highest pressure, and the blue areas indicate the regions with the lowest pressure. Figures 37, 39, and 41 show the massage assembly with the bladder described in this specification as depicted in Figures 32 through 33, while Figures 38, 40, and 42 show the conventional massage assembly with a conventional accordion bladder as depicted in Figures 34 through 35. As shown, the conventional bladder is less concentrated and applies less pressure to the occupant. Figures 37 and 38 show the average maximum pressure applied to the 5th percentile occupant, Figures 39 and 40 show the average maximum pressure applied to the 50th percentile occupant, and Figures 41 and 42 show the average maximum pressure applied to the 95th percentile occupant. In one or more embodiments, the bladder can apply a pressure of at least 1.8 PSI (12.4 kPa), more preferably at least 2.0 PSI (13.8 kPa), and even more preferably at least 2.5 PSI (17.2 kPa) to the occupant.

[0515] Table 1 (below) gives the average maximum pressure based on the body pressure distribution test data.

Table 1

[0516] The average maximum pressure applied to the occupant by the massage assembly having the bladder disclosed in this specification is significantly greater than that of the assembly using the conventional bladder. The concentrated bladder described in this specification also provides a greater massage effect due to the small chamber volume that expands and contracts quickly. Similar results were also obtained with the bladder depicted in Figure 36.

[0517] Referring to FIG. 43, a massage assembly 1500 is disclosed, such as for the seat 1700 shown in FIG. 45. Specifically, the seat 1700 includes a seat back 1700 and / or a seat bottom 1704. The massage assembly 1500 is disposed on the seat back 1702 and / or the seat bottom 1704. In addition to the massage assembly 1500, the seat also includes a seat frame 1706 that supports the assembly 1500 and a cushion 1708. Specifically, the seat 1700 also includes a trim cover 1710 disposed on the cushion 1708. In a variant, the seat 600 is a seat for a vehicle such as an automobile, a motorcycle, a watercraft, an aircraft, and / or a locomotive.

[0518] The massage assembly 1500 includes a plurality of bladders 1510 as described herein and a plurality of fluid passages 1512 having a first end that terminates in a chamber of the plurality of bladders 1510. The second end of the passage 1512 may cooperate with a flow guiding device such as a compressor or a pump so as to receive fluid from the compressor or the pump. Specifically, the second end of the passage 1512 may cooperate with a valve assembly 1514 for adjusting the massage effect. In other words, the valve assembly may be disposed between the fluid passage and the flow guiding device. In a variant, a first seat 1502 and a second seat cooperate to form a plurality of bladders and / or passages. For example, in FIG. 44, a first seat 1502 and a second seat 1504 cooperate to form a passage 1506, and the first seat 1502 has a port 1508 that may be connected to a bladder. Alternatively, the first seat may be shaped in a round shape instead of the port 1508. In other variants, each bladder may be connected to a valve assembly that provides selective fluid communication between the flow guiding device and the chamber via a tube that forms the fluid passage 1512, as shown in FIGS. 32 to 33. In a variant, the plurality of bladders are 2 to 20 bladders, more preferably 4 to 16 bladders, and even more preferably 6 to 12 bladders.

[0519] In one or more embodiments, the massage assembly 1500 is disposed on a carrier board 1800 as shown in FIG. 47. The carrier board 1800 is supported by a frame 1706 such as the frame 1706 of the seat back 1702 as shown in FIG. 48. Specifically, the carrier board 1800 is generally flat and rigid. For example, the carrier board 1800 is a rigid plastic such as polyethylene, polycarbonate, polyurethane, polyvinyl chloride, or a combination thereof. In a variant, the thickness of the carrier board 700 is at least 0.5 mm, more preferably at least 2 mm, and even more preferably at least 2.5 mm. Specifically, the carrier board 700 has a thickness of from 0.5 to 20 mm, more preferably from 1 to 10 mm, and even more preferably from 2 to 3.5 mm. In one or more embodiments, the carrier board 1800 includes a plurality of fasteners / holders for fixing various other components such as flow guiding devices, valve assemblies, inflatable sub-assemblies, electronic devices, or combinations thereof to the carrier board 1800. In a variant, the carrier board 1800 includes a suspension system for fixing to the seat assembly 1300 such as a frame.

[0520] In one or more embodiments, the massage assembly 1500 can be disposed on the seat such that the rounded portion, when seated, defines a contact area with the occupant. It should be understood that direct contact is not required to define the contact area, and that one or more layers such as a trim cover, cushion, and / or foam layer may be disposed between the occupant and the bladder. Specifically, the contact area may be around the apex of the rounded portion. In other words, the rounded portion may protrude into the occupant during inflation.

[0521] As shown in FIG. 49, a method 1900 for creating a bladder having a rounded portion is also disclosed. Method 1900 includes providing a first sheet and a second sheet (i.e., step 1910), forming a rounded portion in the first sheet and / or the second sheet (i.e., step 1920), bringing the first and second sheets together and arranging them to cooperate to define a chamber (i.e., step 1930), and assembling the bladder to the seat such that during operation, the apex of the rounded portion can protrude into the seated occupant (i.e., 1940). For example, FIG. 48 depicts one embodiment of a mold used to form the first sheet and / or the second sheet. The mold has a rounded shape to be formed in the sheet to which it is applied. Specifically, the mold and / or the sheet are heated to soften the sheet and assist in forming. For example, the sheet is heated to at least 500°F (260°C), more preferably at least 650°F (343°C), and even more preferably at least 750°F (399°C). In a variant, the rounded portions of the first sheet and the second sheet are aligned to define a chamber. In yet other details, the first and second sheets are bonded together with an adhesive, heat staked, ultrasonically welded, or otherwise cooperate around the rounded portion to form a seal. In some embodiments, the sheets are adhesively bonded together, heat staked, and / or ultrasonically welded to define a fluid passage to the chamber. In other embodiments, a tube may be sealed to the bladder such that fluid can enter and exit the bladder's chamber through the tube.

[0522] A bladder (e.g., 1200 / 1600 such as a fluid bladder (e.g., a pneumatic bladder)) is provided. The bladder (e.g., 1200 / 1600) includes a first sheet (e.g., 1220 / 1620) and a second sheet (e.g., 1230 / 1630) that cooperate with each other (e.g., heat staked together, fused together, joined together, welded together, heat welded together, ultrasonically welded together, hot plate welded together, heat swaged together, cold pressed together, adhesively bonded together, laser welded together, adhesively bonded together, high frequency welded together, sewn together, chemically welded together) to define a round chamber. In some embodiments, the bladder (e.g., 1200 / 1600) also includes a fluid passage (e.g., 1240) having a terminus in the chamber such that a fluid (e.g., water or air) is transported through the fluid passage (e.g., 1240) to the chamber. The first sheet and / or the second sheet (e.g., 1220 / 1620, 1230 / 1630) have a round portion (e.g., 1210 / 1610) formed therein. Specifically, the sheet (e.g., 1220 / 1620, 1230 / 1630) is formed from an elastic material. In one or more embodiments, the polymeric material is thermoplastic. For example, the sheet (e.g., 1220 / 1620, 1230 / 1630) is cloth, plastic, polyethylene, polypropylene, polyvinyl, polyvinyl chloride, polyurethane, acrylic, polycarbonate, felt, and / or Tyvek®. In one or more embodiments, the round portion (e.g., 1210 / 1610) and the round chamber are spherical (e.g., hemispherical). For example, the chamber is a sphere or a hemisphere. In a variant, the round portion (e.g., 1210 / 1610) is a hemisphere. In various embodiments, the round chamber is a sphere.

[0523] A seat assembly is also provided that includes a frame that supports a massage assembly that includes a bladder (e.g., 1200 / 1600). For example, a subassembly for massaging an occupant can be supported by the frame.

[0524] The subassembly includes a plurality of bladders and a fluid actuator such as a pump (e.g., a compressor). Each bladder (e.g., 1200 / 1600) includes a fluid passage (e.g., 1240) to a round chamber defined by a first sheet (e.g., 1220 / 1620) that cooperates with a second sheet (e.g., 1230 / 1630). (e.g., sheets 1220 / 1620, 1230 / 1630 are heat staked together, fused together, joined together, welded together, thermally welded together, ultrasonically welded together, hot plate welded together, heat swaged together, cold pressed together, adhesively bonded together, laser welded together, adhesively bonded together, high frequency welded together, sewn together, chemically welded together). In various embodiments, the first and / or second sheets (e.g., 1220 / 1620, 1230 / 1630) each define a shaped round portion (e.g., 1210 / 1610). The fluid actuator moves fluid to one or more chambers to pass through one or more fluid passages (e.g., 1240). Specifically, the round portion (e.g., 1210 / 1610) of each bladder (e.g., 1200 / 1600) includes a hemisphere. In a variant, the round chamber is spherical.

[0525] In various embodiments, at least one round portion (e.g., 1210 / 1610) is configured to protrude towards the seat occupant. In one or more embodiments, the contact area with the occupant is such that the bladder (e.g., 1200 / 1600) applies at least 2 PSI (13.8 kPa) of pressure to the occupant and / or at least 2.5 PSI (17.2 kPa) of pressure to the occupant.

[0526] Referring to FIG. 50, a seat assembly 2000 for a vehicle or the like is provided. For example, the seat assembly 2000 is used in motorcycles, automobiles, watercraft, aircraft, trains, and the like. In one or more embodiments, the seat assembly includes a trim cover 2002 disposed on top of a cushion assembly 2004 and a seat frame 2006. As shown in FIGS. 51 through 53 and FIG. 5, the seat assembly 2000 also includes a fluid system 2100 for massaging and / or adjusting the seat.

[0527] In various embodiments, the fluid system 2100 is disposed within, on top of, and / or adjacent to the cushion assembly 2004. In a variation, the cushion assembly 2004 includes a plurality of cushions. For example, the cushion assembly 2004 includes a seat bottom and a seat back each having a center cushion or middle cushion that can be sandwiched between bolster cushions. Specifically, the fluid system 2100 is disposed within, on top of, and / or adjacent to one or more of the cushions. For example, as shown in FIGS. 51 through 55, the fluid system 2100 is disposed in the seat back of the cushion assembly 2004. Specifically, the cushions of the cushion assembly 2004 are foam and / or a plurality of polymer twisted yarns.

[0528] In one or more embodiments, the fluid system 2100 includes a fluid displacement device such as a pump, blower, compressor, and / or fan. During operation, the fluid displacement device moves the fluid or causes a fluid flow. In a variant, the fluid system 2100 includes, as shown in FIG. 53, a first plurality of fluid bladders 2102 arranged along a first direction and / or dimension, such as X1 and Y1 respectively, and a second plurality of fluid bladders 2104 arranged along a second direction and / or dimension. For example, the first direction and / or dimension is defined by the horizontal axis and the second direction and / or dimension is defined by the vertical axis. Specifically, X1 and Y1 are different, not parallel, intersecting, and / or substantially orthogonal or perpendicular (e.g., an angle defined from 15 to 165 degrees, more preferably from 45 to 135 degrees, even more preferably from 60 to 120 degrees, even more preferably 90 degrees). When the first and second pluralities of bladders are arranged in this way, a larger range and capacity can be adopted for different sizes of individuals, supports, massage procedures, and / or configurations. In various embodiments, the bladder or each plurality of bladders includes from 4 to 20 bladders, more preferably from 6 to 16 bladders, even more preferably from 8 to 12 bladders.

