Air distribution device, thermal conditioning system, and seat

Abstract

An air distribution device for a seat comprising a distribution portion, a blower portion, and a carrier portion. The carrier portion is configured to attach to a portion of the seat and seal off leak paths. The carrier portion is coupled to the distribution portion and the blower portion is decoupled from the carrier portion, allowing movement of the blower portion relative to the distribution portion and the carrier portion after installation of the air distribution device on a seat.

Description

AIR DISTRIBUTION DEVICE, THERMAL CONDITIONING SYSTEM, AND SEATCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims the benefit of U.S. Provisional Application No. 63 / 574,937, filed April 5, 2024 and incorporated herein by reference in its entirety.FIELD

[0002] The present teachings generally relate to an air distribution device, a thennal conditioning system comprising the same, and seat comprising the same.BACKGROUND

[0003] Air distribution devices for thermal conditioning of seats are generally known. Typically, these devices are located on a B-side of a foam layer in a seat. These devices distribute air across a surface area of a seat or pull air from across a surface area of a seat.

[0004] Typically, these devices are adhered to a foam layer, such as via a pressure sensitive adhesive. However, said adhesive connection is susceptible, over the service life of a seat, to delamination. This can be due to repeated use of a seat imparting deformations (e.g., tensions) in various regions of the adhesive connection, thermal cycling of the adhesive, and the like. Moreover, connection to a blower can exacerbate deformations upon the adhesive connection, owing to the typical rigid connection mechanisms of the blower to the air distribution device. The blower connection is particularly susceptible to delamination due to rigid blower and / or conduit structures and, in some circumstances, their fixation to other elements of a seat such as the seat frame. In this regard, occupants entering and exiting the seat repeatedly cause compression and decompression of the foam layer and said rigid components can have a tendency to pull away from the foam layer as they do not pliably move with the foam layer, such as in comparison to other generally pliable elements of the device, such as fabric or film elements.

[0005] Regions around vents formed in these devices are also susceptible to delamination. Typically, there is a relatively small extent (e.g., about 10-15mm) of adhesive between some vents and the edge of the device. Greater extents of adhesive can be provided for, to mitigate delamination, by configuration of the dimensions and location of the vents. Yet, limitations in vent dimensions presents other challenges. Installation involves alignment of vents in the device with channels formed in the foam layer. It can be appreciated that misalignment may diminish the performance of thermal conditioning, and that small vent sizes can be difficult to align.

[0006] Said adhesive connection maintains airflow paths between the device and a foam layer. Delamination may introduce leak paths, resulting in airflow leaking into various areas of the seat anddiminishing the airflow intended to be introduced to the occupant or pulled from the scat surface. Thus, the intended effect of thennal conditioning upon an occupant may not be met in the event of one or more sites of delamination.

[0007] It would be desirable to provide an air distribution device that, relative to conventional approaches, is less susceptible to delamination.

[0008] It would be desirable to provide an air distribution device that, relative to conventional approaches, is easier to install in a seat.

[0009] It would be desirable to provide an air distribution device that, relative to conventional approaches, more efficiently exchanges air with a seat surface.SUMMARY

[0010] Tire present disclosure relates to an air distribution device, which may address at least some of the needs identified above. Tire air distribution device may be configured for a seat. The air distribution device may comprise a distribution portion, a blower portion, and a carrier portion. The carrier portion may be coupled to the distribution portion and configured to attach to a portion of the seat and seal off leak paths. The blower portion may be decoupled from the carrier portion, allowing movement of the blower portion relative to the distribution portion and the carrier portion after installation of the air distribution device on the seat.

[0011] Said movement may be pivotal movement. The blower portion may be pivotably engaged with the distribution portion.

[0012] The air distribution device may define an enclosure through which airflow travels. A first portion of the enclosure may be defined within the distribution portion and a second portion of the enclosure may be defined within the blower portion.

[0013] Tire enclosure may be continuous between the distribution portion and the blower portion.

[0014] The air distribution device may further comprise at least one spacer located within the enclosure and maintaining a gap between two opposing internal surfaces of the enclosure. The at least one spacer may include a mesh, a foam, or the like.

[0015] The at least one spacer may be continuous between the distribution portion and the blower portion and may be pivotable at or in proximity to where the distribution portion meets the blower portion. The at least one spacer may include a first spacer located within tire distribution portion and a second spacer located within the blower portion.

[0016] The distribution portion and the blower portion may be both located within a profile of the carrier portion. At least one dimension of the distribution portion and at least one dimension of the blower portion may be less than at least one dimension of the carrier portion.

[0017] The blower portion may comprise a connection mechanism on a first side of the air distribution device for receiving a blower or a conduit that ultimately connects to the blower; and wherein the connection mechanism provides for a rigid connection of the blower or the conduit to the air distribution device.

[0018] The distribution portion may comprise one or more vents located on a second side of the air distribution device, the second side being in opposing relationship to the first side. Tire one or more vents may be adapted for air exchange between the air distribution device and a surface of a seat. The carrier portion may comprise one or more vents in alignment with the one or more vents of the distribution portion.

[0019] The carrier portion may comprise a first side coupled to the distribution portion and a second side comprising an adhesive layer adapted for coupling to the seat, the first side being in opposing relationship to the second side.

