Suspension fabric seat cooling system

Abstract

A seat and cooling system for the seat include a porous seat surface, an air spacer disposed on a side of the seat surface that defines an air channel, a substantially air impermeable barrier having an opening therein in communication with the air channel and a blower configured to draw air through the seat surface and from the air channel. Air drawn from around an occupant on the seat surface draws moisture from the occupant, causing moisture to evaporate, to provide a cooling sensation.

Claims

1. A seat, comprising: a porous seat surface suspended from a carrier, the seat surface being secured to the carrier along an edge of the seat surface; an air spacer disposed on a side of the seat surface, the air spacer defining an air channel; a substantially air impermeable barrier having an opening therein in communication with the air channel; and a blower configured to draw air through the seat surface and from the air channel, wherein at least one of the air spacer and the barrier are configured to move and flex with the seat surface when the seat surface is loaded.

2. The seat of claim 1, wherein the seat surface, the air spacer and the barrier are sealed along a periphery thereof.

3. The seat of claim 1, wherein the barrier is formed as part of the air spacer.

4. The seat of claim 3, wherein the air spacer and barrier are formed as a polymeric member.

5. The seat of claim 4, wherein the polymeric member has a series of projections, and wherein spaces between the projections define, at least in part, the air channel.

6. The seat of claim 1, wherein the barrier is a member separate from the air spacer.

7. The seat of claim 6, wherein the air spacer is formed from polymeric filaments.

8. The seat of claim 6, wherein the air space is defined, in part, by the porous seat surface.

9. The seat of claim 8, wherein the porous seat surface is formed from a woven fabric material.

10. The seat of claim 1, wherein the fabric is formed from warp and weft fibers and wherein the barrier is mounted at selected locations to one of the warp and the weft fibers.

11. The seat of claim 1, wherein the blower is mounted about the opening in the barrier.

12. The seat of claim 1, wherein the blower is suspended from the barrier.

13. The seat of claim 10 including an intake spacer mounted to the barrier to space the blower from the barrier.

14. The seat of claim 13 including a second barrier positioned on the intake spacer between the blower and the blower spacer.

15. The seat of claim 1, wherein the blower is mounted to move with the seat surface, air spacer and barrier.

16. A seat, comprising: a porous seat surface defining an edge, the seat surface being secured to a carrier along the edge so that the seat surface is suspended from the carrier; a substantially air impermeable barrier having an opening therein; an air spacer defining an air space between the seat surface and the barrier; and a vacuum source in communication with the air space, wherein air is drawn through the seat surface into the air space and from the air space by the vacuum source, the air drawn through the seat surface and away from an occupant on the seat surface to effect cooling of the occupant.

17. The seat of claim 16 including a voided material in the air space.

18. The seat of claim 17, wherein the impermeable barrier and the voided material are formed as a unitary member.

19. The seat of claim 16, wherein the vacuum source is a blower, and wherein the blower is mounted to move with the seat surface as the seat surface is loaded.

20. The seat of claim 19, wherein the blower is suspension mounted.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The benefits and advantages of the present embodiments will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:

(2) FIG. 1 is an illustration of an example of a known seat design having a cooling system;

(3) FIG. 2 is an illustration of an embodiment of a suspension fabric seat cooling system in accordance with the present disclosure, a portion of the seat fabric being removed for ease of illustration;

(4) FIG. 3 is an exploded view of the suspension fabric seat cooling system of FIG. 2;

(5) FIG. 4 is a photograph of a monofilament spacer element;

(6) FIG. 5 is an illustration of a manifold layer spacer;

(7) FIGS. 6A and 6B are illustrations of a molded baffle spacer element;

(8) FIGS. 7A and 7B are illustrations of a molded pixelated spacer element; and

(9) FIGS. 8A and 8B illustrate the suspension fabric seat cooling system when under no load (FIG. 8A) and under load (FIG. 8B).

DETAILED DESCRIPTION

(10) While the present disclosure is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described one or more embodiments with the understanding that the present disclosure is to be considered illustrative only and is not intended to limit the disclosure to any specific embodiment described or illustrated.

(11) Referring to the figures and in particular to FIG. 1, there is shown a conventional seat 1 and seat cooling system 2. The seat 1 includes a rigid frame 3, foam 4, such as polyurethane foam over the frame 3 and a seat trim 5, such as leather, vinyl, cloth or the like. The cooling system 2 includes a vacuum manifold 6 mounted to the frame 3 and/or the foam 4, a grommet 7 or like spacer and a vacuum/blower 8 mounted to the grommet.

