Variable temperature seat

Abstract

A seating construction with a plurality of plenums into which is received temperature conditioned air. The air passes through the seat via a plurality of channels formed in the foam of the seat cushion. The air then migrates through a reticulated foam layer that is itself covered with an air permeable layer of material. The reticulated foam and stitching of the seat fabric facilitate diffusion of the air from the foam channel conduits. The air then convectively circulates against and near the occupant of the seat to facilitate climate control around the occupant.

Description

FIG. 5a is a sectional view of another embodiment of the air plenum strengthening method;The As seen in FIG. 5a, the walls 27 are augmented with, for example, stiffeners or liners 41 placed cooperatively with the walls 27 or affixed to the walls 27, as desired, in order to provide additional stiffness to the walls 27. Also, stiffeners can be placed within the cavities of the channels, manifold, and subchannels to resist crushing. The stiffeners 41 would preferably have suitable holes or paths 43 for the air flow to pass through, such that there is not a substantial resistance to air flow.

While the wide perforated or air permeable adhesive-backed material is not preferably used in the practice of this invention, a tape such as the one described, or other alternate materials, may be used. For example, gluing a very porous material, such as a strong cheesecloth-like material, over the subchannels would be another manner of providing extra strength or support to the subchannels. If a adhesive-backed layer is used, it is preferable that it have relatively minimal stretch characteristics, as well as being more porous, relative to the foam seat cushion material 30.

The reticulated foam is preferably polyurethane or the like, with approximately 20 pores per inch (ppi). Other porosities, such as 10 ppi, and 30 or 40 ppi, are also acceptable. Currently, 20 ppi is the preferred foam type, as there is a slight drop off in the breathability of the foam above 20 ppi.

Another alternate embodiment of the invention is shown in FIGS. 2 and 3. This alternate embodiment provides for a different configuration of the air channel distribution system. Conditioned air 105, represented by arrows, enters the seat cushion 110 at air inlet 112. Air is guided along a plurality of lower main channels 114. The lower main channel walls 115 are formed by the surface of a resilient material 160 which separates the seat cushion 110 from the seat cushion springs 162. The upper main channel walls 116 are formed by seat cushion foam material 130. Air is then guided into the respective manifold channels 121. The manifold channel walls 126 are substantially formed by the seat cushion foam 130.

The conditioned air is next directed into the manifold area 120 where the air is further divided into the respective subchannels 132, 133, 134, 135, 136, 137. From this point on, the air travels a path substantially similar the air path described in the first embodiment, i.e., the conditioned air passes through the reticulated foam layer 140 and through the preferably air permeable automotive upholstery 142 in order to cool or heat the occupant.

As in the first embodiment, the automotive upholstery 142 encapsulates the reticulated foam layer 140. The reticulated foam layer forms the occupant side 124 subchannel boundary wall 145 of the respective subchannel 135 and performs a similar wall forming function for the other subchannels.

FIG. 6 shows yet another embodiment in the practice of this invention. Seat cushion foam 30 again forms the lower walls 26, 29 of the subchannels 16, 19. The upper subchannel walls 36, 39, are the part of the subchannel which is in closest proximity to the occupant side 24 of the seat cushion section 61, as shown in FIG. 6. Sewn stitching 62 is used to collapse the reticulated foam layer 40 and the automotive upholstery fabric 42 through the subchannels 16, 19 and into the seat cushion foam 30. By using the stitching 62 to collapse the seat covering, a “valley” 44 is formed in the seat cushion. The valley's convergence is formed by the sewn stitching 62. This valley provides a path for the exiting conditioned air to travel along, in order to provide comfort for the occupant. This valley provides for an additional path for the conditioned air 5 through the reticulated foam layer and the automotive seat covering to the occupant of the seat.

In another alternate embodiment, the reticulated foam layer 40 may be omitted, and the seams 62 used as the primary diffusion areas for directing the conditioned air to the occupant from the subchannels via the valleys. The sewn seam diffusion area, or valley embodiment, may be used with any of the alternate embodiments described in connection with this invention, either with or without foam layers such as the currently preferred reticulated foam layer.