[0020] Tire air distribution device may be fabricated from a lamination of one or more fabric layers and one or more film layers. The one or more fabric layers may include a fleece. The film may be a polymer film.

[0021] The lamination may be bonded by adhesive, welding, stitching, or any combination thereof.

[0022] The one or more film layers may be comprised by the blower portion and the distribution portion. The one or more film layers may define the enclosure. At least some of the one or more fabric layers may be disposed over and / or around the one or more film layers.

[0023] The carrier portion may comprise a first segment and optionally a second segment. The first segment may be located on the second side of the distribution layer and at least a portion of the second segment may be located on the first side of the distribution layer. The second segment may overlap the first segment and may cooperate with the first segment to sandwich an edge of the distribution portion.

[0024] The carrier layer may comprise a third segment coupled to and at least partially extending beyond the distribution portion in an extension direction of tire blower portion. The third segment may comprise one or more tabs, preferably tw o tabs, coupling the third segment to tire first segment. The one or more tabs may extend along opposing edges of the distribution portion to connect to the first segment.

[0025] The present disclosure relates to a thermal conditioning system, which may address at least some of the needs identified above. The thermal conditioning system may comprise the air distribution device according to any one of the preceding paragraphs, the thermal conditioning system further comprising the blower, the conduit, a thermoelectric device, a resistive heater, one or more sensors, or any combination thereof.

[0026] The present disclosure relates to a seat, which may address at least some of the needs identified above. The seat may comprise the air distribution device according to any one of the preceding paragraphs.

[0027] Tire scat may further comprise a trim layer adapted for contact with an occupant and a cushion layer, preferably a foam layer, in fluid communication with the air distribution device and disposed underneath the trim layer. The cushion layer may have an A-side oriented toward the trim layer and a B- side oriented toward the air distribution device.

[0028] The carrier portion of tire air distribution device may be at least partially coupled on the second side thereof to tire cushion layer.

[0029] Tire blower portion may be decoupled from and movable relative to the cushion layer.

[0030] The cushion layer may comprise one or more channels that fluidly communicate with the one or more vents of the distribution portion. The one or more vents may have at least one dimension that is greater than the one or more channels.

[0031] The present disclosure relates to a seat, which may address at least some of the needs identified above. The seat may comprise a trim layer adapted for contact w ith an occupant; a cushion layer, preferably a foam layer, disposed underneath the trim layer; and an air distribution device in fluid communication with the air distribution device at tire A-side. The cushion layer may have an A-side oriented toward the trim layer and a B-side opposing the A-side.

[0032] The air distribution device may comprise a distribution portion, a blower portion, and a carrier portion. The carrier portion may couple the air distribution device to the cushion layer and the distribution portion is coupled to tire carrier portion. The blower portion may be decoupled the cushion layer, allowing movement of the blower portion relative to the cushion portion. It is expressly contemplated by the present teachings that the air distribution device may have one or any combination of features described in the foregoing paragraphs.BRIEF DESCRIPTIONS OF THE DRAWINGS

[0033] FIG. 1A illustrates an air distribution device according to the present teachings.

[0034] FIG. IB illustrates an air distribution device according to the present teachings.

[0035] FIG. 2A illustrates an air distribution device according to the present teachings.

[0036] FIG. 2B illustrates an air distribution device according to the present teachings.

[0037] FIG. 2C illustrates an air distribution device according to the present teachings.

[0038] FIG. 3A shows a thermal profde of a seat.

[0039] FIG. 3B shows a thermal profde of a seat.

[0040] FIG. 4A is an exploded sectional view of an air distribution device.

[0041] FIG. 4B is an exploded sectional view of an air distribution device.

[0042] FIG. 4C is an exploded sectional view of an air distribution device.

[0043] FIG. 4D is an exploded sectional view of an air distribution device.

[0044] FIG. 4E is an exploded sectional view of an air distribution device.DETAILED DESCRIPTION

[0045] The present teachings meet one or more of the needs described above by the improved air distribution device, thermal conditioning system, and seat described herein.

[0046] Tire air distribution device and the thermal conditioning system may be located within a seat, such as a vehicle seat. Examples in the present teachings may refer to automobile seats, although other types of seats are contemplated. The seats may be located in other types of vehicles, such as airplanes, trains, busses, or otherwise. The seats may be furniture, such as office chairs.

[0047] The seat may comprise a trim layer, a cushion layer, and a frame. The trim layer may be contacted by an occupant. In this regard, the trim layer may comprise a surface upon which an occupant is seated. Exemplary trim layer materials may include leather or fabric. The cushion layer may be located underneath the trim layer. The frame may define the structure of the seat. At least a portion of the cushion layer may be disposed upon the frame . The frame may comprise one or more voids in which the air distribution device, conduit, blower, or any combination thereof may fit. The cushion layer may comprise a cutout in which the air distribution device, conduit, blower, or any combination thereof may fit.

[0048] The cushion layer may function to distribute air across a surface of a seat and / or pull air from across a surface of a seat. Tire cushion layer may comprise a compressible material such as a foam. The compressible material may be adapted and configured to provide comfort to an occupant. Tire foam may be a closed-cell foam or an open-cell foam. Although the present teachings may refer to the cushion layer as comprising a foam, any suitable compressible material or combination of compressible materials may be used. The cushion layer may be in fluid communication with the air distribution device. The cushion layer may comprise a plurality of channels, a porosity, or both. Open-cell foam may be one, non-limiting example of porosity. Air may travel through the cushion layer via the plurality of channels, the porosity, or both.

