Automotive vehicle seat insert

• US 20040036326A1
• Filed: 05/09/2003
• Published: 02/26/2004
• Est. Priority Date: 07/03/2002
• Status: Active Grant

• Current Assignee: Gentherm GmbH (Gentherm Incorporated)
• Original Assignee: WET Automotive Systems Limited (Gentherm Incorporated), Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Bajic, Goran, Lazanja, Marinko, Fernandez, Lucas, Liss, Anne Patrice, White, Brennon Lewis, Drobnjakovic, Valerija, Brennan, Lindy
• Granted Patent: US 6,893,086 B2
• Time in Patent Office: Days
• US Class Current: 297/180.14
• CPC Class Codes: B60N 2/56 Heating or ventilating devices
• CPC Class Codes: B60N 2/5635 coming from the passenger compartment
• CPC Class Codes: B60N 2/5642 with circulation of air through a layer inside the seat
• CPC Class Codes: B60N 2/5657 blown towards the seat surface
• CPC Class Codes: B60N 2/5685 Resistance
• CPC Class Codes: Y10T 29/48 Upholstered article making
• CPC Class Codes: Y10T 29/481 Method

Abstract

There is disclosed an insert suitable for placement within a seat of an automotive vehicle. The insert preferably includes multiple layers, one of which includes a heater for providing an occupant of the seat with warmth. The insert also preferably includes a blower or air pump for providing ventilation and/or cooling to the seat occupant.

Claims

1. A ventilated seat for a vehicle, comprising:

a vehicle seat having a seat cushion component and a seat backrest component, at least one of which is ventilated, each ventilated component having an air-permeable trim surface at the occupant contact areas of the seat;

an insert located beneath the trim surface of each ventilated component, the insert including;

i) a forward layer having a heater sub-layer;

ii) a rearward layer having a barrier sub-layer; and

iii) a middle layer having a spacer sub-layer defining an open space wherein at least one of the forward layer and the rearward layer is adhesively secured to the middle layer; and

an air mover attached to the insert in fluid communication with the open space of the spacer sub-layer.

2. A ventilated seat as in claim 1 wherein insert includes an extension that extends behind the cushion of the seat to the air mover.

3. A ventilated seat as in claim 1 wherein the insert is positioned between a foam cushion of the vehicle seat and the air-permeable trim surface.

4. A ventilated seat as in claim 1 wherein at least one through-hole extends through the insert and a barrier sub-layer of the forward layer and a barrier sub-layer of the rearward layer seal about the at least one through-hole to prevent fluid communication between the open space of the spacer sub-layer and the at least one through hole.

5. A ventilated seat as in claim 4 wherein a material extends through the at least one through-hole for assisting in securing the insert to the seat cushion component.

6. A ventilated seat as in claim 1 further comprising a control unit in communication with the air mover and the heater sub-layer.

7. A ventilated seat as in claim 6 wherein the control unit is programmed with instructions for commanding the air mover and the heater sub-layer to change output levels if a temperature sensor senses a temperature above or below one or more threshold levels.

8. A ventilated seat as in claim 1 wherein a plurality of through-holes extend through the forward layer and the through-holes get progressively larger from one side of the insert to another.

9. A ventilated seat as in claim 1 wherein the forward layer includes a barrier sub-layer laminated to the heater sub-layer with a hot melt adhesive sub-layer.

10. A ventilated seat as in claim 1 wherein in at least one of the forward layer and the rearward layer are laminated to the middle layer with an adhesive.

11. A ventilated seat for a vehicle, comprising:

a vehicle seat having a seat cushion component and a seat backrest component, at least one of which is ventilated, each ventilated component having an air-permeable trim surface at the occupant contact areas of the seat;

an insert located beneath the trim surface of each ventilated component, the insert including;

i) a forward layer having a first barrier sub-layer and a heater sub-layer, said forward layer including a plurality of first openings;

ii) a rearward layer having a second barrier sub-layer, at least one of the rearward layer and the forward layer including at least one second opening; and

iii) a middle layer having a spacer sub-layer defining an open space; and

an air mover attached to the insert and in fluid communication with the plurality of first openings and the open space;

wherein the first barrier sub-layer is sealingly attached to the second barrier layer about a periphery of the insert.

12. A ventilated seat as in claim 11 wherein the insert includes an extension that extends behind the cushion of the seat to the air mover.

13. A ventilated seat as in claim 11 wherein the insert is positioned between a foam cushion of the vehicle seat and the air-permeable trim surface.

14. A ventilated seat as in claim 11 wherein at least one through-hole extends through the insert and the barrier sub-layer of the forward layer and the barrier sub-layer of the rearward layer seal about the at least one through-hole to prevent fluid communication between the open space of the spacer sub-layer and the at least one through hole.

15. A ventilated seat as in claim 14 wherein a material extends through the at least one through-hole for assisting in securing the insert to the seat cushion component.

16. A ventilated seat as in claim 11 further comprising a control unit in communication with the air mover and the heater sub-layer wherein the control unit is programmed with instructions for commanding the air mover and the heater sub-layer to change output levels if a temperature sensor senses a temperature above or below one or more threshold levels.

17. A ventilated seat as in claim 11 wherein the openings of the plurality of openings in the forward layer get progressively larger from one side of the insert to another.