(12) Referring now to FIGS. 2 and 3, there is shown a suspension fabric seat 10 and suspension fabric seat cooling system 12 in accordance with the present disclosure. The seat 10 includes a fabric seat surface 14 having a carrier 16 on an edge of the seat surface 14. The fabric seat surface 14 and carrier 16 form a seat surface/carrier assembly 18. The seat surface/carrier assembly 18 is positioned in a frame 20. In embodiments, the carrier 16 is overmolded onto the seat surface 14 and the frame 20 is overmolded onto the seat surface/carrier assembly 18. In other embodiments, the seat surface 14 may be mounted to the carrier 16 and the seat surface/carrier assembly 18 mounted to the frame 20 using fasteners, adhesives and the like.

(13) An air/vacuum spacer element 22 (referred to herein as the “air spacer”) is disposed adjacent to the seat surface/carrier assembly 18, and an air impermeable member or barrier 24, such as a film or other relatively air impermeable element is disposed on a side of the air spacer 22 opposite the seat surface/carrier assembly 18. The air impermeable member 24 has an opening 26 therein. It will be appreciated that the air impermeable barrier 24 is substantially air impermeable, and may not be completely impermeable. That is although air may pass through the air impermeable member 24, any air passing through or around the member 24 is negligible compared to the air the maintained by the member 24.

(14) An intake spacer 28 is disposed on the air impermeable member 24 and a second air impermeable member 30 is disposed on the intake spacer 28. The intake spacer 28 and the second air impermeable member 30 both have openings 32, 34, respectively, therein that align with one another.

(15) A blower mount 36 is mounted to the intake spacer 28 and the second air impermeable member 30 at their respective openings 32, 34. A blower 38, having a blower motor 39, is mounted to the blower mount 36. In an embodiment, the blower 38 functions as a vacuum and draws air away from the seat surface 14.

(16) In an embodiment, the seat surface 14, the first and second air impermeable members 24, 30, and the intake spacer 28 are all relatively flexible so as to flex and move with the seat surface 14 as will be described in more detail herein.

(17) Referring briefly to FIG. 5, in an embodiment, the seat surface 14 is formed from a fabric. In an embodiment, the fabric is woven from fibers or yarns (used interchangeably herein) and includes a series of warp fibers 40, illustrated as the vertical fibers, and weft fibers 42 illustrated as the horizontal fibers. Typically, the warp fibers 40 are fill yarns and extend in the front-to-rear direction of a seat bottom surface or a top-to-bottom direction in a seat back surface or headrest. The weft fibers 42 are typically monofilament fibers that extend in a side-to-side direction transverse to the warp fibers 40. An example of a woven fabric is disclosed in Coffield, U.S. Pat. No. 8,329,281, which patent is commonly assigned with the present application, the disclosure of which is incorporated herein in its entirety. Examples of the monofilament fibers are disclosed in Coffield, et al., U.S. Pat. No. 8,857,033 and Coffield, U.S. Pat. No. 9,156,211, which patents are commonly assigned with the present application, the disclosures of which are incorporated herein in their entirety.

(18) The warp fibers or yarns 40 are relatively inelastic and elongate less than about 12 to 15 percent and preferably, less than about 5 percent. The warp fibers 40 give the fabric bulk and thickness and are able to be colored for a colored fabric suspension assembly. The warp fibers 40 are used to shape the seat surface 14 by pulling the monofilament (weft) fibers 42 out of straight line position to form a parabolic shape in the overall fabric seat surface 14. The warp fibers 40 can be formed from, for example, a polyester yarn or like, suitable materials.

(19) The weft fibers 42 are typically elastic and can be formed from, for example, a block copolymer monofilament. These fibers 42 can be orientated and elongate more than 10 percent, and up to about 30 percent when measured on a stress strain curve. The monofilament weft fibers 42 can be oriented and conditioned (as at an elevated temperature) and can be treated zonally to obtain a desired occupant pressure map of the seat 10 shape making the seat 10 more comfortable.

(20) It will be appreciated that such a fabric seat surface 14 is porous so as to promote air flow through the fabric, between the fibers or yarns 40, 42.

(21) In an embodiment, the woven seat surface 14 fabric is overmolded with the carrier 16. A carrier 16 material can be, for example, a block copolymer that is chemically similar to the fabric monofilaments (the weft fibers 42), which permits chemical bonding during the injection mold process. Mechanical bonding also takes place during overmolding. However, as noted above, in embodiments, the seat surface 14 may also be mounted to the carrier 16 using fasteners, friction fit, adhesives and the like.