[0049] The side of the cushion layer oriented toward the trim layer and the occupant may be referred to as an A-side. Tire side of the cushion layer oriented toward tire air distribution device may be referred to as a B-side. A-side and B-side may refer to similar orientations of any elements described herein (e.g., trim layer, air distribution device, distribution portion, blower portion, carrier portion, etc.), and in general, the A-side may be oriented toward the occupant and the B-side may be oriented away from the occupant.

[0050] Tire seat may comprise a base portion and a back portion. An occupant’s buttocks and legs may rest upon the base portion. An occupant’s back may rest upon the back portion. The air distribution device may be located in the base portion, the back portion, or both. It is contemplated that a plurality of air distribution devices may be located in the base portion, the back portion, or both. By way of example, butnot limitation, the back portion may comprise a first air distribution device in an upper section thereof and a second air distribution device in a lower section thereof.

[0051] The air distribution device may comprise a distribution portion, a blower portion, and a carrier portion. The distribution portion and the blower portion may cooperate to direct an airflow to or from a seat surface. That is, a blower may cause air to flow through the distribution portion and the blower portion. The carrier portion may couple the air distribution device to the seat, particularly to the cushion layer. The carrier portion may couple the distribution portion to the seat.

[0052] The air distribution device may define an enclosure through which air may travel. The air distribution device may be referred to as a bag, due to the configuration of the enclosure within the distribution and blower portions, through which air may travel. The enclosure may comprise a first portion defined within the distribution portion and a second portion defined within the blower portion. The enclosure may be continuous between the distribution portion and tire blower portion.

[0053] Tire enclosure may comprise one or more walls therewithin. The one or more walls may connect to the two opposing internal surfaces of the enclosure. The walls may direct airflow, split airflow into a plurality of discrete streams, impose a tortuous path upon the airflow, or any combination thereof.

[0054] The air distribution device may comprise at least one spacer. The at least one spacer may function to maintain a gap between two opposing internal surfaces of the enclosure. The two opposing internal surfaces may be formed by film layers. The at least one spacer may include a mesh (e.g., a 3D lattice mesh), a foam, tire like, or any combination thereof.

[0055] The at least one spacer may be continuous between the distribution portion and the blower portion. Said continuous spacer may be pivotable at or in proximity to where the distribution portion meets the blower portion. That is, at or in proximity to the parting line between the distribution and blower portions. The at least one spacer may include a first spacer located within the distribution portion and a second spacer located within the blower portion, the first spacer being pivotable relative to the second spacer.

[0056] In a push mode, air may be pushed from the blower to a seat surface. In the push mode, tire blower portion may have a connection mechanism that fiinctions as an inlet, and tire distribution portion may have a vent that functions as an outlet. In a pull mode, air may be pulled from the seat surface to the blower. In the pull mode, the blower portion may have a connection mechanism that fiinctions as an outlet, and the distribution portion may have a vent that fiinctions as an inlet.

[0057] Tire distribution portion may function to deliver air to or receive air from the cushion layer. The distribution portion may fluidly communicate with tire cushion layer. The distribution portion may fluidly communicate with the blower portion. The distribution portion may be coupled at least in some regions to the carrier portion. The distribution portion, via the carrier portion, may be coupled to the cushion layer.

[0058] The distribution portion may comprise one or more vents. The one or more vents may function to permit air exchange between the air distribution device and the cushion layer. Hie one or more vents may fluidly communicate with the cushion layer (e.g., with channels, porosity, or the like formed in the cushion layer). The one or more vents may be located on a side of the air distribution device opposing a side of the air distribution device having the connection mechanism described herein. The one or more vents may be located on an A-side of the distribution portion. The one or more vents may generally align with channels, porosity, or both formed in the cushion layer. In this regard, air may be exchanged through the channels, porosity, or both.

[0059] The one or more vents may include four or less vents, three or less vents, two or less vents, or even one vent. Fewer vents may be achieved by the air distribution device of the present disclosure due to the greater adhesion surface area and the configuration of the blower portion to preclude or at least substantially mitigate delamination, which will be described in greater detail below.

[0060] Tire present teachings contemplate any suitable arrangement of the one or more vents. Each of the one or more vents may fluidly communicate with a channel. A vent may fluidly communicate with a plurality of channels. A plurality of vents may fluidly communicate with a channel. Any combination of the foregoing is within the scope of the present teachings.

[0061] As will be described herein, the configuration of the blower portion may preclude or at least substantially mitigate challenges with delamination of the air distribution device from the cushion layer. In this regard, the air distribution device of the present teachings may provide for larger vent dimensions relative to convention. That is, with a reduced propensity for delamination of the distribution portion, the surface area of the distribution portion that is adhered or otherwise coupled to the cushion layer may be reduced, relative to convention. With such reduction of adhered or otherwise coupled surface area, one or more dimensions of the one or more vents may be increased. In this regard, the area occupied by the one or more vents may be about 30% or more, about 40% or more, about 50% or more, about 60% or more, or even about 70% or more of the surface area of the A-side of the distribution portion. Tire area occupied by the one or more vents may be about 95% or less, 90% or less, 85% or less, 80% or less, or even 75% or less of the surface area of the A-side of the distribution portion. The present teachings contemplate any range defined by any two of the foregoing endpoints (e.g., about 30% to 75%, about 40% to 90%, etc ). Larger vents may be advantageous for ensuring alignment with channels formed in the cushion layer of the seat, offering greater tolerances in assembly processes.