[0529] In some further embodiments, a third plurality of bladders 2106 and a fourth plurality of bladders 2108 are arranged along a third direction and / or dimension (e.g., X2) and a fourth direction and / or dimension (e.g., Y2). Specifically, X2 is parallel or substantially parallel to X1 (e.g., within 20% of parallel, more preferably within 10% of parallel, even more preferably within 5% of parallel). The greater the number of bladders, the more customizable to the various occupant sizes, shapes, and comfort levels. In other variations, the bladders are arranged in at least a 4×4 grid pattern, more preferably at least a 4×6 grid pattern, even more preferably at least a 6×6 grid pattern, corresponding to multiple groups of bladders along different dimensions, directions, and / or axes. Specifically, the fluid system 2100 includes at least 16 bladders, more preferably at least 20 bladders, even more preferably at least 24 bladders.

[0530] In some embodiments, a plurality of bladders, such as the first / second / third / fourth plurality of bladders 2102 / 2104 / 2106 / 2108, are arranged within a specific region of the cushion assembly and may correspond to an occupant's region (e.g., back, lower back, upper back, middle back, buttocks, thighs, left side, right side, central portion, etc.). For example, the first plurality of bladders 2102 (or the third plurality of bladders 2106) are arranged in the lower region 2110 (or upper region 2112) of the seat back corresponding to, for example, the lower (or upper) part of the occupant's back. In yet other embodiments, the second plurality of bladders 2104 (or the fourth plurality of bladders 2108) are arranged on the first side or half 2114 (or the second side or half 2116) of the seat assembly 2000. As shown in FIGS. 52 to 53, it should be understood that multiple groups or a plurality of bladders may be arranged in the same region (e.g., lower back, upper back, left side, right side).

[0531] In one or more embodiments, the dimensions in which a plurality of bladders are arranged correspond to occupant dimensions such as the width and / or height of the occupant (e.g., the dimensions of the lower back (waist), shoulders, neck, thighs, etc.). Specifically, the dimensions are greater than the 10th percentile of the occupant's dimensions, more preferably greater than the average dimensions of the occupant, even more preferably dimensions of 75th percentile or more of the occupant, even more preferably dimensions of 85th percentile or more of the occupant, and even more preferably dimensions of 90th percentile or more of the occupant.

[0532] For example, the dimensions correspond to a shoulder width such that the plurality of bladders extend along dimensions corresponding to a shoulder width that is 10th percentile or more of the occupant, more preferably a shoulder width that is average shoulder width or more of the occupant, even more preferably a shoulder width that is 75th percentile or more of the occupant, even more preferably a shoulder width that is 85th percentile or more of the occupant, and even more preferably a shoulder width that is 90th percentile or more of the occupant.

[0533] In yet another variation, different groups of the plurality of bladders are arranged to correspond to different populations of occupants. For example, a first group of bladders (e.g., the innermost row of bladders including 2108) corresponds to a population of occupants having dimensions (e.g., shoulder width) smaller than average, a second group of bladders (e.g., the innermost row and the second innermost row of bladders including 2108 and 2104) corresponds to a second population of occupants having approximately average dimensions (e.g., shoulder width), and a third group of bladders (e.g., all rows of bladders) corresponds to a third population of occupants having dimensions (e.g., shoulder width) larger than average.

[0534] In one or more embodiments, a first plurality of bladders are arranged along dimensions, directions, or axes corresponding to the width, height, or length of the seat bottom or seat back, and a second plurality of bladders are arranged along different dimensions, directions, or axes corresponding to the width, height, or length of the seat bottom or seat back.

[0535] In yet other embodiments, the seat assembly 2000 includes a controller 2200 that communicates and cooperates with a fluid system 2100, as shown in FIG. 56. In a variation, the controller 2200 includes a memory 2202 and a processor 2204. For example, the memory 2202 stores computer-executable code or instructions that are executed by the processor 2204 to perform the various functions described herein. Specifically, the controller 2200 cooperates with and communicates with a fluid displacement device 2118 and / or a valve assembly 2120, and fluid (e.g., air or water) displaced by the fluid displacement device 2118 (e.g., a compressor or a pump) via the valve assembly 2120 is adapted to fill / inflate or release / contract one or more bladders 2122. In one or more embodiments, an actuator, such as a valve actuator 2400 as shown in FIG. 58, cooperates with a plurality of valves 2402 that open and close together. For example, an actuator head 2404 opens and closes a first valve 2406, a second valve 2408, and a third valve 2410. In various embodiments, the valve actuator 2400 is used, for example, with the fluid system of FIG. 53, where the first valve 2406 serves a large dimension (e.g., outer), the second valve 2408 serves an intermediate dimension, and the third valve 2410 serves a small dimension (e.g., inner). By using this type of valve actuator, cost can be reduced while providing efficient customization for the occupant.

[0536] In a variant, the system 2100 also includes one or more sensors 2124, such as a pressure sensor that detects the pressure associated with one or more bladders 2122. Specifically, the pressure is directly measured by the pressure sensor. In other embodiments, proxy variables are used to detect the pressure. The sensors can additionally or alternatively be disposed within or in the vicinity of each bladder to detect the associated pressure of that bladder. For example, the sensors are disposed at positions configured to detect the pressure associated with a group or plurality of bladders. For example, the sensors are disposed in passages (e.g., supply passages and / or exhaust passages) associated with a first plurality of bladders and their respective corresponding plurality of bladders. Specifically, various pluralities or groups of bladders are filled / expanded, and fluid is released through the exhaust passage so that a sensor in the exhaust passage determines the pressure associated with the plurality or group of bladders. In short, the sensors are disposed within and / or proximate to the bladder or bladder group to determine the pressure associated with each bladder or bladder group. For example, a pneumatic sensor such as a pneumatic pressure attached to a substrate is used. In yet other examples, the sensor measures the elongation or pressure of the seat. In yet other examples, thin-film sensors and / or push-button sensors are used. In some embodiments, a combination of sensors is used.

[0537] In one or more embodiments, the controller 2200 cooperates with and communicates with one or more sensors 2124. Specifically, the controller 2200 performs a scan to determine the size and / or dimensions of the occupant. In a variant, the scan is performed by filling / expanding one or more bladders, emptying / contracting one or more bladders, and detecting the (first) pressure associated with one or more bladders. In various embodiments, the (first) pressure indicates the size or dimensions of the occupant. For example, if the dimensions of the occupant exceed a threshold pressure, it indicates that the occupant is adjacent to one or more bladders.

[0538] In other embodiments, or the same embodiment, if the (first) pressure is greater than the (second) pressure associated with one or more other bladders, it indicates that the occupant is adjacent to one or more bladders. For example, when the occupant is seated, if the first pressure associated with the inner group of bladders is 2.00 PSI (13.9 kPa), a pressure below the threshold for the inner group of bladders may indicate that the occupant is not adjacent to that bladder group. In other words, a pressure drop of at least 10%, more preferably at least 25%, and even more preferably at least 50% indicates that the occupant is not adjacent to the bladder group. For example, a second pressure associated with an outer group of bladders having a pressure greater than 1.0 PSI (6.89 kPa), more preferably greater than 1.5 PSI (10.3 kPa), and even more preferably greater than 1.8 PSI (12.4 kPa) may indicate that the occupant is adjacent to the outer bladder group, i.e., that the occupant's dimensions extend at least to the outer bladder group. However, if the second pressure associated with the outer group of bladders is 1.8 PSI (12.4 kPa) or less, more preferably 1.5 PSI or less (10.3 kPa), and even more preferably 1.0 PSI (6.89 kPa) or less, the occupant is not adjacent to the outer group of bladders, i.e., the occupant's dimensions do not extend to the outer group of the occupant. In one or more embodiments, the pressure associated with each group, or all bladders, is detected to determine the size or dimensions of the occupant. In some embodiments, the scan acts inwardly by first determining the pressure associated with the outer group or bladders. The scan proceeds inwardly until the size or dimensions of the occupant are determined. Specifically, the scan determines the pressure associated with a particular bladder or group, such as the innermost group, before acting inwardly to establish a threshold pressure or reference pressure.

[0539] In the above example, a first (inner) group and a second (outer) group are described for illustrative purposes. However, it should be understood that the scan may include a number of groups, and different groups may overlap or share bladders. For example, the inner and outer groups may refer to inner and outer columns along the back, but the scan may include lower and upper groups of the back that include portions of the inner and outer groups to determine the dimensions of the entire occupant's back in two different directions (e.g., width and height).

[0540] In various embodiments, the scan determines a number of dimensions of the occupant. For example, in at least one embodiment, the scan determines a first dimension of the occupant corresponding to the occupant's shoulder width and a second dimension corresponding to the occupant's waist width. Additionally or alternatively, the scan determines the height dimension of the occupant's back.

[0541] In one or more embodiments, the controller 2200 cooperates with and communicates with the bladder 2122, the sensor 2124, the fluid displacement device 2118, the valve assembly 2120, and / or a control unit 2210 such as a cellular phone via a wired and / or wireless network 2206. For example, the network 2206 includes the Internet 2208. In various embodiments, different networks such as wired or wireless networks are used to communicate with different components. Specifically, the control unit 2210 is used to control sub-assemblies such as the massage system 2100. For example, an occupant can initiate a scan from the control unit 2210, turn the massage unit on or off, and select specific conditions such as desired support and / or massage procedures. Additionally or alternatively, the scan is automatically initiated when the occupant is seated and the vehicle is in operation.

[0542] In various embodiments, after determining or obtaining one or more (e.g., one, two, three, four, five, etc.) occupant dimensions, the controller 2200 uses the occupant dimension(s) to perform custom tasks such as providing a support and / or massage protocol. For example, the system 2100 takes into account the occupant size of FIG. 54 and employs a massage using all 24 bladders, but may use only 16 bladders to massage the occupant of FIG. 55. In other words, the controller 2200 employs a massage that does not use the outer rows of bladders, taking into account that the occupant's dimensions do not protrude from those bladders. Specifically, this selectivity provides a comfortable custom-made massage. Also, no energy is wasted on bladders that are not in contact with the occupant.

[0543] In still some embodiments, the scan detects "hot spots", i.e., one or more points where abnormal or high pressure is being applied by the occupant. In various embodiments, the support or massage subsequently employed by the controller 2200 is targeted or directed at one or more points. For example, additional support is provided to other areas to relieve the pressure at the hot spot. In one or more embodiments, the bladders are used not only for massage effects but also to provide support. In such embodiments, the amount of support of the bladders, i.e., the pressure, corresponds to the amount of pressure exerted by the occupant on the bladder or bladder group as determined by the scan.

[0544] In one or more embodiments, the controller 2200 cooperates with and communicates with the fluid passages 2128, 2129, the fluid displacement device 2118, the valve assembly 2120, and one or more bladders 2122, and can individually fill / inflate the bladders or simulate one or more scans to perform in the same manner as different massage functions. For example, the scan includes filling the bladders in various columns and rows to determine the dimensions of the occupant, but after determining the dimensions of the occupant, the individual bladders can be filled to provide a massage effect such as an acupressure effect within the dimensions.

[0545] In addition to various massage effects such as acupressure, Swedish, deep tissue, trigger point, etc. being known, various techniques for simulating such massages are also known. For example, the bladder is filled / inflated to a pressure such that it presses against the occupant, and then the bladder is released and the pressure is relieved, thereby obtaining an acupressure massage effect. This can be repeated at different locations multiple times to simulate the pressure applied by the hands or fingers to the occupant. In any case, the massage effect refers to applying and relieving pressure by filling / inflating and releasing / contracting one or more bladders. As described above, the massage effect is based on the dimensions of the occupant. For example, bladders outside the occupant or bladders extending beyond the dimensions of the occupant are excluded from the massage or support procedure. In other words, the pressure change within the bladder is within the range of the dimensions of the occupant.