(22) Referring again to FIG. 3, the air spacer 22 is disposed on a bottom side of the seat surface 14 fabric. The air spacer 22 creates a sustained air space, channels or manifold 44 between the seat surface 14 and the first air impermeable member 24 through which air can be drawn from seat surface. The air spacer 22 can be affixed to the seat surface 14 by any of a variety of known way, such as adhesives and the like. Alternately, the air spacer 22 can “float” relative to the seat surface 14 while being maintained in place by, for example, the frame 20 or other portion of the seat 10 structure.

(23) The air spacer 22 can be formed from a variety of materials. For example, as seen in FIG. 4, one embodiment of an air spacer 22 is a fiber spacer formed from, for example, monofilament fibers. A monofilament fiber material 46 is sufficiently robust that it offers limited compression, but has significant porosity creating channels for air flow, while also offering the ability to stretch and flex with the seat surface 14 without collapsing onto itself even under high and pinpoint loads.

(24) Another embodiment of an air spacer 122 is illustrated in FIG. 5, in which the air spacer 122 is formed as part of the seat surface 114. In this embodiment, the air spacer 122 is formed by the peaks 148 and valleys 150 that are defined by the seat surface 114 fabric. In an embodiment, the peaks 148 and valleys 150 are formed by the weft fibers 142 (the monofilament fibers) that form the seat surface 114. It is anticipated that in such an embodiment, the fabric thickness will be sufficient to provide spaces between warp fibers 140 or yarns to create a manifold 144 for air flow. In this construction, the peaks 148 serve as a spacer creating the manifold 144 and control the attachment of the impermeable member 124, which is attached directly to the bottom side of the seat surface 114. The valleys 150 between the warp fiber 142 rows define the manifold 144 for air flow. The impermeable member 124 seals the manifold 144 on the bottom side of the seat surface 114 fabric, while air flow occurs toward the top side of seat surface 114 to toward the occupant. It will be appreciated that in this embodiment, the fibers of the seat surface 140, 142, and more specifically, the weft fibers 142 in the seat surface 114, along with the impermeable member 124 form the manifold 144 for proper air flow away from the occupant.

(25) In another embodiment, illustrated in FIGS. 6A and 6B, the air spacer 222 is formed from a low durometer baffle, having a series of upstanding, compressible projections 252 that form a manifold 244. The air spacer baffle 222 can be a molded element formed from, for example, a thermoplastic elastomer (TPE) material. The baffle 222 configuration allows the manifold 244 to stretch and flex/hammock as need for comfort and further allows the baffle 222 to be attached to the bottom side of the seat surface (bot shown) fabric. The baffle 222 can be formed as a layer in a single molding or it can be formed in a two-shot molding on the suspension frame as one part molded from two materials chemically bonded to perform two independent functions. And, similar to the embodiment of FIG. 5, this embodiment of the air spacer 222 can also function as the first impermeable member.

(26) In still another embodiment, illustrated in FIGS. 7A and 7B, the air spacer 322 can be formed from an oriented polymeric member, such as that disclosed in Coffield, et al., U.S. Pat. No. 8,185,985, and Coffield, U.S. Pat. No. 9,131,776, both commonly assigned with the present application, the disclosures of which are incorporated herein in their entirety. In this embodiment, the air spacer 322 is formed from a polymeric material, such as a block copolymer, having nodes 354 and connectors 356. As can be seen in FIG. 7B, the connectors 356 are thinner than the nodes 354. As such, the spaces 358 between the connectors 356 form the manifold 344 or channels for air flow. As the polymeric member 322 is oriented, such as by stretching, the connectors 356 are oriented and stretch to a greater extent than the nodes 354, which give the polymeric member the ability to stretch and flex, while the non-oriented or less-oriented nodes 354 provide the depth necessary to maintain the space or manifold 344 between the seat surface (not shown) and the first impermeable member 324. In this embodiment, the spaces or manifold 344 between nodes 354 can be filled in with minor wall stock (not shown), while leaving the spaces between and around the connectors 356 and between the seat surface and the polymeric spacer member 322 open, so that the polymeric member is not porous, eliminating the need for a separate first impermeable member.