[0062] The blower portion may function to receive one or more blowers or one or more conduits that ultimately extend to one or more blowers. The blower portion may fluidly communicate with the distribution portion. The blower portion may be decoupled from or coupled to the carrier portion. Theblower portion, whether or not coupled to the carrier portion, may ultimately be decoupled from the cushion layer.

[0063] Decoupled from the cushion layer, as described herein, may refer to a substantial surface area (e.g., about 95% or more, about 97% or more, or even about 99% or more) of the A-side surface of the blower portion being decoupled from the cushion layer. Stated differently, a substantial portion of the blower portion may be able to move (e.g., pivot) relative to the carrier and distribution portions and the cushion layer. It is understood that at least one edge of the blower portion may be coupled to the cushion layer via the carrier layer described herein, or in another aspect, that at least one edge of the blower portion may be coupled with the distribution portion which itself may be coupled to the cushion layer.

[0064] The blower portion may move relative to the distribution portion and optionally the carrier portion, after installation in a seat. Said movement may be pivotal movement. The blower portion may be pivotably engaged with the distribution portion. Said pivotal engagement may be via a living hinge. That is, one or more structures connecting the blower portion to the distribution portion may be pliable to provide for said pivotal movement.

[0065] The blower portion may be decoupled from and movable relative to the cushion layer. In this regard, repeated compression and decompression of the cushion layer may be independent of the blower portion. The air distribution device of the present teachings may be advantageous for mitigating or substantially preventing delamination of the air distribution device from the cushion layer. As described above, this arrangement may allow a greater vent size relative to convention, as a lesser surface area coverage of adhesive may be required to maintain engagement of the air distribution device with the cushion layer.

[0066] In some aspects, the carrier portion may be coupled, at least in part, to the blower portion, and at least a portion of the carrier portion may be decoupled from the cushion layer in the region of the blower portion.

[0067] By decoupling the blower portion, or the carrier portion together with the blower portion, from the cushion layer, the blower portion may be free to move independent from the cushion layer. Thus, repeated compression and decompression of the cushion layer, thermal cycling, or otherwise may be precluded from lead to delamination of the air distribution device from the cushion layer.

[0068] The blower portion may comprise a connection mechanism. The connection mechanism may function to receive a blower or a conduit that ultimately connects to a blower. The connection mechanism may snap-fit to a blower or a conduit, although any other suitable mechanism is envisioned by the present teachings, such as a twist-lock mechanism or fasteners (e.g., screws) extending through the blower or conduit and into the connection mechanism (such as extending through engaged flanges of the blower and conduit). The connection mechanism may provide for a rigid connection of the blower or the conduit to the air distribution device.

[0069] The connection mechanism may comprise a first member and a second member. The first member may be located within an enclosure defined by the blower portion. The second member may be located exterior of the enclosure. The first and second mechanisms may sandwich one or more fabric and / or film layers of the blower portion. The first and second members may fasten together such as via a snap-fit mechanism or any other suitable arrangement, such as a twist-lock mechanism or fasteners (e.g., screws) extending through the first and second members.

[0070] Tire connection mechanism may comprise a gasket. The gasket may function to aid in fluidly sealing the connection mechanism. The gasket may be sandwiched between the first and second members. The gasket may be located within the enclosure defined by the blower portion and thus, sandwiched between the first member and the blower portion. The gasket may be located exterior of the enclosure defined by tire blower portion and thus sandwiched between the second member and the blower portion.

[0071] Tire carrier portion may function to secure the air distribution device, particularly the distribution portion to the cushion layer. The carrier portion may be at least partially coupled to the cushion layer. The distribution portion may be at least partially coupled to tire cushion layer via the carrier portion.

[0072] The carrier portion may comprise an adhesive layer adapted to couple to the cushion layer. The carrier portion may comprise a B-side engaged with (e.g., adhesively engaged with) the distribution portion and optionally at least a portion of the blower portion. The carrier portion may comprise an A-side adapted for engagement with the cushion layer. The A-side may be in opposing relationship to the B-side.

[0073] The carrier portion may comprise one or more vents. Tire one or more vents may align with the one or more vents of the carrier portion. The one or more vents of the carrier portion and the one or more vents of the distribution portion may be formed after coupling of the carrier and distribution portions. The one or more vents of the carrier portion may be formed independently of the one or more vents of the distribution portion, and vice versa, and the same may be aligned upon coupling the carrier and distribution portions together.

[0074] The distribution portion and optionally the blower portion may be located within a profile of the carrier portion. That is, at least one dimension (e.g., a length and / or a width) of the distribution portion and at least one dimension (e.g., a length and / or a width) of the blower portion may be less than at least one dimension (e g., a length and / or a width) of the carrier portion.