[0546] In various embodiments, the seat frame 2006 is any material suitable for supporting the subassembly and the occupant. In a variant, the seat frame 2006 includes a rigid material such as metal, plastic, wood, or a combination thereof. For example, a seat frame 2006 made of steel and / or aluminum is used. The cushion assembly 2004 includes one or more cushions. In various embodiments, the trim cover 2002 is configured to be adjacent to the seated occupant. That is, the trim cover 2002 includes an outermost layer that defines the outermost surface. In a variant, as shown in FIGS. 51 to 55, the trim cover 2002 is disposed on one or more subassemblies. Specifically, the trim cover 2002 includes a cloth, a woven fabric, a synthetic leather, or a leather surface. For example, the trim cover 2002 includes cotton, polyester, polyurethane, nylon, or other suitable materials.

[0547] As described above, the system includes, in various embodiments, computer-executable code or instructions stored on a non-transitory computer-readable medium on a local device or in the cloud via the network 2206. A non-transitory computer-readable medium having computer-readable instructions configured to be executed by a processor is provided to perform various functions for the operation of the system and the seat assembly 2000, such as operating the fluid displacement device or determining the pressure associated with one or more bladders via a sensor. The pressure may be directly measured using a sensor, or surrogate parameters for determining the pressure may be used. For example, the pressure may be determined by measuring the force (applied to a known area).

[0548] In one or more embodiments, the processor includes one or more devices selected from a high-performance computing system including high-performance cores, a microprocessor, a microcontroller, a digital signal processor, a microcomputer, a central processing unit, a field programmable gate array, a programmable logic device, a state machine, a logic circuit, an analog circuit, a digital circuit, or any other device that operates on signals (analog or digital) based on computer-executable instructions residing in a memory. In a variation, the memory includes a single memory device or a number of memory devices including, but not limited to, random access memory (RAM), volatile memory, non-volatile memory, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, cache memory, or any other device capable of storing information. Specifically, the non-volatile memory / storage includes one or more persistent data storage devices such as a hard drive, an optical drive, a tape drive, a non-volatile solid state device, cloud storage, or any other device capable of permanently storing information.

[0549] In one or more embodiments, the executable code / instructions may reside in a software module. Specifically, the software module includes an operating system and an application. In various embodiments, the software module is compiled or interpreted from a computer program created using various programming languages and / or techniques including, but not limited to, Java, C, C++, C#, Objective C, Fortran, Pascal, Java Script, Python, Perl, and PL / SQL. The non-volatile storage also includes data that supports functions, features, calculations, processes.

[0550] In some embodiments, the system described above includes a computer-readable storage medium, which is essentially non-transitory and implemented in any method or technology for storing information such as computer-readable instructions, data structures, program modules, or other data, including volatile or non-volatile, and removable and non-removable tangible media. In a variant, the computer-readable storage medium further includes random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid-state memory technologies, portable compact disc read-only memory (CD-ROM), or other optical storage devices, magnetic cassettes, magnetic tapes, magnetic disk storage devices or other magnetic storage devices, or any other medium that can be used to store desired information and is readable by a computer. In various embodiments, the computer-readable program instructions can be downloaded to a computer, other types of programmable data processing devices, or other device forms of a computer-readable storage medium, or an external computer or external storage device via a network.

[0551] In one or more embodiments, the computer-readable program instructions stored on the computer-readable medium are used to direct a computer, other types of programmable data processing devices, or other devices to function in a particular manner so as to manufacture a manufactured article that includes instructions for performing the functions, acts, and / or operations described herein. The functions, acts, and / or operations described herein may be performed in any order, serially, continuously, or simultaneously.

[0552] Referring to FIG. 57, a method 2300 for scanning and / or applying a massage is also disclosed. In one or more embodiments, the method 2300 includes determining a first pressure 410 and a second pressure 420 associated with a first bladder and a second bladder, respectively, and determining a first occupant dimension based on the first and / or second pressure 440. For example, a sensor detects or measures the pressure associated with the bladder. The first and second pressures are compared to each other or to a threshold pressure, and the first occupant dimension is determined. Specifically, the method 2300 includes determining a third pressure associated with a third bladder 430. In various embodiments, the method 2300 includes determining a second occupant dimension based on the third pressure 450. In a variant, the third pressure is compared to the first and / or second pressure or the threshold pressure to determine the second occupant dimension. The method also includes applying a massage or a massage effect based on the first and / or second occupant dimension. For example, the massage or the massage effect utilizes a bladder that extends within the occupant dimension(s), but does not utilize a bladder that extends beyond or outside the occupant dimension(s).

[0553] A seat massage assembly (such as 2000 in a vehicle seat such as for a motorcycle, automobile, watercraft, aircraft, or train) is provided. This includes a first plurality of bladders (such as pneumatic bladders) arranged along a first direction X1 (such as horizontally, for example, along the width of the seatback) or along a vertical direction (such as along the height of the seatback), and a controller 2200 that cooperates with the first plurality of bladders (such as 2102). For example, the first plurality of bladders (such as 2102) can be the uppermost row of bladders, the middle row of bladders 2106, the lowermost row of bladders 2102, the left column of bladders 2104, the middle column of bladders 2108, or the right column of bladders. In some embodiments, the first plurality of bladders (such as 2114) are the outer or inner rows or columns of bladders. In various embodiments, the controller (such as 2200) fills one or more bladders (such as 2122 (for example, each bladder individually, or outer and inner bladders, etc.)) with a fluid (such as air or water) and determines the associated pressure (such as the pressure applied by an occupant to one or more bladders 2122, or the pressure of the fluid flow (such as an air flow) released from one or more bladders 2122). The controller 2200 can be provided as one or more controllers or control modules for various components and systems. The controller 2200 and the control system can include any number of controllers, can be integrated into a single controller, or can have various modules. Some or all of the controller can be connected by a Controller Area Network (CAN) or other system. It is recognized that any controller, circuit, or other electrical device disclosed herein can include any number of microprocessors, integrated circuits, memory devices (such as 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.Furthermore, 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. In a variant, the scan may determine the size of the occupant, such as by determining the dimensions of the occupant (e.g., shoulder width, waist width, shoulder height, back length, neck height, neck length, head height, thigh width, thigh length, etc.). Specifically, the scan is configured to determine a first dimension of the occupant (see FIGS. 54 to 55), and optionally, a second dimension of the occupant. In one or more embodiments, the controller 2200 is configured to control a first plurality of bladders (e.g., 2114) to massage the occupant according to a first dimension (e.g., shoulder width, waist width, back length, shoulder height, neck length, neck height, head height, thigh width, or thigh length, etc.). In some embodiments, the scan includes filling each bladder (e.g., 2122) and determining a corresponding pressure (e.g., the pressure applied by the occupant to one or more bladders 2122, or the pressure of the fluid flow (e.g., air flow) released from one or more bladders 2122). In one or more embodiments, the scan includes filling a first group of bladders (e.g., outer bladders, intermediate bladders, inner bladders, left bladders, right bladders, upper bladders, lower bladders) of the first plurality of bladders (e.g., 2114), determining a first pressure corresponding to the first group of bladders (e.g., 2104), filling a second group of bladders (e.g., outer bladders, intermediate bladders, inner bladders, left bladders, right bladders, upper bladders, lower bladders) from a first plurality of bladders different from the first group of bladders (e.g., 2104), and determining a second pressure corresponding to the second group (e.g., the pressure applied by the occupant to one or more bladders 2122, or the pressure of the fluid flow released from one or more bladders 2122).In a variant, the assembly (e.g., 2000) also includes one or more sensors (e.g., 2124) corresponding to each blade (e.g., 2122) of the first plurality of blades (e.g., 2114), and / or one or more sensors such as those disposed in the exhaust path (e.g., 2128) of the first plurality of blades to determine the pressure of the fluid (e.g., air) released from the first plurality of blades, i.e., one or more sensors (e.g., 2124) corresponding to different groups of blades. A seat assembly (e.g., 2000 such as for a vehicle) is also disclosed. This includes a frame (e.g., 2006) (e.g., a rigid material such as metal, plastic, and / or wood) that supports the assembly (e.g., 2000).

[0554] An assembly (e.g., a seat massage assembly 2000 as in a vehicle seat) is also provided. This includes a first bladder (e.g., 2106) arranged along a first axis (e.g., X1) (e.g., a horizontal axis, a vertical axis, an inner axis, an outer axis, a diagonal axis), a second plurality of bladders (e.g., 2102) arranged along a second axis (e.g., X2) different from the first axis (e.g., X1) (e.g., a horizontal axis, a vertical axis, an inner axis, an outer axis, a diagonal axis), and one or more sensors (e.g., 2124 such as a pressure sensor) arranged to determine pressures associated with different groups of bladders. For example, the sensor (e.g., 2124) may be arranged in a primary exhaust (e.g., 2129) that services all bladders (e.g., 2122), or sensors (e.g., 2124) that service an exhaust (e.g., 2128) may be arranged for each row or column of bladders. In various embodiments, the bladders (e.g., 2122) are configured to be individually filled via a valve assembly (e.g., 2120) to scan the occupant and simultaneously filled to employ a massage effect. A seat component such as a seat back or a seat bottom including a frame (e.g., 2006) (e.g., a rigid material such as metal, plastic, wood) that supports the assembly is also provided. In various embodiments, the first plurality of bladders (e.g., 2106) are arranged along the width of the seat back at a first position (e.g., upper, lower, middle), and the second plurality of bladders (e.g., 2102) are arranged along the width of the seat back at a second position different from the first position (e.g., upper, lower, middle). In some embodiments, the first plurality of bladders (e.g., 2106) are arranged along the width of the seat back, and the second plurality of bladders (e.g., 2108) are arranged along the height of the seat back. In some embodiments, the first plurality of bladders (e.g., 2104) are arranged along the height of the seat back at a first portion (e.g., left, right, center), and the second plurality of bladders (e.g., 2108) are arranged along the height of the seat back at a second position different from the first position (e.g., left, right, center).In one or more embodiments, an assembly (e.g., 2000) fills one or more bladders (e.g., 2122) with fluid and determines a related pressure such as a pressure applied to one or more bladders (e.g., 2122) by an occupant or a pressure of a fluid flow (e.g., an air flow) released from one or more bladders (e.g., 2122), and includes a controller (e.g., 2200) that cooperates with a first plurality of bladders (e.g., 2106) to scan the occupant. In various embodiments, the scan is configured to determine one or more dimensions of the occupant.

[0555] A method 2300 for scanning and massaging an occupant will be described. The method 2300 is provided. This includes determining a first pressure associated with a first bladder (i.e., step 2310), determining a second pressure associated with a second bladder (i.e., step 2320), and determining a first occupant dimension based on the first and second pressures (i.e., step 2340). In various embodiments, the first and second pressures are determined by releasing fluid from the first and second bladders. In some embodiments, the method 2300 also includes applying a massage effect to the occupant based on the first occupant dimension (i.e., step 2360). In a variant, the method 2300 also includes determining a third pressure associated with a third bladder (i.e., step 2330) and determining a second occupant dimension based on the third pressure (i.e., step 2350) and the first and / or second pressures. In one or more embodiments, the method 2300 also includes applying a massage effect based on the first and second dimensions (i.e., step 2360).