The seat coverings or automotive upholstery used in any of the described embodiments is preferably of an air permeable fabric or synthetic. However, other materials can be used, such as leather. To help facilitate air flow through alternate materials, such as leather, the sewn seam diffusion techniques described can be employed. Preferably, materials such as leather are perforated with small holes, in addition to the stitching holes of the sewn seam diffusion technique, to facilitate the air flow. For example, the holes can be approximately the same size or larger than the holes made by the stitching of automotive seat coverings. In addition, the holes can be used together with the sewn seam diffusion techniques. Alternate sized holes, either larger or smaller, can also be used. However, the smaller the holes, assuming the number of holes remains constant, the more the cooling will rely upon conduction rather than convection for cooling the occupant. As the holes become smaller, the convective air flow is proportionately reduced.

FIGS. 7 and 8 show yet another alternate embodiment of the invention. As schematically shown in FIG. 7, conditioned air 205, represented by arrows, enters the air inlet 212 of the seat configuration 210. The conditioned air is then divided among a plurality of channels 214 at a manifold area 220. The conditioned air travels along the channels 214 from the manifold area 220 to the foot outlet 217 or the head outlet 218. As shown in FIG. 7, the foot outlet 217 exhausts near the occupant's feet. However, the head outlet 218 exhausts out the “back”, or non-occupant side of the seat. Alternately, the seat may provide for a head outlet that exhausts on the occupant side 224, preferably near the neck area of the occupant. In this alternate embodiment, air exiting at the head and foot outlets facilitate cooling in these respective locations of an occupant that is in close proximity to the occupant side 224.

Conditioned air 205 is able to cool the occupant of the seat, via an air flow path through the seat fabric, as well. Conditioned air traveling via the channels 214 is directed at and near the occupant through an air permeable seat covering 242. A reticulated foam layer is omitted in this embodiment, though it can be added, if desired.

FIG. 8 shows a plurality of air channels 214 which are formed in the seat cushion foam 230. This sectional view also shows a side support “wing” 239 of the seat, wherein the air channels do not occupy this region of the seat cushion foam. However, in an alternate embodiment, the channels can extend even into these areas of the seat, if desired.

Yet another embodiment of the foam air distribution channels as schematically shown in FIG. 7 is shown in FIG. 9. Here the foam seat cushion 230 is of a foam density which is less than the foam density of the air channel forming foam 231. Air channels 215 formed by the denser air channel foam 231, cooperating with the automotive upholstery 242, is used in place of the air channels 214 as schematically shown in FIG. 7. An adhesive may be used to bond the automotive upholstery 242 to the air channel foam 231 at bond line 157. A relatively non-permeable barrier 258, constructed of a synthetic material, can be placed between the air channel foam 231 and the seat cushion foam 230 to provide for a pneumatic, moisture, or thermal barrier, as desired.

Another embodiment of the denser air channel foam 231 of FIG. 9 is shown in FIGS. 10A and 10B. Inlet conditioned air is supplied to a first plurality of channels 270, which are oriented relatively perpendicular to the plurality of channels 214, 215 as previously shown in FIGS. 7, 8, and 9, and are also perpendicular to the second plurality of channels 272, as shown in FIG. 10A. The second plurality of channels 272 are oriented substantially similar to the plurality of channels as shown in FIGS. 7, 8, and 9. Channels 270 cooperate with channels 272, such that the conditioned air is able to pass from the first plurality of channels 270 to the second plurality of channels 272 via a plurality of overlapping common manifold areas 274. A common manifold area 274 preferably occurs at each intersection of a first channel with a second channel.

The relatively dense air channel forming foam 231 of FIGS. 10A and 10B can be substituted for the foam 231 as shown in FIG. 9, and may be used with or without the non-permeable barriers, as well as with or without the adhesive layers. The permeable automotive upholstery can be augmented or replaced, as desired, with a stitching embodiment as an air flow path to the occupant, as previously described.

The air channel forming foam 231 of the embodiments shown in FIGS. 9, 10A, and 10B is preferably approximately 12 pounds per cubic foot and the seat cushion 230 foam is preferably approximately 6 pounds per cubic foot. However, other foam densities can be substituted for either type of foam, and other materials can be substituted for the various foam types. Any of the foam or foam-like materials described may be suitably cut, laser sculpted, molded, injected, stitched, glued, bonded or other such techniques as are known, in order to achieve the shapes desired to practice this invention.