[0075] Although in some aspects the blower portion may be decoupled from the carrier portion, the carrier portion may extend along the blower portion and couple to tire cushion layer in the region of the blower portion. This arrangement may provide a fabric layer which the blower portion may, at least at times, contact. This may prevent abrasion of the blower portion directly against the cushion layer.

[0076] The carrier portion may comprise one or more segments. Tire one or more segments may locate at least partially on the first and / or second side of the distribution portion. The one or more segments may aid in sealing the enclosure of the air distribution device, reinforcing the air distribution device, or both.

[0077] The carrier portion may comprise a first segment. The first segment may be located on the A-side of the distribution portion. The first segment may have one or more dimensions (e.g., a length and / or a width) that are generally equal to one or more dimensions (e.g., a length and / or a width) of the distribution portion and optionally the blower portion. Tire first segment may have one or more dimensions (e.g., a length and / or a width) that are greater than one or more dimensions (e.g., a length and / or a width) of the distribution portion and optionally the blower portion. The distribution portion and optionally the blower portion may be located within the profile of the first segment. The distribution portion and optionally the blower portion may be coextensive, with respect to at least one dimension, with the first segment.

[0078] Tire carrier portion may comprise a second segment. At least a portion of the second segment may be located on the B-side of the distribution layer. Tire second segment may overlap the first segment. The first and second segments may sandwich an edge of the distribution portion therebetween. Said edge may be an edge opposing the edge to which the blower portion is attached.

[0079] The carrier portion may comprise a third segment. The third segment may at least partially extend beyond the distribution portion in an extension direction of the blower portion. The third segment may comprise one or more tabs, preferably two tabs, that connect the third segment to the first segment. The two tabs may extend along opposing edges of the distribution portion. The one or more tabs may cooperate with the first segment to sandwich one or more edges of the distribution portion.

[0080] The second and third segments may at least partially overlap the edges of the distribution portion. In this regard, the seams of the distribution portion may be reinforced.

[0081] The different segments of the carrier portion may be connected by adhesive (e.g., a pressure sensitive adhesive), welding, stitching, or any combination thereof. Regions where different segments overlap or otherwise contact may be referred to herein as seams.

[0082] With the one or more segments of the carrier portion, the dimensions (e.g.. a length and / or a width) of the carrier portion may extend beyond the dimensions (e.g., a length and / or a width) of the distribution and blower portions. In this regard, a larger adhesive surface area, relative to conventional devices, may be provided for around vents that fluidly communicate with the cushion layer of a seat. Said larger adhesive surface area may provide for larger vent dimensions, larger tolerances for fitting the vents to channels in the cushion layer, easier installation, or any combination thereof.

[0083] The carrier portion may extend about 20 mm or more, 25 mm or more, 30 mm or more. 35 mm or more, or even 40 mm or more from one or more edges of the distribution and blower portions. The carrier portion may extend about 60 mm or less, 55 mm or less, 50 mm or less, or even 45 mm or less from one ormore edges of the distribution and blower portions. Tire one or more edges may be opposing edges shared by both of the blower and distribution portions.

[0084] The carrier portion may extend about 100 mm or more, 150 mm or more, 200 mm or more, or even 250 mm or more from an edge of the distribution portion and / or an edge of the blower portion. The carrier portion may extend about 400 mm or less, 350 mm or less, or even 300 mm or less from an edge of the distribution portion and / or an edge of tire blower portion. Said edges may be edges exclusive to the distribution portion and exclusive to the blower portion.

[0085] For all edges of the distribution and blower portions, preferably the carrier portion extends therefrom no less than 20 mm. more preferably no less than 25 mm.

[0086] The distribution portion, the blower portion, and the carrier portion may be fabricated from a lamination of one or more fabric layers, one or more film layers, or both. Tire one or more fabric layers may be fabricated from fleece. The one or more film layers may be fabricated from polymer (e.g., polyurethane). Preferably, tire film layers may be generally fluid impermeable. The one or more film layers may define the enclosure and at least some of the one or more fabric layers may be disposed over and / or around tire one or more film layers.

[0087] The one or more fabric layers and one or more film layers may be laminated by adhesive (e.g., a pressure sensitive adhesive), welding, stitching, or any combination thereof. Tire adhesive may be provided as a continuous layer and / or in discrete regions.

[0088] The A-side of the carrier portion may comprise an adhesive. Tire adhesive may be provided with a peel-away layer such as a film or a paper. In this regard, the air distribution device can be pre-assembled and provided to a secondary assembly process wherein the peel-away layer can be removed and the air distribution device can be installed to a seat.

[0089] The air distribution device described herein may be comprised by a thermal conditioning system. Tire thermal conditioning system may function to pull air from a surface of a seat, deliver air to a surface of a seat, heat and / or cool air, or any combination thereof. Tire thermal conditioning system may comprise one or more blowers, conduits, thennoelectric devices, resistive heaters, sensors, controllers, or any combination thereof.

[0090] The one or more blowers or conduits may attach to the blower portion, as described herein. The blower may function to move air through the air distribution device. The blower may pull air from a surface of tire seat contacted by an occupant or from a region underneath, forw ard of, or behind the seat, or any combination thereof. The blower may deliver air to a surface of the seat contacted by an occupant or to a region underneath, forward of, or behind the seat, or any combination thereof. The blower may comprise an axial fan or a radial fan.