[0556] FIG. 59 shows a seat assembly 2420 according to some embodiments. The seat assembly 2420 may be a vehicle seat assembly for a land vehicle, a water bike, an aircraft, etc. Although the vehicle seat assembly 2420 is illustrated and disclosed, any seat assembly 2420 such as an office chair, a comfort chair, etc. may be employed.

[0557] The seat assembly 2420 includes a seat bottom 2422 for supporting a passenger's pelvis and thighs. The seat bottom 2422 is supported on a supporting surface below, such as a vehicle floor. The seat back 2424 extends in an upright direction from the seat bottom 2422 and supports the passenger's back and shoulders. The seat back 2424 may be supported by the seat bottom 2422 or the supporting surface therebelow. A headrest 2426 for supporting the passenger's head may also be provided on the seat back 2424.

[0558] The seat assembly 2420 provides contact surfaces 2428, 2430 for receiving and comfortably supporting a passenger. The seat assembly 2420 includes a plurality of actuators 2432, 2434 provided within the seat assembly 2420 within the contact surfaces 2428, 2430. Although two actuators 2432, 2434 are illustrated and described, any number or position of actuators 2432, 2434 may be employed. The actuators 2432, 2434 may be utilized to impart tactile effects to the passenger, such as vibrations to convey an alert, vibrations to impart a massage, or pressure to impart a pressure massage effect.

[0559] In the illustrated embodiment, the actuators 2432, 2434 are fluid bladders 2432, 2434, such as air bladders 2432, 2434, for imparting a pressure massage effect to the passenger. FIG. 60 shows an actuator assembly 2436 for a seat assembly 2420 according to some embodiments. The actuator assembly 2436 is schematically illustrated and may be installed within the seat assembly 2420. The actuator assembly 2436 includes a fluid pump 2438, such as a pneumatic pump 2438, for providing a pressurized air source. The actuator assembly 2436 also includes a valve assembly 2440 in fluid communication with the pump 2438. A first fluid line 2442 connects the pump 2438 to the valve assembly 2440 to send pressurized air from the pump 2438 to the valve assembly 2440.

[0560] The valve assembly 2440 includes a housing 2444 having a plurality of fluid chambers 2446, 2448. Each fluid chamber 2446, 2448 receives a valve sub-assembly 2450, 2452 for translation within the fluid chambers 2446, 2448. The actuator assembly 2436 also includes a controller 2454 that cooperates with the valve sub-assemblies 2450, 2452 for actuation of the respective valve sub-assemblies 2450, 2452. For example, the controller 2454 includes a plurality of solenoids and can impart linear actuation to each of the valve sub-assemblies when current is conducted through the solenoids.

[0561] The prior art utilizes separate valve sub-assemblies to inflate and deflate the air bladders within the seat assembly. To minimize the number of valve sub-assemblies 2450, 2452 within the valve assembly 2440, the valve sub-assemblies 2450, 2452 are each a two-way valve having three ports and two positions, known as a 3-2 valve. Each valve sub-assembly 2450, 2452 is operable to inflate and deflate one of the air bladders 2432, 2434. By utilizing two-way valves, the number of valves is halved, reducing the cost, weight, and size of the valve assembly 2440.

[0562] Each of the fluid chambers 2446, 2448 includes first ports 2456, 2458 at the distal ends of the fluid chambers 2446, 2448 that are in fluid communication with the first fluid line 2442, and pressurized air is conveyed into the fluid chambers 2446, 2448 through the first ports 2456, 2458. The first valve sub - assembly 2450 is shown to be in the actuated position by the controller 2454, whereby the first valve sub - assembly 2450 is actuated to move away from the first port 2456. Each valve sub - assembly 2450, 2452 includes a compression spring 2460 within its respective fluid chamber 2446, 2448. Each valve sub - assembly 2450, 2452 also includes an inlet seal 2462 on a translatable valve body 2464. Actuation of the first valve sub - assembly 2450 translates the valve body 2464 away from the first port 2456, thereby compressing the spring 2460, removing the inlet seal 2462 from the first port 2456, and allowing pressurized air to enter the fluid chamber 2446 through the first port 2456. As illustrated with reference to the second valve sub - assembly 2452, removal of current from the solenoid for the second valve sub - assembly 2452 by the controller 2454 results in expansion of the spring 2460, whereby the inlet seal 2462 is pressed against the first port 2458, thereby closing the first port 2458.

[0563] Second ports 2466, 2468 are provided in each of the fluid chambers 2446, 2448 within the housing 2444. Outlet fluid lines 2470, 2472 connect each of the second ports 2466, 2468 to one of the air bladders 2432, 2434. In the actuated or expanded position of the first valve sub - assembly 2450, air enters the fluid chamber 2446 through the first port 2456, passes around the valve body 2464, exits through the second port 2466, passes through the outlet line 2470, and expands the air bladder 2432.

[0564] The valve sub - assemblies 2450, 2452 each include a second seal 2474 and a third seal 2476 provided on a valve body 2464, sequentially spaced from a first seal 2462. The housing 2444 also includes third ports 2478, 2480 formed in each fluid chamber 2446, 2448 to pass through the housing, as exhaust ports. In the expanded position of the first valve sub - assembly 2450, the third port 2478 is blocked and isolated between the second and third seals 2474, 2476. In the contracted position of the second valve sub - assembly 2452, the first port 2458 is sealed to disconnect the fluid chamber 2448 from the pressurized air. In the contracted position, the spring 2460 extends the valve body 2464 such that the second and third seals 2474, 2476 move beyond the second port 2468. In the contracted position, the second port 2468 and the third port 2480 are in fluid communication, whereby the pressurized air in the air bladder 2434 is depressurized, passes through the second fluid line 2472, through the second port 2468, through the fluid chamber 2448, and exits through the exhaust port 2480 to the atmosphere. The contraction of the air bladder 2434 can be further assisted by the compression of the seated occupant against the air bladder 2434.

[0565] Figure 61 shows a valve assembly 2482 according to some embodiments, also referred to as a control module. The valve assembly 2482 includes a housing 2484 for surrounding a plurality of fluid chambers 2486. A plurality of valve sub - assemblies 2488 are each provided in one of the fluid chambers 2486.

[0566] Figures 62 and 63 depict one of the valve sub-assemblies 2488 removed from the housing 2444. Each valve sub-assembly 2488 has an elongated valve body 2490. To minimize the weight and cost of the valve body 2490, the valve body 2490 is formed from a polymeric material such as, for example, polypropylene. This is a structurally elastic and lightweight material. According to some embodiments, the valve body 2490 can be reinforced with, for example, glass fibers. The valve body 2490 is sized to translate within the fluid chamber 2486.

[0567] Referring again to FIG. 61, the housing 2484 includes a primary inlet port 2492. The primary inlet port 2492 is connected to the pump 2438 to receive pressurized air. The housing 2484 includes a pressure chamber 2494 that is in fluid communication with the primary inlet port 2492. The pressure chamber 2494 provides a reservoir for storing pressurized air to a plurality of valve sub-assemblies 2488. A plurality of first valve ports 2496 provide fluid communication from the pressure chamber 2494 to each fluid chamber 2486.

[0568] Referring again to FIGS. 62 and 63, the valve sub-assembly 2488 includes a first seal 2498 and a second seal 2500 that are spaced apart on opposite sides and mounted to the distal end of the valve body 2490. Referring again to FIG. 61, the valve body 2490 is extended to the contracted position. In the contracted position, each of the plurality of first seals 2498 engages one of the plurality of first ports 2496 to seal the first port 2496 and isolate each fluid chamber 2486 from the pressure chamber 2494.

[0569] Figures 62 and 63 show that the valve subassembly 2488 includes an integral compression spring 2502. The spring 2502 extends from the distal end of the valve body 2490 adjacent to the first seal 2498 and extends partially toward the other distal end. The spring 2502 is sinusoidal with alternating curves as a compression spring 2502. A beam 2504 extends generally parallel to the valve body 2490 from the spring 2502. The beam 2504 may be integrally formed with the spring 2502 and the valve body 2490. The beam 2504 has a thickness greater than the thickness of the spring 2502 so that the deformation of the spring 2502 can be controlled as can be observed in Figure 63. Similarly, the valve body 2490 also has a thickness greater than the spring 2502 to limit the deformation of the spring 2502.

[0570] The beam 2504 is designed to maintain a stationary position while the valve body 2490 translates within the fluid chamber 2486 and the spring 2502 is compressed and expanded. The beam 2504 includes a plurality of protrusions 2506, 2508 that extend outwardly from the beam 2504. Referring now to Figure 61, the lateral protrusion 2506 is received in a slot 2510 of the housing 2484 to prevent axial movement of the beam 2504. During installation of the valve subassembly 2488 into the fluid chamber 2486, the first seal 2498 contacts the first port 2496, and then the spring 2502 is partially compressed to bias the first seal 2498 and close the first port 2496. The slot 2510 may be slightly tapered so that as the protrusion 2506 is installed in the slot 2510, the beam 2504 is gradually positioned toward the first port 2496 to slightly compress the spring 2502 and preload the spring 2502. The protrusion 2508 extends toward the valve body 2490 in Figure 62 and provides an alignment spacer between the valve body 2490 and the beam 2504 to maintain the valve body 2490 in alignment with the translation path toward and away from the first port 2496.

[0571] As shown in FIGS. 62 and 63, a pair of conductive terminals 2512, 2514 are mounted at the distal end of the beam 2504. The conductive terminals 2512, 2514 contact a terminal (not shown) and a cover of the housing 2484 (also not shown). The conductive terminals 2512, 2514 are in electrical communication with the controller 2454. A linear actuator such as a shape memory alloy (SMA) 2516 is connected to both terminals 2512, 2514. The SMA 2516 extends from the terminals 2512, 2514, along the beam 2504, along the spring 2502, and around the distal end of the valve body 2490 adjacent to the first seal 2498.

[0572] The SMA 2516 is formed of a material that operates by passing a current through the SMA 2516. For example, the SMA 2516 may be formed of a nickel-titanium alloy that contracts when a current is passed therethrough. When a current is conducted through the SMA 2516, the SMA 2516 shortens its length, thereby compressing the spring 2502 and moving the valve body 2490 away from the first port 2496.

[0573] FIG. 64 shows a partial fragmentary valve assembly 2482 in which one of the valve subassemblies 2488 is sectioned. The valve body 2490 in FIG. 64 is shown in its fully contracted position. The housing 2484 includes a plurality of second ports 2518. Each of these second ports 2518 is connected to one of the fluid chambers 2486 and one of the plurality of air bladders 2432, 2434. The second ports 2518 are parallel to the first port 2496. The housing 2484 also includes a plurality of third ports 2520 provided at the distal ends of the fluid chambers 2486, each venting the respective fluid chamber 2486 to the external atmosphere. The third ports 2520 are axially aligned with the first port 2496. In the contracted position of FIG. 64, air can enter the fluid chamber 2486 from the air bladders 2432, 2434 through the second ports 2518, contract therein, and exit through the exhaust ports 2520. As described above, in the contracted position, the first seal 2498 seals the first port 2496 to prevent pressurized air from entering the fluid chamber 2486.

[0574] Next, referring to FIG. 65, a cross-sectioned valve sub-assembly 2488 is shown in the expanded position. In this figure, the controller 2454 passes current through terminals 2512, 2514, and SMA 2516. The current passing through the SMA 2516 shortens the length of the SMA, thereby actuating the valve body 2490 and simultaneously compressing the spring 2502. The valve body 2490 is translated within the fluid chamber 2486 such that the second seal 2500 engages and seals the exhaust port 2520. In this expanded position, the movement of the valve body 2490 removes the first seal 2498 from the first port 2496. In this position, pressurized air enters the first port 2496 from the pressure chamber 2494, passes through the fluid chamber 2486, exits through one of the second ports 2518 to the air bladders 2432, 2434, and expands the air bladders 2432, 2434.