If desired, an alternate embodiment of the seat as shown in FIG. 1 can be constructed for use in, for example, public transportation systems, such as a subway, bus, or other passenger-carrying vehicle. The seat's foam 30 of FIG. 1 is replaced with a substantially stiff material, such as fiberglass reinforced ABS. The stiff “cushion” member preferably has air channels molded or cut into its structure. At least partially encapsulating the stiff “cushion” member is a substantially resilient member, preferably formed of a reticulated foam layer or the like. If desired, an air-permeable structural wall, such as a adhesive tape with holes, or a plastic screen with holes, can be placed between the reticulated foam layer and the stiff cushion or plastic seat. By adding this structural screen or tape, it is more difficult for an occupant to feel the channels in the stiff materials with either their body while they are sitting, or with their hands. This screen acts in a similar manner as the adhesive backed material described previously. The seat arrangement is covered so as to substantially encapsulate the plastic channel cushion, the plastic screen and the reticulated foam, for example, with seat covering material similar to that previously described. The seat components can be assembled via stitching, screwing, bonding, gluing, cutting, and other means of attachment as is known.

The practice of the invention disclosed herein provides an easy and preferable means with which to construct a variable temperature seat. This provides for a convenient manner for environmentally comforting the seat's occupant.

While only preferred embodiments of the invention are described herein in detail, the invention is not limited thereby. It is believed that the advantages and improved results of the invention will be apparent from the foregoing description. It will be apparent that various changes and modifications may be made without departing from the spirit and scope of the invention as sought to be defined in the following claims.

Claims

1. Apparatus for selectively varying the environmental temperature of a vehicle seat comprising:

a support member in the seat formed from a resilient material, wherein the support member includes:

an integral air flow channel that extends through the support member from a bottom surface to a top surface of the support member, the air flow channel having an inlet at the bottom surface of the support member for receiving temperature conditioned air therein, and further having an outlet at the top surface of the support member for dispensing temperature conditioned air therefrom; and

at least one air subchannel integral with and extending along a top surface of the support member, wherein the air subchannel is connected with the outlet of the air flow channel; and

a porous member which substantially covers the top surface area of the support member, the porous member having an interface with the air subchannel; and

a seat cover that substantially encapsulates the porous member to the support member.

2. An apparatus as defined in claim 1 wherein the porous member comprises;

a first porous member that is disposed adjacent and substantially covers the top surface of the support member; and

a second porous member substantially encapsulating the first porous member.

3. An apparatus for selectively varying the environmental temperature of a vehicle seat comprising:

a seat cushion in the seat formed from a resilient material including:

an integral air flow channel extending vertically therethrough from a top surface of the seat cushion to a bottom surface of the seat cushion, wherein the air flow channel has an inlet adjacent the bottom surface of the seat cushion for receiving temperature conditioned air therein, and further has an outlet adjacent the top surface of the seat cushion for dispensing temperature conditioned air therefrom; and

a porous member which substantially covers the top surface area of the seat cushion;

at least one air subchannel that is integral with and extends along the top surface of the seat cushion, wherein the air subchannel is connected with the outlet of the air flow channel, and wherein the porous member is contact with the air subchannel; and

a seat covering substantially encapsulating the porous member to the seat cushion.

4. An apparatus for selectively varying the environmental temperature of a vehicle seat comprising:

a seat cushion in the seat formed from a resilient material including:

an integral air flow channel extending vertically therethrough from a top surface of the seat cushion to a bottom surface of the seat cushion, wherein the air flow channel has an inlet adjacent the bottom surface of the seat cushion for receiving temperature conditioned air therein, and further has an outlet adjacent the top surface of the seat cushion for dispensing temperature conditioned air therefrom; and

a porous member which substantially covers the top surface area of the seat cushion;

at least one air subchannel that is integral with and extends along the top surface of the seat cushion, wherein the air subchannel is connected with the outlet of the air flow channel, and wherein the porous member is contact with the air subchannel;

an air manifold integral with and extending along the top surface of the seat cushion, wherein the air manifold is interposed between the outlet of the air flow channel and the air subchannel to facilitate the distribution of temperature conditioned air therebetween; and

a seat covering substantially encapsulating the porous member to the seat cushion.

5. Apparatus for selectively varying the environmental temperature of a vehicle seat comprising:

a support member in the seat in the form of a resilient cushion, wherein the support member includes:

an air flow channel integral with the support member and extending therethrough from a bottom surface to a top surface of the support member, wherein the air flow channel has an inlet at the bottom surface for receiving temperature conditioned air, and an outlet at the top surface for dispensing temperature conditioned air,

at least one air subchannel integral with and extending along the top surface of the support member; and

an air manifold integral with and extending along the top outer surface of the support member between the air flow channel outlet and the air subchannel for dispersing temperature conditioned air from the air flow channel to the air subchannel; and

a flexible porous member disposed over the top surface of the support member and having an interface with the air subchannel; and

a flexible seat cover substantially encapsulating an outer surface of the flexible porous member.