[0091] The one or more thermoelectric devices may function to heat or cool air. The one or more resistive heaters may function to heat air. Hie one or more thennoelectric devices, resistive heaters, or both may be located upstream of the blower, downstream of the blower, or both. The one or more thennoelectric devices resistive heaters, or both may be integrated into the blower.

[0092] The one or more sensors may include temperature sensors, humidity sensors, or both. The one or more sensors may function to provide feedback signals to a controller. Tire feedback signals may be used to control current and / or voltage provided to the one or more blowers, thennoelectric devices, resistive heaters, or any combination thereof. More specifically, the current and / or voltage may control a blower speed, thermoelectric device polarity, thermoelectric device temperature, resistive heater temperature, or any combination thereof. The one or more sensors may be located within a blower, a conduit, an enclosure of an air distribution device, a cushion layer, or any combination thereof.

[0093] FIG. 1A and FIG. IB illustrate an air distribution device 10 according to the present teachings. FIG. 1A shows a first side of the air distribution device 10 and FIG. IB shows a second side of the air distribution device 10. The air distribution device 10 comprises a distribution portion 12, a blower portion 14, and a carrier portion 16.

[0094] The distribution portion 12 has a vent 18 adapted for exchanging air, directly or indirectly, with a surface of a seat. Tire present teachings contemplate that the distribution portion 12 may have multiple vents. Tire vent 18 is located on the second side of the air distribution device 10. The blower portion 14 has a connection mechanism 20 adapted for receiving a blower or a conduit that ultimately connects to a blower. In a push operation, an airflow may be generated by a blower and travel to tire vent 18. In a pull operation, air may be pulled from the vent 18 to the blower.

[0095] The carrier portion 16 comprises a first segment 22, a second segment 24, and a third segment 26. The first segment 22 is located on a second side of the distribution portion 12. A portion of the second segment 24 is located on a first side of the distribution portion 12. Tire portion of the second segment 24 cooperates with the first segment 22 to sandwich the distribution portion 12 therebetween. In this regard, additional reinforcement of a seam of the distribution portion 12 may be provided for. The third segment 26 locates underneath the blower portion 14, while remaining decoupled from the blower portion 14. The third segment 26 comprises two tabs that extend over the first side of the first segment 22. Although the present teachings contemplate that the tabs extend between the first segment 22 and the distribution portion 12.

[0096] FIG. 2A through FIG. 2C illustrate an air distribution device 28 installed on a seat 30. The air distribution device 28 is located onto a cushion layer 32 (e.g., foam) in the seat 30.

[0097] The air distribution device 28 comprises a distribution portion 34, a blower portion 36, and a carrier portion 38. The blower portion 38 is movable relative to the distribution portion 34 and the carrier portion 38.

[0098] FIG. 3 A and FIG. 3B show a thermal profile of a seat 40. The thermal profile illustrated in FIG. 3A is of a conventional air distribution device and the thermal profile illustrated in FIG. 3B is of an air distribution device according to the present teachings. In both cases, the air distribution device is providing heated air to the surfaces of the seat. It can be seen that the air distribution device of the present teachings provides for a higher seat surface temperature (compare 39.2 degC to 24.2 degC) relative to the conventional air distribution device. In this regard, the air distribution device of the present teaching mitigates or even substantially prevents leak paths to the effect that thermal energy is more efficiently delivered to the seat surface.

[0099] FIG. 4A through FIG. 4E are exploded sectional views of air distribution devices 42 according to the present teachings. Various configurations of air distribution device 42 are shown. The present teachings are not intended to be limited to these configurations and one or more features illustrated in FIG. 4A through FIG. 4E may be combined in any configuration not shown. Moreover, one or more layers of fabric, film, and / or adhesive may be added, such as for reinforcement.

[0100] The air distribution device 42 comprises a distribution portion 44, a blower portion 46, and a carrier portion 48. The air distribution device 42 and said portions thereof are formed from a layered stack-up of elements. The distribution portion 44 and the blower portion 46 are defined by first and second fabric layers 50, 50' and first and second film layers 52, 52', where the first and second film layers 52, 52’ are contained within the first and second fabric layers 50, 50'. Seams may be formed along one or more edges of the air distribution device 42, the seams being formed by welding, stitching, adhesive, or any combination thereof.

[0101] The distribution portion 44 and the blower portion 46 define an enclosure 54. A spacer 56 is located within tire enclosure 54 to maintain a gap between the first and second film layers 52, 52'.

[0102] The blower portion 46 can connect to a blower (not shown) via a connection mechanism 58. Hie connection mechanism 58 includes a snap ring 60 located inside the enclosure 54 and a snap ring 62 located outside of the enclosure 54. A gasket 64 is located between the snap rings 60, 62 for forming an air-tight seal therebetween. The snap rings 60, 62 sandwich the first fabric layer 50 and the first film layer 52.

[0103] The carrier portion 48 comprises fabric layer 66 and two adhesive layers 68, 68' located on opposing sides of the fabric layer 66. Hie adhesive layer 68 adheres to the second fabric layer 50' and the adhesive layer 68' is adapted to adhere to a seat, such as a cushion layer of a seat.