[0575] Once the controller 2454 shuts off the current to the SMA 2516, the SMA 2516 elongates, allowing the spring 2502 to expand. The expansion of the spring 2502 presses against the beam 2504 and the valve body 2490, translating the valve body back to the contracted position of FIG. 64. In the absence of a signal to the SMA 2516, the air bladders 2432, 2434 contract. This state is often referred to as a constant contraction.

[0576] FIG. 66 shows the assembled valve sub-assembly 2488. FIG. 67 shows the valve sub-assembly 2488 during the assembly step. In FIG. 67, the terminals 2512, 2514 are being slid onto the beam 2504. FIG. 68 shows the conductive components 2512, 2514, 2516 of the valve sub-assembly 2488. The SMA 2516 includes an intermediate loop 2522 spaced from the terminals 2512, 2514.

[0577] FIG. 69 shows the assembly steps for attaching the SMA 2516 to the valve body 2490. As terminals 2512, 2514 are slid onto beam 2504 of FIG. 67, the intermediate loop 2522 of the SMA 2516 is slid over the distal end of the valve body 2490. The valve body 2490 includes an inclined retainer 2524 and a retaining slot 2526 such that loop 2522 slides over the retainer 2524 and into the slot 2526 to hold the SMA 2516 at the distal end of the valve body 2490.

[0578] The valve subassembly 2488 operates to reduce the number of valves by inflating and deflating the air bladders 2432, 2434. The integrated spring 2502 further reduces the number of parts. Only one signal is required to operate each valve subassembly 2488, thereby simplifying the programming and cost of the controller 2454. The translatable valve body 2490 also eliminates the prior art flexible hinges, which are often severe and require costly manufacturing tolerances.

[0579] An assembly (e.g., seat assembly 2420, actuator assembly 2436, valve assemblies 2440, 2482, valve sub-assemblies 2450, 2452, 2488) having a valve body (e.g., valve bodies 2464, 2490) sized for translation within a fluid chamber (e.g., fluid chambers 2446, 2448) is described. The valve body may be elongate and may be formed from a lightweight and elastic material such as a polymer material like polypropylene, may be reinforced with glass fibers, or may be formed from an aluminum alloy. The valve body may include a beam. The beam extends generally parallel to the valve body from the valve body. The beam may be integrally formed with a spring. The beam may have a first thickness. The beam may include a plurality of lateral protrusions that extend outwardly from the beam and are received in slots of a housing to prevent axial translation of the beam, and the slots are slightly tapered such that as the protrusions are installed in the slots, the beam is gradually positioned toward a first port, compressing the spring slightly to provide a preload. The protrusions extend toward the valve body, providing an alignment spacer between the valve body and the beam and maintaining the valve body in alignment with a translation path toward and away from the first port. The valve body may include a valve stem and a valve end. The valve body may be sealed at three axial locations relative to the inner surface of the bore. The fluid chamber may be a housing having a first port formed therein, a second port parallel to the first port, and a third port axially aligned with the first port and venting to an external atmosphere in fluid communication with the fluid chamber. The valve body is oriented within the fluid chamber such that while the third port is sealed from the fluid chamber, fluid enters the first port from a pressurized fluid source and flows out of the second port through the fluid chamber, translating to an inflated position to inflate fluid bladders such as a lumbar bladder, a bolster bladder, a shoulder bladder, etc., and such that while the first port is sealed from the fluid chamber, fluid enters the second port from the fluid bladder and flows out of the third port through the fluid chamber, translating to a deflated position to deflate the fluid bladder.The housing can be formed from a lightweight and structurally elastic material such as a polymeric material or a lightweight metal alloy, using a gasket, cover, fastener, laser welding, friction welding, and / or an adhesive. A pair of opposing seals (e.g., seals 2462, 2474, 2476, 2498, 2500) are oriented on a valve body (e.g., valve bodies 2464, 2490) to seal a pair of ports (e.g., ports 2456, 2458, 2466, 2468, 2478, 2480, 2492, 2496, 2518, 2520). The plurality of seals may be made of elastomer and may be spaced apart and oriented at the distal end of the elongated valve body. A linear actuator (e.g., a solenoid, shape memory alloy 2516) is mounted to the valve body (e.g., valve bodies 2464, 2490) to actuate the valve body (e.g., valve bodies 2464, 2490). The linear actuator may be a shape memory alloy, and an electrical terminal is mounted at the distal end of a beam that is in electrical communication with the shape memory alloy. The shape memory alloy may extend from the terminal, along the beam, along the spring, and around the distal end of the valve body adjacent to the first seal. The shape memory alloy may be formed from a material that operates in response to an electric current, such as a nickel-titanium alloy that contracts when an electric current is passed through it. The linear actuator may translate the valve body in response to an electric current conducted through the shape memory alloy (SMA), causing the SMA to shorten in length, thereby compressing the spring and moving the valve body away from the first port.

[0580] In some embodiments, a linear actuator (e.g., a solenoid, shape memory alloy 2516) further includes a shape memory alloy (e.g., shape memory alloy 2516) that translates a valve body (e.g., valve bodies 2464, 2490) in response to a current conducted through the shape memory alloy. The shape memory alloy may be provided with electrical terminals mounted at the distal end of the beam and in electrical communication with the shape memory alloy. The shape memory alloy may extend from the terminals, along the beam, along the spring, and around the distal end of the valve body adjacent to the first seal. The shape memory alloy (SMA) may be formed from a material that actuates in response to an electric current, such as a nickel-titanium alloy that contracts when an electric current is passed through the material, causing the SMA to shorten its length, thereby compressing the spring and moving the valve body away from the first port.

[0581] In some embodiments, the valve body (e.g., valve bodies 2464, 2490) is elongated, and each of a pair of opposing seals (e.g., seals 2462, 2474, 2476, 2498, 2500) is oriented spaced apart at the distal end of the elongated valve body (e.g., valve bodies 2464, 2490).

[0582] In some embodiments, the housing (e.g., housings 2444, 2484) may be provided with fluid chambers (e.g., fluid chambers 2446, 2448) formed therein. A first port (e.g., first ports 2456, 2458, 2496), a second port (e.g., second ports 2466, 2468, 2518), and a third port (e.g., third ports 2478, 2480, 2520) are in fluid communication with the fluid chamber (e.g., fluid chambers 2446, 2448). The housing can be formed from a lightweight and structurally elastic material such as a polymer material or a lightweight metal alloy, using a gasket, a cover, a fastener, laser welding, friction welding, and / or an adhesive. The second port may be parallel to the first port. The third port may be axially aligned with the first port. The fluid chamber may be vented to the external atmosphere. The valve body (e.g., valve bodies 2464, 2490) is oriented to translate relatively within the fluid chamber (e.g., fluid chambers 2446, 2448).

[0583] In some embodiments, the valve body (e.g., valve bodies 2464, 2490) is translatable to an expanded position to expand the fluid bladder (e.g., fluid bladders 2466, 2468, 2518), such that fluid enters from a pressurized fluid source (e.g., pump 2438) into a first port (e.g., first ports 2456, 2458, 2496), passes through a fluid chamber (e.g., fluid chambers 2446, 2448), exits from a second port (e.g., second ports 2466, 2468, 2518) to expand the fluid bladder (e.g., fluid bladders 2432, 2434), while a third port (e.g., third ports 2478, 2480, 2520) is sealed from the fluid chamber (e.g., fluid chambers 2446, 2448). The fluid bladder may impart tactile effects to the occupant, such as vibrations for conveying attention ventilation, vibrations for imparting massage, and pressure for imparting a pressurized massage effect, like an air bladder such as a lumbar bladder, a bolster bladder, and / or a shoulder bladder. The valve body (e.g., valve bodies 2464, 2490) is translatable to a contracted position, such that fluid enters from the fluid bladder (e.g., fluid bladders 2432, 2434) into a second port (e.g., second ports 2466, 2468, 2518), passes through a fluid chamber (e.g., fluid chambers 2446, 2448), exits from a third port (e.g., third ports 2478, 2480, 2520) to contract the fluid bladder (e.g., fluid bladders 2432, 2434), while a first port (e.g., first ports 2456, 2458, 2496) is sealed from the fluid chamber (e.g., fluid chambers 2446, 2448).

[0584] In some embodiments, an actuator (e.g., fluid bladders 2432, 2434) is connected to a second port (e.g., second ports 2466, 2468, 2518). The actuator may impart tactile effects to the occupant, such as vibrations for conveying attention ventilation, vibrations for imparting massage, and pressure for imparting a pressurized massage effect, like a fluid bladder such as an air bladder such as a lumbar bladder, a bolster bladder, and / or a shoulder bladder.

[0585] In some embodiments, a housing (e.g., housing 2444, 2484) having a plurality of fluid chambers (e.g., fluid chambers 2446, 2448) formed therein each has a first port (e.g., first ports 2456, 2458, 2496), a second port (e.g., second ports 2466, 2468, 2518), and a third port (e.g., third ports 2478, 2480, 2520). The housing can be formed from a lightweight and structurally elastic material such as a polymer material or a lightweight metal alloy using gaskets, covers, fasteners, laser welding, friction welding, and / or adhesives. The second port may be in parallel with the first port. The third port may be axially aligned with the first port. The fluid chambers may vent to the external atmosphere. A plurality of valve assemblies (e.g., valve assemblies 2440, 2482, valve sub-assemblies 2450, 2452, 2488) are provided. The valve body (e.g., valve bodies 2464, 2490) of each valve assembly (e.g., valve assemblies 2440, 2482, valve sub-assemblies 2450, 2452, 2488) is oriented to translate within one of the plurality of fluid chambers (e.g., fluid chambers 2446, 2448).