6. The apparatus as recited in claim 5 wherein the resilient cushion can be selected from the group of materials consisting of cellular spongy material, foam, and fiberglass reinforced plastic.

7. The apparatus as recited in claim 5 wherein the flexible porous member comprises:

a first porous member substantially covering the top surface of the support member and having an interface with the air subchannels; and

a second porous member substantially encapsulating the first porous member.

8. A method for selectively varying the environmental temperature of a vehicle seat comprising the steps of:

routing temperature conditioned air from an air inlet to an air outlet of an air flow channel extending through a support member of the seat;

distributing temperature conditioned air from the air outlet along a top surface of the support member through at least one air subchannel disposed within the top surface;

passing temperature conditioned air from the air subchannels through a porous member disposed adjacent the outer surface, and then to a seat covering disposed adjacent the porous member.

9. A method as recited in claim 8 wherein the temperature conditioned air is routed from a bottom surface of the support member to a top surface of the support member.

10. A method for selectively varying the environmental temperature of a vehicle seat, comprising the steps of:

routing temperature-conditioned air from an air inlet to an air outlet of an airflow channel extending through a support member of the seat;

distributing temperature conditioned air from the air outlet along a top surface of the support member through at least one air subchannel disposed within the top surface;

passing the air through an air-porous member disposed adjacent the top surface of the support member and over the at least one air subchannel, through an intermediate layer interposed between the support member and the air-porous member, and away from an air-impermeable barrier located on a side of the air subchannel opposite the air-porous member; and

passing temperature-conditioned air from the air subchannels through the porous member and subsequently to a seat covering adjacent the air-porous member and substantially encapsulating the air-porous member to the support member.

11. The method as recited in claim 10, wherein the temperature-conditioned air is routed from a bottom surface of the support member to a top surface of the support member.

12. A method as recited in claim 10, wherein the support member comprises a resilient material, and the air-porous member comprises a layer of air-permeable support material which is selected to be substantially less stretchable than the resilient material of the support member.

13. A method as recited in claim 10, wherein the air-porous member has a plurality of holes and the air passes through the holes.

14. A method as recited in claim 10, wherein the air-porous member is adhered to the support member so that the air-porous member helps to resist collapse and blockage of the air subchannel as air passes therethrough.

15. A method as recited in claim 10, wherein the intermediate layer is selected to comprise a structural screen making it difficult for a seat occupant to feel the channels when the seat occupant is sitting on the seat.

16. A method as recited in claim 10, comprising the further step of adhering the air-porous member to the support member.

17. A method for selectively varying the environmental temperature of a vehicle seat, comprising the steps of:

routing temperature-conditioned air from an air inlet to an air outlet of an airflow channel extending through a support member of the vehicle seat;

distributing temperature-conditioned air from the air outlet along a top surface of the support member through at least one air subchannel disposed within the top surface;

placing a liner in the air subchannel to resist crushing of the air subchannel when the weight of a seat occupant is placed on the support member and the air subchannel;

passing the air through an air-porous member disposed adjacent the top surface of the support member and over the at least one air subchannel; and

passing temperature-conditioned air from the air subchannels through the porous member and subsequently to a seat covering adjacent the air-porous member and substantially encapsulating the air-porous member to the support member.

18. A method as recited in claim 17, comprising the further step of passing air through the liner to the air-porous member.

19. A method as recited in claim 18, comprising the further step of affixing the liner to the wall of the air subchannel and passing the temperature-conditioned air through the liner as it is affixed to the wall.

20. Apparatus for selectively varying the environmental temperature of a vehicle seat comprising:

a support member in the seat formed from a resilient material, wherein the support member includes:

an integral air flow channel that extends through the support member from a bottom surface to a top surface of the support member, the air flow channel having an inlet at the bottom surface of the support member for receiving temperature conditioned air therein, and further having an outlet at the top surface of the support member for dispensing temperature conditioned air therefrom;

at least one air subchannel that is molded or formed in the support member and extends adjacent the top surface of the support member, wherein the air subchannel is connected with the outlet of the air flow channel; and

an air-impermeable barrier on a side of the air subchannel opposite the top surface of the support member;

a porous member which substantially covers the top surface area of the support member, the porous member having an interface with the air subchannel; and

a seat cover that substantially encapsulates the porous member to the support member.