[0104] In some aspects, the blower portion 46 can be decoupled from the carrier portion 48. In other aspects, the blower portion 46 can be coupled to the carrier portion 48, but the carrier portion 48 can be decoupled from the cushion layer in the region of the blower portion 46. FIG. 4C illustrates an airdistribution device 42 whereby an additional fabric layer 70, disposed over the blower portion 46, is folded over itself with one flap adhesively bonded to the fabric layer 66 via an additional adhesive layer 72 and another flap adhesively bonded to the fabric layer 50' via the adhesive layer 68. FIG. 4D illustrates an air distribution device 42 whereby the fabric layer 66 is adhesively bonded to the blower portion 46, but the adhesive layer 68 does not extend over the blower portion 46. Thus, tire blower portion 46 can be coupled to the carrier portion 48 but remains decoupled from the cushion layer of a seat. FIG. 4E illustrates an air distribution device 42 similar to those of FIG. 4B and FIG. 4D, but the adhesive layers 68, 68' extend along the entire length of both sides of the fabric layer 66, but an additional fabric layer 74 is disposed over the adhesive layer 68 in the region of the blower portion 46 to prevent adhesion thereof.

[0105] It is understood that the above description is intended to be illustrative and not restrictive. The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application.

[0106] Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. Many embodiments as well as many applications besides the examples provided herein will be apparent to those of skill in the art upon reading the above description.

[0107] Accordingly, the specific embodiments of the invention set forth herein are not intended as being exhaustive or limiting of the teachings. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0108] The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

[0109] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes.

[0110] Plural elements or steps can be provided by a single integrated element or step. Alternatively, a single element might be divided into separate plural elements.

[0111] The disclosure of “a” or "‘one” to describe an element is not intended to foreclose additional elements.

[0112] The use of “about” or “approximately” in connection with a range applies to both ends of tire range. Tirus, “about 20 to 30” is intended to cover “about 20 to about 30”, inclusive of at least the specified endpoints.

[0113] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints in increments of one unit provided that there is a separation of at least 2 units between any lower endpoint and any higher endpoint. As an example, if it is stated that the amount of a component or a property is, e.g.,from 1 to 90, from 20 to 80, or from 30 to 70, it is intended that intermediate range values such as, c.g., 15 to 85, 22 to 68, 43 to 51, 30 to 32. etc., are within the teachings of this specification. Likewise, individual intermediate values are also within the present teachings.

[0114] For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest endpoint and the highest endpoint enumerated are to be considered to be expressly stated in this application in a similar manner.

[0115] The term “consisting essentially of’ to describe a combination shall include the elements or components identified, and such other elements or components that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements or components herein also contemplates embodiments that consist essentially of the elements or components.

[0116] While the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used to distinguish one element, component, region, layer, and / or section from another region, layer, and / or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Tirus, a first element, component, region, layer, and / or section discussed below could be termed a second element, component, region, layer, and / or section without departing from the teachings.

[0117] Spatially relative terms, such as “inner,” “outer.” “beneath,” “below,” “lower,” “above.” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the drawings. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the drawings. For example, if the device in the drawings is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0118] The terms “generally” or “substantially” to describe angular measurements may mean about + / - 10° or less, about + / - 5° or less, or even about + / - 1° or less. The terms “generally” or “substantially” to describe angular measurements may mean about + / - 0.01° or greater, about + / - 0.1° or greater, or even about + / - 0.5° or greater.

[0119] The terms “generally” or “substantially” to describe linear measurements, percentages, or ratios may mean about + / - 10% or less, about + / - 5% or less, or even about + / - 1 % or less. The terms “generally”or “substantially” to describe linear measurements, percentages, or ratios may mean about + / - 0.01% or greater, about + / - 0.1% or greater, or even about + / - 0.5% or greater.REFERENCE NUMERALS