[0586] An assembly (e.g., sheet assembly 2420, actuator assembly 2436, valve assemblies 2440, 2482, valve sub-assemblies 2450, 2452, 2488) is described as having a valve body (e.g., valve bodies 2464, 2490) formed from a polymeric material. The valve body may be elongate and may be formed from a lightweight and elastic material such as polypropylene, may be reinforced with glass fibers, or may be formed from an aluminum alloy. The valve body may include a beam. The beam extends generally parallel to the valve body from the valve body. The beam may be integrally formed with a spring. The beam may have a first thickness. The beam may include a plurality of lateral protrusions that extend outwardly from the beam to be received in a slot of a housing to prevent axial translation of the beam, and the slot is slightly tapered such that as the protrusion is installed in the slot, the beam is gradually positioned toward a first port, compressing the spring slightly to apply a preload. The protrusion extends toward the valve body, providing an alignment spacer between the valve body and the beam and maintaining the valve body in alignment with a translation path toward and away from the first port. The valve body may include a valve stem and a valve end. The valve body may be sealed at three axial locations relative to the inner surface of the bore. The valve body (e.g., valve bodies 2464, 2490) is sized for translation within a fluid chamber (e.g., fluid chambers 2446, 2448). The fluid chamber may be a housing having a first port formed therein, a second port parallel to the first port, and a third port axially aligned with the first port and exhausting to an external atmosphere in fluid communication with the fluid chamber.While the third port of the valve body is sealed from the fluid chamber, fluid enters the first port from a pressurized fluid source, flows through the fluid chamber, and exits through the second port to translate to an inflated position to inflate fluid bladders such as the lumbar bladder, the bolster bladder, and the shoulder bladder. And while the first port is sealed from the fluid chamber, fluid enters the second port from the fluid bladder, flows through the fluid chamber, and exits through the third port, and is oriented within the fluid chamber so as to be translatable to a contracted position to contract the fluid bladder. The housing can be formed from a lightweight and structurally elastic material such as a polymer material or a lightweight metal alloy using a gasket, a cover, a fastener, laser welding, friction welding, and / or an adhesive. Springs (e.g., springs 2460, 2502) are integrally formed with the valve body (e.g., valve bodies 2464, 2490), extend from the valve body (e.g., valve bodies 2464, 2490), and bias the valve body (e.g., valve bodies 2464, 2490) in one direction. The spring may be a compression spring. The spring may be sinusoidally curved alternately. The spring may have a reduced second thickness relative to the first thickness so as to limit the deformation of the spring. A linear actuator (e.g., a solenoid, a shape memory alloy 2516) is mounted to the valve body (e.g., valve bodies 2464, 2490) to actuate the valve body (e.g., valve bodies 2464, 2490) and compress the spring (e.g., springs 2460, 2502). The linear actuator may be a shape memory alloy, and an electrical terminal is mounted at the distal end of a beam that is in electrical communication with the shape memory alloy. The shape memory alloy may extend from the terminal, along the beam, along the spring, and around the distal end of the valve body adjacent to the first seal. The shape memory alloy may be formed from a material that operates in response to an electric current, such as a nickel-titanium alloy that contracts when an electric current flows. The linear actuator may translate the valve body in response to an electric current conducted through the shape memory alloy (SMA), and the SMA shortens in length, thereby compressing the spring and moving the valve body away from the first port.The linear actuator translates the valve body in response to a current conducted through a shape memory alloy, causing the SMA to shorten in length, thereby compressing the spring and moving the valve body away from the first port.

[0587] In some embodiments, a linear actuator (e.g., a solenoid, shape memory alloy 2516) further includes a shape memory alloy (e.g., shape memory alloy 2516) that translates a valve body (e.g., valve bodies 2464, 2490) in response to a current conducted through the shape memory alloy. The shape memory alloy may be provided with electrical terminals mounted at the distal end of the beam and in electrical communication with the shape memory alloy. The shape memory alloy may extend from the terminal, along the beam, along the spring, and around the distal end of the valve body adjacent to the first seal. The shape memory alloy (SMA) may be formed from a material that actuates in response to an electric current, such as a nickel-titanium alloy that contracts when an electric current is passed through the material, causing the SMA to shorten in length, thereby compressing the spring and moving the valve body away from the first port.

[0588] In some embodiments, a beam (e.g., beam 2504) extends from a valve body (e.g., valve bodies 2464, 2490). The beam may generally be parallel to the valve body. The beam may be integrally formed with the spring. The beam may have a first thickness. The beam may include a plurality of lateral protrusions that extend outwardly from the beam and are received in slots of the housing to prevent axial translation of the beam, the slots being slightly tapered such that the beam is gradually positioned toward the first port as the protrusions are installed in the slots, compressing the spring slightly to provide a preload. The protrusions extend toward the valve body and provide an alignment spacer between the valve body and the beam, maintaining the valve body in alignment with the translation path toward and away from the first port.

[0589] In some embodiments, a beam (e.g., beam 2504) has a first thickness. A spring (e.g., springs 2460, 2502) has a second thickness that is reduced relative to the first thickness. By reducing the thickness, deformation of the spring can be restricted.

[0590] In some embodiments, a spring (e.g., springs 2460, 2502) further comprises a compression spring. The spring may be sinusoidal with alternating curvatures.

[0591] In some embodiments, electrical terminals (e.g., terminals 2512, 2514) that are in electrical communication with a shape memory alloy (e.g., shape memory alloy 2516) are mounted to a beam (e.g., beam 2504). The shape memory alloy may extend from the terminals, along the beam, along the spring, and around a distal end of a valve body adjacent to a first seal. The shape memory alloy may be formed from a material that operates in response to an electric current, such as a nickel-titanium alloy that contracts when an electric current flows through it.

[0592] In some embodiments, a housing (e.g., housings 2444, 2484) may be provided with a fluid chamber (e.g., fluid chambers 2446, 2448) formed therein. A first port (e.g., first ports 2456, 2458, 2496), a second port (e.g., second ports 2466, 2468, 2518), and a third port (e.g., third ports 2478, 2480, 2520) are in fluid communication with the fluid chamber (e.g., fluid chambers 2446, 2448). The housing can be formed from a lightweight and structurally elastic material such as a polymer material or a lightweight metal alloy, using gaskets, covers, fasteners, laser welding, friction welding, and / or adhesives. The second port may be parallel to the first port. The third port may be axially aligned with the first port. The fluid chamber may be vented to the external atmosphere. A valve body (e.g., valve bodies 2464, 2490) is oriented to translate relatively within the fluid chamber (e.g., fluid chambers 2446, 2448).

[0593] In some embodiments, the valve body (e.g., valve bodies 2464, 2490) is translatable to an expanded position to expand the fluid bladder (e.g., fluid bladders 2466, 2468, 2518), such that fluid enters from a pressurized fluid source (e.g., pump 2438) into a first port (e.g., first ports 2456, 2458, 2496), passes through a fluid chamber (e.g., fluid chambers 2446, 2448), exits through a second port (e.g., second ports 2466, 2468, 2518) to expand the fluid bladder (e.g., fluid bladders 2432, 2434), while a third port (e.g., third ports 2478, 2480, 2520) is sealed from the fluid chamber (e.g., fluid chambers 2446, 2448). The fluid bladder may impart a tactile effect to the occupant, such as vibrations to convey attention switching, vibrations to impart a massage, or pressure to impart a pressurized massage effect, like an air bladder such as a lumbar bladder, a bolster bladder, and / or a shoulder bladder. The valve body (e.g., valve bodies 2464, 2490) is translatable to a contracted position, such that fluid enters from the fluid bladder (e.g., fluid bladders 2432, 2434) into a second port (e.g., second ports 2466, 2468, 2518), passes through a fluid chamber (e.g., fluid chambers 2446, 2448), exits through a third port (e.g., third ports 2478, 2480, 2520) to contract the fluid bladder (e.g., fluid bladders 2432, 2434), while a first port (e.g., first ports 2456, 2458, 2496) is sealed from the fluid chamber (e.g., fluid chambers 2446, 2448).

[0594] In some embodiments, an actuator (e.g., fluid bladders 2432, 2434) is connected to a second port (e.g., second ports 2466, 2468, 2518). The actuator may impart tactile effects to an occupant, such as vibrations for communicating attentional ventilation, vibrations for imparting massage, and pressure for imparting a pressurized massage effect, like a fluid bladder such as an air bladder, such as a lumbar bladder, a bolster bladder, and / or a shoulder bladder. A source of pressurized fluid (e.g., pump 2438) is connected to a first port (e.g., first ports 2456, 2458, 2496).

[0595] In some embodiments, a housing (e.g., housings 2444, 2484) having a plurality of fluid chambers (e.g., fluid chambers 2446, 2448) formed therein each has a first port (e.g., first ports 2456, 2458, 2496), a second port (e.g., second ports 2466, 2468, 2518), and a third port (e.g., third ports 2478, 2480, 2520). The housing can be formed from a lightweight and structurally elastic material, such as a polymeric material or a lightweight metal alloy, using a gasket, a cover, a fastener, laser welding, friction welding, and / or an adhesive. The second port may be parallel to the first port. The third port may be axially aligned with the first port. The fluid chambers may vent to the external atmosphere. A plurality of valve assemblies (e.g., valve assemblies 2440, 2482, valve sub-assemblies 2450, 2452, 2488) are provided. The valve body (e.g., valve bodies 2464, 2490) of each valve assembly (e.g., valve assemblies 2440, 2482, valve sub-assemblies 2450, 2452, 2488) is oriented to translate within one of the plurality of fluid chambers (e.g., fluid chambers 2446, 2448).

[0596] An assembly (e.g., a seat assembly 2420, an actuator assembly 2436, a valve assembly 2440, 2482, a valve sub - assembly 2450, 2452, 2488) is described as having a housing (e.g., housings 2444, 2484) in which a fluid chamber (e.g., fluid chambers 2446, 2448) is formed. A first port (e.g., first ports 2456, 2458, 2496), a second port (e.g., second ports 2466, 2468, 2518), and a third port (e.g., third ports 2478, 2480, 2520) are in fluid communication with the fluid chamber (e.g., fluid chambers 2446, 2448). The housing can be formed from a lightweight and structurally elastic material such as a polymeric material or a lightweight metal alloy, using gaskets, covers, fasteners, laser welding, friction welding, and / or adhesives. The second port may be parallel to the first port. The third port may be axially aligned with the first port. The fluid chamber may vent to the external atmosphere. The first port (e.g., first ports 2456, 2458, 2496) or the third port (e.g., third ports 2478, 2480, 2520) is formed at the distal end of the fluid chamber (e.g., fluid chambers 2446, 2448). A valve (e.g., valve bodies 2464, 2490) is oriented to translate to an expanded position within the fluid chamber (e.g., fluid chambers 2446, 2448) such that fluid enters from a pressurized fluid source (e.g., a pump 2438) into the first port (e.g., first ports 2456, 2458, 2496), passes through the fluid chamber (e.g., fluid chambers 2446, 2448) and exits through the second port (e.g., second ports 2466, 2468, 2518) to inflate a fluid bladder (e.g., fluid bladders 2432, 2434), while the third port (e.g., third ports 2478, 2480, 2520) is sealed from the fluid chamber (e.g., fluid chambers 2446, 2448). The fluid bladder may impart tactile effects to the occupant such as vibrations for conveying attention - switching, vibrations for imparting massage, and pressure for imparting a pressurized massage effect, like an air bladder such as a lumbar bladder, a bolster bladder, and / or a shoulder bladder.The valve (e.g., valve bodies 2464, 2490) is also translatable to a contracted position, allowing fluid to enter from the fluid bladder (e.g., fluid bladders 2432, 2434) into the second port (e.g., second ports 2466, 2468, 2518), pass through the fluid chamber (e.g., fluid chambers 2446, 2448), exit from the third port (e.g., third ports 2478, 2480, 2520), and contract the fluid bladder (e.g., fluid bladders 2432, 2434), while the first port (e.g., first ports 2456, 2458, 2496) is sealed from the fluid chamber (e.g., fluid chambers 2446, 2448). The valve body may be elongated and may be formed of a lightweight and elastic material such as a polymer material like polypropylene, may be reinforced with glass fibers, or may be formed of an aluminum alloy. The valve body may include a beam. The beam extends generally parallel to the valve body from the valve body. The beam may be integrally formed with a spring. The beam may have a first thickness. The beam may include a plurality of lateral protrusions that extend outward from the beam to be received in a slot of the housing to prevent axial translation of the beam, and the slot may be slightly tapered so that as the protrusion is installed in the slot, the beam is gradually positioned toward the first port, slightly compressing the spring to provide a preload. The protrusion extends toward the valve body, providing an alignment spacer between the valve body and the beam, and may maintain the valve body in alignment with the translation path toward and away from the first port. The valve body may include a valve stem and a valve end. The valve body may be sealed at three axial locations against the inner surface of the bore.

[0597] Figure 70 shows a seat system 2620 according to some embodiments. The seat system 2620 is a vehicle seat system 2620 for a land vehicle, a watercraft, an aircraft, etc. The seat system 2620 may also be a seat system 2620 such as a comfort chair, an office chair, etc. In a vehicle environment, the seat system 2620 may be a front row seat system 2620, or may be a subsequent middle row or rear row seat system 2620.