18. A ventilated seat as in claim 11 wherein the forward layer includes a barrier sub-layer laminated to the heater sub-layer with a hot melt adhesive sub-layer.

19. A ventilated seat as in claim 11 wherein in at least one of the forward layer and the rearward layer are laminated to the middle layer with an adhesive.

20. A ventilated seat as in claim 11 further comprising a rigid attachment component secured to at least one of the forward layer, the rearward layer and the middle layer wherein the attachment component includes a through-hole aligned with the at least one second opening.

21. A ventilated seat as in claim 20 wherein the air mover includes a housing having flanges and wherein the flanges are attached to the attachment component.

22. A ventilated seat for a vehicle, comprising:

a vehicle seat having a seat cushion component and a seat backrest component, at least one of which is ventilated, each ventilated component having an air-permeable trim surface at the occupant contact areas of the seat;

an insert located beneath the trim surface of each ventilated component, the insert including;

i) a forward layer including a first barrier sub-layer formed of a plastic material, a heater sub-layer formed as a lay-wire heater, and a plurality of openings;

ii) a rearward layer having a second barrier sub-layer formed of a plastic material, said rearward layer including at least one opening; and

iii) a middle layer having a spacer sub-layer defining an open space, the spacer sub-layer being formed of interwoven polymeric strand material;

a blower attached to the insert and at least partially disposed within the at least one opening of the rearward layer, the blower in fluid communication with the plurality of openings in the forward layer and the open space;

wherein the first barrier sub-layer is sealingly attached to the second barrier sub-layer about a periphery of the insert and wherein the blower is configured to pull air through the plurality of openings in the forward layer and through the open space of the spacer sub-layer.

23. A ventilated seat as in claim 22 wherein at least one of the forward layer, the rearward layer and the middle layer form an extension that extends behind the cushion of the seat to the air mover.

24. A ventilated seat as in claim 22 wherein the insert is positioned between a foam cushion of the vehicle seat and the air-permeable trim surface.

25. A ventilated seat as in claim 22 wherein includes at least one through-hole extends through the insert and the barrier sub-layer of the forward layer and the barrier sub-layer of the rearward layer seal about the at least one through-hole to prevent fluid communication between the open space of the spacer sub-layer and the at least one through hole.

26. A ventilated seat as in claim 25 wherein a material extends through the at least one through-hole for assisting in securing the insert to the seat cushion component.

27. A ventilated seat as in claim 22 further comprising a control unit in communication with the blower and the heater sub-layer wherein the control unit is programmed with instructions for commanding the blower and the heater layer to change output levels if a temperature sensor senses a temperature above or below one or more threshold levels.

28. A ventilated seat as in claim 22 wherein the openings of the plurality of openings in the forward layer get progressively larger from one side of the insert to another.

29. A ventilated seat for a vehicle, comprising:

a vehicle seat having a seat cushion component and a seat backrest component, at least one of which is ventilated, each ventilated component having an air-permeable trim surface at the occupant contact areas of the seat;

an insert located beneath the trim surface of each ventilated component, wherein;

i) the insert is sealed about a peripheral edge; and

ii) the insert includes a spacer material forming open space within the insert; and

iii) the insert includes at least one first opening and a second opening; and

an air mover in fluid communication with the first opening, the second opening and the open space of the spacer sub-layer.

30. A ventilated seat as in claim 29 wherein the insert includes a resistive heating element disposed thereon.

31. A ventilated seat as in claim 30 wherein the insert includes an extension of substantially smaller width than the rest of the insert wherein the extension extends behind the cushion of the seat to the air mover.

32. A ventilated seat as in claim 31 wherein the air mover includes a fan.

33. A ventilated seat as in claim 32 wherein the air mover is configured to pull air through the first opening, then through the open space to the air mover.

34. A method of forming a ventilated seat, comprising:

providing a forward layer having a forward barrier sub-layer, a heater sub-layer;

forming a plurality of first through-holes in the forward layer;

providing a rearward layer having a rearward barrier sub-layer;

providing at least one second through-hole extending through at least one of the forward layer and the rearward layer.

providing a middle layer having a spacer sub-layer; and

laminating at least the forward layer to the rearward layer about a peripheral strip with the middle layer being substantially encapsulated by the forward layer and the middle layer.

35. A method of forming a ventilated seat as in claim 34 wherein the step of providing a forward layer includes laminating the heater sub-layer to the forward barrier layer with an adhesive.

36. A method of forming a ventilated seat as in claim 34 wherein the middle layer is secured to at least one of the forward layer and the rearward layer during the step of laminating the forward layer to the rearward layer.

37. A method of forming a ventilated seat as in claim 34 further comprising providing a rigid attachment component adjacent the second through-hole and securing flanges of a blower housing to the attachment component for allowing a blower to be in fluid communication with the second through-hole.

38. A method of forming a ventilated seat as in claim 34 wherein the heater sub-layer is provided as a carbon-fiber heater laminated to gauze.

39. A method of forming a ventilated seat as in claim 34 wherein the rearward layer includes a sub-layer adhesively laminated to the rearward barrier layer.

40. A method of forming a ventilated seat as in claim 39 wherein the heater sub-layer is adhesively secured to the forward barrier layer and the forward layer and the rearward layer are adhesively secured to the middle layer.