[0120] 10 Air distribution device

[0121] 12 Distribution portion

[0122] 14 Blower portion

[0123] 16 Carrier portion

[0124] 18 Vent

[0125] 20 Connection mechanism

[0126] 22 First segment

[0127] 24 Second segment

[0128] 26 Third segment

[0129] 28 Air distribution device

[0130] 30 Seat

[0131] 32 Cushion layer

[0132] 34 Distribution portion

[0133] 36 Blower portion

[0134] 38 Carrier portion

[0135] 40 Seat

[0136] 42 Air distribution device

[0137] 44 Distribution portion

[0138] 46 Blower portion

[0139] 48 Carrier portion

[0140] 50 First fabric layer

[0141] 50' Second fabric layer

[0142] 52 First film layer

[0143] 52' Second film layer

[0144] 54 Enclosure

[0145] 56 Spacer

[0146] 58 Connection mechanism

[0147] 60 Snap ring

[0148] 62 Snap ring

[0149] 64 Gasket

[0150] 66 Fabric layer

[0151] 68 Adhesive layer

[0152] 68' Adhesive layer

[0153] 70 Additional fabric layer

[0154] 72 Additional adhesive layer

[0155] 74 Additional fabric layer

Claims

CLAIMSWhat is claimed is:Claim 1 : An air distribution device for a seat comprising: a distribution portion, a blower portion, and a carrier portion coupled to the distribution portion and configured to attach to a portion of the seat and seal off leak paths; wherein the blower portion is decoupled from the carrier portion, allowing movement of the blower portion relative to the distribution portion and the carrier portion after installation of the air distribution device on the seat.Claim 2: The air distribution device according to Claim 1, wherein said movement is pivotal movement; and wherein the blower portion is pivotably engaged with the distribution portion.Claim 3: Tire air distribution device according to Claim 1 or Claim 2, wherein the air distribution device defines an enclosure through which airflow travels; and wherein a first portion of the enclosure is defined within the distribution portion and a second portion of the enclosure is defined within tire blower portion.Claim 4: The air distribution device according to Claim 3, wherein the enclosure is continuous between the distribution portion and the blower portion.Claim 5 : The air distribution device according to Claim 3 or Claim 4, further comprising at least one spacer located within the enclosure and maintaining a gap between two opposing internal surfaces of the enclosure: and wherein the at least one spacer includes a mesh, a foam, or the like.Claim 6: Tire air distribution device according to Claim 5, wherein the at least one spacer is continuous between tire distribution portion and the blower portion and is pivotable at or in proximity to where the distribution portion meets tire blower portion; or the at least one spacer includes a first spacer located within the distribution portion and a second spacer located within the blower portion.Claim 7 : The air distribution device according to any one of the preceding claims, wherein the distribution portion and the blower portion are both located within a profde of the carrier portion; and wherein at least one dimension of the distribution portion and at least one dimension of the blower portion is less than at least one dimension of tire carrier portion.Claim 8: Tire air distribution device according to any one of the preceding claims, wherein the blower portion comprises a connection mechanism on a first side of the air distribution device for receiving a blower or a conduit that ultimately connects to the blower; and wherein the connection mechanism provides for a rigid connection of the blower or the conduit to the air distribution device.Claim 9: Tire air distribution device according to Claim 8, wherein the distribution portion comprises one or more vents located on a second side of the air distribution device, the second side being in opposing relationship to the first side; wherein the one or more vents are adapted for air exchange between tire air distribution device and a surface of a seat; and wherein the carrier portion comprises one or more vents in alignment with the one or more vents of the distribution portion.Claim 10: Tire air distribution device according to any one of the preceding claims, wherein the carrier portion comprises a first side coupled to the distribution portion and a second side comprising an adhesive layer adapted for coupling to the seat, the first side being in opposing relationship to the second side.Claim 11 : The air distribution device according to any one of the preceding claims, wherein the air distribution device is fabricated from a lamination of one or more fabric layers and one or more film layers: preferably the one or more fabric layers include a fleece; and preferably the one or more film layers include a polymer film.Claim 12: The air distribution device according to Claim 11, wherein the lamination is bonded by adhesive, welding, stitching, or any combination thereof.Claim 13: Tire air distribution device according to Claim 11 or Claim 12, wherein the one or more film layers are comprised by the blower portion and the distribution portion, and define the enclosure; and wherein at least some of the one or more fabric layers are disposed over and / or around the one or more film layers.Claim 14: The air distribution device according to any one of tire preceding claims, wherein the carrier portion comprises a first segment and optionally a second segment; wherein the first segment is located on the second side of the distribution layer and at least a portion of the second segment is located on the first side of the distribution layer; and wherein the second segment overlaps the first segment and cooperates with the first segment to sandwich an edge of the distribution portion.Claim 15: The air distribution device according to Claim 14, wherein the carrier layer comprises a third segment coupled to and at least partially extending beyond the distribution portion in an extension direction of the blower portion; and optionally wherein the third segment comprises one or more tabs, preferably two tabs, coupling the third segment to the first segment, the one or more tabs extending along opposing edges of the distribution portion to connect to the first segment.Claim 16: A thermal conditioning system comprising the air distribution device according to any one of the preceding claims, the thermal conditioning system further comprising the blower, the conduit, a thermoelectric device, a resistive heater, one or more sensors, or any combination thereof.Claim 17: A seat comprising the air distribution device according to any one of Claims 1 through 15, the seat further comprising: a trim layer adapted for contact with an occupant; and a cushion layer, preferably a foam layer, in fluid communication with the air distribution device and disposed underneath the trim layer, the cushion layer having an A-side oriented toward the trim layer and a B-side oriented toward the air distribution device.Claim 18 : The seat according to Claim 17, wherein the carrier portion of the air distribution device is at least partially coupled on the second side thereof to the cushion layer.Claim 19: The seat according to Claim 17 or Claim 18. wherein the blower portion is decoupled from and movable relative to the cushion layer.Claim 20: Tire seat according to any one of Claims 17 through 19, wherein the cushion layer comprises one or more channels that fluidly communicate with the one or more vents of the distribution portion; optionally wherein the one or more vents have at least one dimension that is greater than the one or more channels.Claim 21: A scat comprising : a trim layer adapted for contact with an occupant; a cushion layer, preferably a foam layer, disposed underneath the trim layer, the cushion layer having an A-side oriented toward the trim layer and a B-side opposing the A-side; and an air distribution device in fluid communication with the air distribution device at the A-side and comprising a distribution portion, a blower portion, and a carrier portion; wherein the carrier portion couples tire air distribution device to the cushion layer and the distribution portion is coupled to the carrier portion; and wherein the blower portion is decoupled the cushion layer, allowing movement of the blower portion relative to the cushion portion.

Images