[0598] The seat system 2620 includes a seat bottom 2622 sized to support the occupant's pelvis and thighs. The seat bottom 2622 is adapted to be mounted to the vehicle floor. The seat back 2624 extends in an upright direction from the seat bottom 2622. The seat back 2624 is sized to receive and support the occupant's back. The seat back 2624 may be supported by the seat bottom 2622 or a support surface thereunder. A headrest 2626 for supporting the occupant's head is also provided on the seat back 2624.

[0599] The seat system 2620 provides contact surfaces 2628, 2630 for receiving and comfortably supporting the occupant. The seat system 2620 includes a plurality of actuators 2632, 2634 provided within the seat system 2620 within the contact surfaces 2628, 2630. Although the arrangement of the actuators 2632, 2634 is illustrated and described, any number or position of the actuators 2632, 2634 may be employed. The actuators 2632, 2634 may be utilized to impart tactile effects to the occupant such as vibrations to convey an alert, vibrations to impart a massage, pressure to impart a pressure massage effect, support to the occupant, and the like.

[0600] In the illustrated embodiment, the actuators 2632, 2634 are fluid bladders 2632, 2634 such as air bladders 2632, 2634. The fluid bladder 2632 is for imparting a pressure massage effect to the occupant. The fluid bladder 2634 is disposed in the side bolster of the seat back 2624 and provides adjustable support to the occupant.

[0601] The seat system 2620 includes a gate valve assembly 2636 that is in fluid communication with fluid bladders 2632, 2634. The gate valve assembly 2636 is in fluid communication with a fill valve assembly 2638 and a logic valve assembly 2640. A pump 2642, such as a compressor, is in fluid communication with the fill valve assembly 2638 and the logic valve assembly 2640 and provides a source of pressurized fluid, such as compressed air, to the fill valve assembly 2638 and the logic valve assembly 2640. The pump 2642 and the electric valve 2638 may be used in any quantity. Alternatively, multiple pumps 2642 may be used without using any electric valves 2638, 2640.

[0602] The controller 2644 is in electrical communication with the pump 2642 and operates the pump 2642 to generate a source of pressurized air. The controller 2644 is also in electrical communication with the fill valve assembly 2638 and the logic valve assembly 2640 and controls the fill valve assembly 2638 and the logic valve assembly 2640 to regulate the flow of pressurized air to the gate valve assembly 2636. The valve assemblies 2636, 2638, 2640 are housed within the seat back 2624 or the seat bottom 2622 of the seat system 2620. The controller 2644 is housed within the vehicle and, in some embodiments, within the seat back 2624 or the seat bottom 2622. The fill valve assembly 2638 and the logic valve assembly 2640 may be manufactured as a single unit. In this case, the controller 2644 may be pre-assembled and integrated into this single unit. If the fill valve assembly 2638 and the logic valve assembly 2640 are manufactured as two separate units, the controller 2644 may also be split into two units, with each unit attachable to its respective valve assembly 2638, 2640.

[0603] The gate valve assembly 2636 is illustrated in detail in FIG. 71. The gate valve assembly 2636 includes a matrix of gate valve sub-assemblies 2646. Each gate valve sub-assembly 2646 is utilized to inflate one of the fluid actuators 2632, 2634. The gate valve assembly 2636 employs a 2×3 matrix or linear array of gate valve sub-assemblies 2646. Although a 2×3 matrix is illustrated and described, any arrangement and quantity of gate valve sub-assemblies 2646 may be employed, such as 2×3, 1×4, 4×4, 6×9, etc.

[0604] The gate valve assembly 2636 utilizes gate valve sub-assemblies 2646 and pneumatic logic to expand and contract a number of fluid actuators while minimizing the number of electrically controlled valves 2638, 2640. Electrically controlled valves 2638, 2640 are expensive, heavy, and typically occupy volume within the seat system 2620. In comparison, gate valve sub-assemblies 2646 are mechanically controlled, inexpensive, compact, and lightweight. In the example depicted, five electrically operated valves are utilized to operate a 2×3 matrix of six gate valve sub-assemblies 2646 for the purpose of actuating six fluid actuators 2632, 2634 in order to reduce one electrically operated valve assembly. According to another example, nine electrically operated valves may be employed for a 3×6 matrix of gate valve sub-assemblies 2646 for the purpose of actuating 18 fluid actuators 2632, 2634 in order to reduce nine electrically operated valves.

[0605] The gate valve assembly 2636 includes a housing 2648. The housing 2648 is formed from a lightweight and structurally elastic material such as a polymer material or a lightweight metal alloy. The housing 2648 includes a matrix of fluid chambers 2650, each having one gate valve sub-assembly 2646 therein. Referring now to FIGS. 71 and 72, a pair of covers 2652, 2654 (shown in phantom lines) are attached to the housing 2648. Gaskets 2656, 2658 are provided between the covers 2652, 2654 and the housing 2648. Fasteners 2660 attach the covers 2652, 2654 and the gaskets 2656, 2658 to the housing 2648. According to some embodiments, the covers 2652, 2654 may be directly attached to the housing 2648 by laser welding, friction welding, adhesion, or other methods to omit the gaskets 2656, 2658 and the fasteners 2660.

[0606] Referring again to FIG. 71, the matrix 2636 of gate valve sub-assemblies 2646 includes two subsets 2662, 2664 of gate valve sub-assemblies 2646, which are oriented in rows 2662, 2664 in the figure. The first row 2662 of gate valve sub-assemblies 2646 is configured to operate the fluid actuator 2634 in a constant expansion state, as will be described in more detail below. The constant expansion state is utilized for bladders 2634 that maintain pressure, such as a lumbar bladder, a bolster bladder, a shoulder bladder, etc. The second row 2664 of gate valve sub-assemblies 2646 is configured to operate the fluid actuator 2632 in a constant contraction state, as will be described in more detail below. The constant contraction state is employed for bladders 2632 that rapidly expand and contract, such as the massage bladder 2632.

[0607] The housing 2648 includes a plurality of inflation connectors 2666, each of which provides an inflation pressure inlet to a subset of the gate valve sub-assemblies 2646 that each include one gate valve sub-assembly 2646 from rows 2662, 2664 or columns 2668, 2670, 2672. Three inflation connectors 2666 are each connected to a pressure chamber reservoir or bus 2674. The bus 2674 extends along the length of each column 2668, 2670, 2672 and is in fluid communication with each fluid chamber 2650 in each of the columns 2668, 2670, 2672. The bus 2674 is also enclosed and sealed by a cover 2652 and a gasket 2656. The connectors 2666 are provided with valves for the purpose of connection to a hose for receiving pressurized air from the filling valve assembly 2638.

[0608] The housing 2648 also includes a plurality of control connectors 2676, each of which provides a control pressure inlet to one of rows 2662, 2664 of the gate valve sub-assembly 2646. Two control connectors 2676 are each connected to a bus 2678 as shown in FIG. 72. The bus 2678 extends along the length of each of rows 2662, 2664 for fluid communication with each fluid chamber 2650 within each of rows 2662, 2664. The bus 2678 is enclosed and sealed by a cover 2654 and a gasket 2658. The control connectors 2676 receive pressurized air from the logic valve assembly 2640.

[0609] FIGS. 71 and 72 show that the housing 2648 includes a plurality of port connectors 2680, each of which is in fluid communication with one of the fluid chambers 2650. The port connectors 2680 are also each in fluid communication with one of the fluid actuators 2632, 2634, sending pressurized fluid from the fluid chamber 2650 to the fluid actuators 2632, 2634 to inflate the fluid actuators 2632, 2634.

[0610] Referring again to FIG. 70, during operation of the gate valve subassembly 2646 at line 2662, the controller 2644 operates the pump 2642 to provide a source of pressurized air. The controller 2644 also operates the fill valve assembly 2638 to allow pressurized air to enter into the connector 2666 (FIG. 71) and pass into the bus 2674 of the gate valve assembly 2636. Referring to FIGS. 73 and 74, for each gate valve subassembly 2646, a lateral fluid line 2682 is provided, which branches from the corresponding bus 2674 towards the corresponding fluid chamber 2650. A fill inlet 2684 is shown in FIG. 74. This is formed to reach the ...

Claims

Claim 1 An assembly comprising: a) a trim cover layer, a non-foamed layer attached to the trim cover layer, and one or more fasteners connected to the trim cover layer and / or the non-foamed layer; b) a mesh pad of polymer fibers joined together by a molten portion of the polymer fibers, the mesh pad formed in a seat cushion, a seat cover including a tie-down strip attached to the seat cover, the tie-down strip defining a plurality of holes, and a helical retainer for fixing the tie-down strip to the polymer fibers, the helical retainer being wound through the holes and looped into the welded polymer fibers; c) a base including a contact surface, a connector attached to the base, the connector having a width smaller than the width of the base and sized to extend through a slot in the cushion, and a retainer having a width larger than the width of the connector and a thickness smaller than the width of the retainer, the retainer being pivotally attached to the connector spaced from the base and configured to be inserted in the thickness direction into the slot of the cushion, and further configured to be pivoted outwardly of the cushion such that the width of the retainer engages the cushion, the retainer for holding the base on the cushion; d) a twisted thermoplastic mesh seat cushion, an envelope surrounding and conforming to the seat cushion, and a multi-layer trim cover having an outer layer and an inner layer, the inner layer being attached to the envelope by a surface fastener; e) a twisted thermoplastic mesh seat cushion, an envelope surrounding the seat cushion, and a multi-layer trim cover having an outer layer and an inner layer fastened to the envelope, the envelope being adapted to the seat cushion by maintaining a partial vacuum within the envelope; and / or f) A twisted yarn thermoplastic mesh sheet cushion having a concave surface, an envelope surrounding the sheet cushion, the envelope having a reinforcing material adjacent to the concave surface to prevent the envelope from separating from the concave surface, and a multilayer trim cover having an outer layer and an inner layer fastened to the envelope. **Claim 2** Further comprising a trim assembly, wherein the trim assembly comprises the trim cover layer, the non-foamed layer attached to the trim cover layer, and one or more fasteners connected to the trim cover layer and / or the non-foamed layer. The assembly according to claim 1. **Claim 3** The trim assembly according to claim 2, wherein the non-foamed layer comprises a twisted yarn mesh material member. **Claim 4** The trim assembly according to claim 3, wherein the twisted yarn mesh material member comprises a polymer mesh having a plurality of integrated polymer twisted yarns. **Claim 5** The trim assembly according to claim 4, wherein the non-foamed layer comprises a plastics spacer material. **Claim 6** The trim assembly according to any one of claims 2 to 5, wherein the non-foamed layer defines a trench intersecting at least one of the first side and the second side of the non-foamed layer. **Claim 7** The trim assembly according to claim 6, wherein the one or more fasteners further comprise a tie-down connected to the trim cover layer and extending distally to the free end into the trench of the non-foamed layer. **Claim 8** The trim assembly according to any one of claims 2 to 7, wherein the one or more fasteners further comprise hog rings, hook fasteners, loop fasteners, arrows, loops, clips, paddles, and / or drawstrings. **Claim 9** The trim assembly according to any one of claims 2 to 8, wherein the trim cover layer is attached to the non-foamed layer via a seam. **Claim 10** The trim assembly according to any one of claims 2 to 8, wherein the trim cover layer is attached to the non-foamed layer via a welded connection. **Claim 11** The trim assembly further comprises a third layer connected to the trim cover layer and / or the non-foamed layer, wherein the non-foamed layer is disposed between the trim cover layer and the third layer. **Claim 12** The trim assembly according to claim 11, wherein the third layer comprises a non-woven fabric. **Claim 13** The trim assembly according to any one of claims 2 to 12, wherein the trim assembly is provided without a spacer fabric.