21. An apparatus as defined in claim 20 wherein the porous member comprises:

a first porous member that is disposed adjacent and substantially covers the top surface of the support member; and

a second porous member substantially encapsulating the first porous member.

22. An apparatus for selectively varying the environmental temperature of a vehicle seat comprising:

a seat cushion in the seat formed from a resilient material including:

an integral air flow channel extending vertically therethrough from a top surface of the seat cushion to a bottom surface of the seat cushion, wherein the air flow channel has an inlet adjacent the bottom surface of the seat cushion for receiving temperature conditioned air therein, and further has an outlet adjacent the top surface of the seat cushion for dispensing temperature conditioned air therefrom; and

a porous member which substantially covers the top surface area of the seat cushion;

at least one air subchannel that is molded or formed in the seat cushion and extends adjacent the top surface of the seat cushion, wherein the air subchannel is connected with the outlet of the air flow channel, and wherein the porous member is contact with the air subchannel;

an air-impermeable barrier on a side of the air subchannel opposite the top surface of the support member; and

a seat covering substantially encapsulating the porous member to the seat cushion.

23. An apparatus for selectively varying the environmental temperature of a vehicle seat comprising:

a seat cushion in the seat formed from a resilient material including:

an integral air flow channel extending vertically therethrough from a top surface of the seat cushion to a bottom surface of the seat cushion, wherein the air flow channel has an inlet adjacent the bottom surface of the seat cushion for receiving temperature conditioned air therein, and further has an outlet adjacent the top surface of the seat cushion for dispensing temperature conditioned air therefrom; and

a porous member which substantially covers the top surface area of the seat cushion;

at least one air subchannel that is molded or formed in the seat cushion and extends adjacent the top surface of the seat cushion, wherein the air subchannel is connected with the outlet of the air flow channel, and wherein the porous member is contact with the air subchannel;

an air-impermeable barrier on a side of the air subchannel opposite the top surface of the support member;

an air manifold integral with and extending along the top surface of the seat cushion, wherein the air manifold is interposed between the outlet of the air flow channel and the air subchannel to facilitate the distribution of temperature conditioned air therebetween; and

a seat covering substantially encapsulating the porous member to the seat cushion.

24. Apparatus for selectively varying the environmental temperature of a vehicle seat comprising:

a support member in the seat in the form of a resilient cushion, wherein the support member includes:

an air flow channel integral with the support member and extending therethrough from a bottom surface to a top surface of the support member, wherein the air flow channel has an inlet at the bottom surface for receiving temperature conditioned air, and an outlet at the top surface for dispensing temperature conditioned air;

at least one air subchannel that is molded or formed in the support member and extends adjacent the top surface of the support member;

an air-impermeable barrier on a side of the air subchannel opposite the top surface of the support member;

an air manifold integral with and extending along the top outer surface of the support member between the air flow channel outlet and the air subchannel for dispersing temperature conditioned air from the air flow channel to the air subchannel;

a flexible porous member disposed over the top surface of the support member and having an interface with the air subchannel; and

a flexible seat cover substantially encapsulating an outer surface of the flexible porous member.

25. The apparatus as recited in claim 24 wherein the resilient cushion can be selected from the group of materials consisting of cellular spongy material, foam, and fiberglass reinforced plastic.

26. The apparatus as recited in claim 24 wherein the flexible porous member comprises:

a first porous member substantially covering the top surface of the support member and having an interface with the air subchannels; and

a second porous member substantially encapsulating the first porous member.

27. A method for selectively varying the environmental temperature of a vehicle seat comprising the steps of:

routing temperature conditioned air from an air inlet to an air outlet of an air flow channel extending through a support member of the seat;

distributing temperature conditioned air from the air outlet along a top surface of the support member through at least one air subchannel disposed within the top surface; and

passing temperature conditioned air from the air subchannels in a direction opposite an air-impermeable barrier positioned adjacent the air subchannels, through a porous member disposed adjacent the top surface, and then to a seat covering disposed adjacent the porous member.

28. A method as recited in claim 27 wherein the temperature conditioned air is routed from a bottom surface of the support member to a top surface of the support member.