14. A seat assembly, comprising: a support member; the trim assembly according to any one of claims 2 to 13; and a seat assembly including the same.

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

16. Further comprising a seat cushion defining a first surface for supporting an occupant and a second surface opposite the first surface, wherein the seat cushion is supported by the support member and disposed between the support member and the trim assembly, and the trim assembly is connected to the seat cushion and / or the support member via the one or more fasteners.

17. The seat assembly according to claim 16, wherein the seat cushion includes a non-foamed member and / or a foamed member.

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

19. The mesh pad of polymer fibers joined together by a molten portion of the polymer fibers, the mesh pad being formed in the seat cushion; the seat cover including a tie-down strip attached to the seat cover, the tie-down strip defining a plurality of holes; and the helical retainer for fixing the tie-down strip to the polymer fibers, the helical retainer being wound through the holes and the helical retainer being looped into the welded polymer fibers. The assembly according to claim 1, further comprising the same.

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

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

22. The assembly according to any one of claims 19 to 21, wherein the tie-down strip is a plastic strip including a bead reinforcement.

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

24. The assembly according to any one of claims 19 to 23, wherein each of the tie-down strips includes a bead reinforcement and a flexible flange formed as a combination.

25. The mesh pad defines a groove, the seat cover includes a segment of flexible sheet material sewn together with the tie-down strip, the tie-down strip is received in the groove, and the tie-down strip is disposed in the groove together with a guide comb when the helical retainer is wound through the groove to fix the tie-down strip to the welded polymer fibers. The assembly according to any one of claims 19 to 24.

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

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

28. Further comprising a retainer assembly, The retainer assembly includes The base including the contact surface, The connector attached to the base, the connector including a width smaller than the width of the base and sized to extend through the slot of the cushion, And a retainer including a width larger than the width of the connector Further comprising The retainer includes a thickness smaller than the width of the retainer, the retainer is pivotally attached to the connector spaced from the base and configured to be inserted in the thickness direction into the slot of the cushion, and further, the width of the retainer is configured to pivot outward of the cushion so as to engage the cushion, and the retainer holds the base on the cushion. The assembly of claim 1.

29. The retainer assembly according to claim 28, further including a surface fastener on the base contact surface.

30. The retainer assembly of claim 28 or 29, wherein the base provides a plane. **Claim 31** The retainer assembly of any one of claims 28 to 30, wherein the connector comprises a fibrous material. **Claim 32** The retainer assembly of any one of claims 28 to 31, wherein the base comprises a polymer material. **Claim 33** The retainer assembly of any one of claims 28 to 32, wherein the retainer comprises a polymer material. **Claim 34** The retainer assembly of any one of claims 28 to 33, wherein the connector is stitched to the surface of the base on the side opposite the contact surface. **Claim 35** The retainer assembly of any one of claims 28 to 34, wherein the connector is stitched to the retainer. **Claim 36** A vehicle seat assembly comprising: a seat bottom adapted to be attached to a vehicle floor; a seat back extending in an upright position; a seat cushion connected to the seat bottom or the seat back; and a retainer assembly according to any one of claims 28 to 35 attached to a part of the seat cushion. The vehicle seat assembly further comprising a vehicle seat assembly. **Claim 37** The vehicle seat assembly of claim 36, wherein the seat cushion further comprises a twisted yarn thermoplastic mesh. **Claim 38** The vehicle seat assembly of claim 36 or 37, wherein a slot sized to receive the retainer assembly is formed through the cushion. **Claim 39** The vehicle seat assembly of any one of claims 36 to 38, further comprising a seat trim, an actuator, and / or a heat transfer layer attached to the contact surface of the base. **Claim 40** The vehicle seat assembly of any one of claims 36 to 39, wherein the base further comprises a seat trim, an actuator, and / or a heat transfer layer. **Claim 41** The vehicle seat assembly of any one of claims 36 to 40, wherein the seat cushion further comprises a twisted yarn thermoplastic mesh seat cushion connected to the seat bottom or the seat back, and a slot is formed through the cushion. **Claim 42** The vehicle seat assembly of claim 41, further comprising a hook-and-loop fastener on the base contact surface. **Claim 43** The vehicle seat assembly according to claim 41 or 42, further comprising at least one of a seat trim, an actuator, and a heat transfer layer attached to the contact surface of the base.

44. The vehicle seat assembly according to any one of claims 41 to 43, wherein the base further comprises at least one of a seat trim, an actuator, and a heat transfer layer.

45. A twisted yarn thermoplastic mesh sheet cushion, An envelope surrounding and conforming to the seat cushion, The multilayer trim cover having the outer layer and the inner layer, wherein the inner layer is attached to the envelope by the surface fastener, the multilayer trim cover The assembly according to claim 1, further comprising.

46. The assembly according to claim 45, wherein the envelope has a portion having a loop, and the inner layer of the multilayer trim cover includes a hook engaging with the loop.

47. The assembly according to claim 45 or 46, wherein the inner layer of the multilayer trim cover has a loop, and the envelope has a portion having a hook engaging with the loop.

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

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

50. The assembly according to claim 49, wherein the envelope includes a plurality of features extending into the slots to prevent the envelope from separating from the concave surface.

51. The assembly according to claim 49 or 50, wherein the envelope has a reinforcing material adjacent to the concave surface to prevent the envelope from separating from the concave surface.

52. The assembly according to any one of claims 45 to 51, wherein a partial vacuum is maintained in the envelope, and the envelope conforms to the seat cushion.

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

54. A twisted yarn thermoplastic mesh sheet cushion, An envelope surrounding the seat cushion, The multilayer trim cover having the outer layer and the inner layer fastened to the envelope, further comprising, The assembly of claim 1, wherein the partial vacuum is maintained within the envelope, causing the envelope to conform to the seat cushion.

55. The assembly of claim 54, wherein the envelope has a portion with a loop, and the inner layer of the multilayer trim cover includes hooks that engage the loop.

56. The assembly of claim 54 or 55, wherein the inner layer of the multilayer trim cover has loops, and the envelope has a portion with hooks that engage the loops.

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

58. The assembly of any one of claims 54 to 57, wherein the surface of the seat cushion adjacent to the trim cover is concave.

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

60. The twisted yarn thermoplastic mesh seat cushion having a concave surface, The envelope surrounding the seat cushion, the envelope having a reinforcing material adjacent to the concave surface and preventing the envelope from separating from the concave surface, And the multilayer trim cover having an outer layer and an inner layer fastened to the envelope. The assembly of claim 1, further comprising.

61. The assembly of claim 60, wherein the envelope has a portion with a loop, and the inner layer of the multilayer trim cover includes hooks that engage the loop.

62. The assembly of claim 60 or 61, wherein the inner layer of the multilayer trim cover has loops, and the envelope has a portion with hooks that engage the loops.

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

64. The assembly of any one of claims 60 to 63, wherein the envelope includes a plurality of features that extend into the slots to prevent the envelope from separating from the concave surface.

65. A machine, A jig for receiving a mesh pad of polymer fibers joined together in the form of a seat cushion, a seat cover including a tie-down strip defining a plurality of holes, and a guide, A rotary tool including a helical retainer and including a machine in which the helical retainer is wound around the welding polymer fibers of the mesh pad so as to pass through the plurality of holes, and holds the tie-down strip at a predetermined position in the mesh pad.

66. The machine according to any one of the preceding claims 65, further comprising a guide comb including a plurality of teeth defining an inter-tooth gap.

67. The machine according to any one of the preceding claims 65 to 66, wherein the guide comb includes a plurality of teeth defining an inter-tooth gap spaced apart by a distance between each of the plurality of holes.

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

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

70. A method comprising a) attaching a trim cover layer to a non-foamed layer and attaching one or more fasteners to the trim cover layer and / or the non-foamed layer, wherein the trim cover layer, the non-foamed layer, and the one or more fasteners form a trim assembly, b) selecting a mesh pad of welding polymer fibers, wherein the mesh pad defines a plurality of grooves at predetermined positions, selecting a cover including a tie-down strip, and inserting at least one of the tie-down strips into at least one of the grooves defined in the mesh pad, wherein each of the tie-down strips defines a plurality of equally spaced holes above a reinforcing bead attached to the tie-down strip, and winding a helical retainer around the reinforcing bead, through the tie-down strip, and in the grooves so as to pass through the welding polymer fibers of the mesh pad, wherein the spiral retainer is wound so as to pass through the plurality of equally spaced holes and the welding polymer fibers, and holds the tie-down strip at a predetermined position, and / or c) tipping the retainer along the connector of the retainer assembly, inserting the retainer and the connector of the retainer assembly into a slot formed through the seat cushion, translating the retainer through the seat cushion with the connector still at least partially within the slot, expanding the retainer relative to the connector to contact an area of the cushion adjacent to the slot, and holding the connector within the slot. A method.

71. Attaching the trim cover layer to the non-foam layer and attaching one or more fasteners to the trim cover layer and / or the non-foam layer, wherein the trim cover layer, the non-foam layer, and the one or more fasteners form a trim assembly. The method of claim 70.

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

73. Further comprising forming a trim cover layer, forming a non-foam layer The method according to claim 71 or 72.

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

75. Forming a trench in the non-foam layer, Placing a seam formed by sewing the trim cover layer to the non-foam layer into the trench The method of claim 74.

76. Forming a trench in the non-foam layer, Connecting the trim cover layer to the non-foam layer by one or more tag fasteners to form the trim assembly The method according to any one of claims 71 to 75.

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

78. Forming a pocket in the trim cover layer, Inserting the non-foam layer into the pocket, Closing the pocket The method according to any one of claims 71 to 77.

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

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

81. The method according to any one of claims 71 to 80, further comprising connecting the cushion to the support structure before attaching the trim assembly.

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

83. Selecting a mesh pad of welded polymer fibers, the mesh pad defining a plurality of grooves at predetermined positions, selecting a cover including tie-down strips, inserting at least one of the tie-down strips into at least one of the grooves defined in the mesh pad, each tie-down strip defining a plurality of holes arranged at equal intervals above a reinforcing bead attached to the tie-down strip, wrapping the helical retainer around the reinforcing bead, through the tie-down strip, and in the groove so as to pass through the welded polymer fibers of the mesh pad, the helical retainer being wound so as to pass through the plurality of holes arranged at equal intervals and the welded polymer fibers, and holding the tie-down strip in a predetermined position The method of claim 70, further comprising.

84. The method of claim 83, further comprising forming the mesh pad into the shape of a seat cushion.

85. The method according to claim 83 or 84, further comprising sewing the tie-down strip to the cover, the cover being a seat cover.

86. The method according to any one of claims 83 to 85, further comprising inserting a guide comb into the groove to align the plurality of holes arranged at equal intervals with a gap defined by the guide comb and a plurality of turns of the helical retainer.

87. The method according to any one of claims 83 to 86, further comprising inserting a mandrel into the helical retainer and guiding the helical retainer when the helical retainer is rotated and enters into the mesh body.

88. tilting the retainer along the connector of the retainer assembly, inserting the retainer and the connector of the retainer assembly into the slot formed to pass through the seat cushion, translating the retainer through the seat cushion while the connector is still at least partially within the slot, expanding the retainer relative to the connector to contact an area of the cushion adjacent to the slot and hold the connector within the slot The method of claim 70, further comprising.

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

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

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

Images