(27) The first air impermeable members (referred to collectively as 24) and the second air impermeable member 30 can be formed from a wide variety of materials. The members 24, 30 are flexible and can stretch with movement of the seat surface (referred to collectively as 14). The first member 24 forms a barrier so that air is drawn from seat surface 14 (by the blower 38) through the air spacer (referred to collectively as 22), rather than from the environment around, but not through, the seat surface 14. As discussed above, some embodiments of the air spacer 22 do not require a separate first impermeable member 24 as the barrier is formed as part of the air spacer 22. The air spacer 22 includes an opening 26 through which the air is drawn by the blower 38.

(28) The intake spacer 28 is disposed on the first air impermeable member 24 (or the air spacer 22 where the first impermeable member is formed as part of the air spacer). The intake spacer 28 forms a space between the blower mount 36 and the blower 38 to assure an air space is present between the blower 38 and the air spacer 22 and to provide a flexible area around the blower mount 36 and blower 38. The intake spacer 28 includes an opening 32 at which the blower mount 36 and blower 38 are positioned.

(29) The second air impermeable member 30 provides a seal around the opening 26 in the first air impermeable member 24 (or the air spacer 22) and the intake spacer 28. The blower mount 36 and blower 38 are positioned at the openings 32, 34 in the intake spacer 28 and second impermeable member 30.

(30) FIGS. 8A and 8B illustrate the suspension fabric seat 10 and cooling system 12 in the unloaded state (FIG. 8A) and in the loaded state (FIG. 8B). As will be appreciated, the various components or layers, such as the air spacer 22, the first impermeable member 24 (if used), the intake spacer 28 and the second impermeable member 30 all flex and move with the seat surface 14, as the seat 10 is loaded L. The blower mount 36 and blower 38 are mounted to the seat 10 by the intake spacer 28 and as such do not flex. Rather, the flex and movement is provided by the intake spacer 28. The configuration assures that the air flow path from the seat surface 14 to the blower 38 is not blocked or impeded by any of the seat 10 components, or when loaded by an occupant.

(31) It will also be appreciated that in each of the disclosed embodiments, the air space provided by the air spacer 22 includes an impermeable back layer 24 (either as the separate first impermeable member 24 or as part of the air spacer 22) that prevents or limits air flow from unintended areas on the bottom side of the seat 10. In this manner, air flow will enter the air spacer 22 through the seat surface 14 fabric. This air flow path assures air is moving in turbulent flow very near the occupant with enough velocity to promote moisture evaporation. Moving air next to the occupant's skin offers an effective method of removing and evaporating moisture from around the occupant to provide a cooling sensation.

(32) As an example, referring to the air spacer 22 in FIG. 3, the air spacer thickness is configured so that the air velocity is sufficient to maintain moisture evaporation and cooling from around the occupant. It is anticipated that a thickness of about 2 mm to 15 mm will provide the required performance; however, other thicknesses of the air spacer 22 will be suitable and are within the scope and spirit of the present disclosure.

(33) In addition, the seat surface 14 and air spacers 22 are free to stretch and hammock with no compression hard points under the seat 10 structure and resulting pinching of the air spacer 22, as seen in FIGS. 8A and 8B. The spacer 22 will resist collapse, enabling the cooling function under excessive loads and pin pointed loads. The blower 38 is sufficiently spaced from the seat surface 14 to prevent air path blockage and possible air path collapse. The blower spacer 28 material is an additional layer used to prevent localized loading near the blower 38 intake. It is also anticipated that the blower 38 location can be moved to, for example, a hinge point on the seat 10, to eliminate any risk of blocking or collapsing the air path and to eliminate or reduce the need for the blower spacer 28.

(34) In the disclosed embodiments, the air flow channel or manifold 44 does not impede the suspension hammocking effect of the seat surface 14, and as such, occupant comfort is enhanced because the seat surface 14 and manifold 44 move as one under load, as illustrated in FIG. 8B. The blower 38 provides a vacuum for air and moisture evaporation that can be attached directly to the seat surface 14 and manifold 44 assembly.

(35) Blower 38 noise, typically associated with the blower motor 39 can be reduced because the seat surface 14 is suspended, isolating the motor 39 from vehicle hard points, thus reducing fan and motor vibration noise.

(36) As noted above and as seen in FIGS. 8A and 8B, the seat 14 and manifold 44 assembly does not collapse under point loads or high loads because the seating surface 14, manifold 44 and blower 38 and motor 39 move all as one avoiding contact with hard points that would otherwise collapse the manifold (air paths) 44.

(37) It will be appreciated that, the drawn air flows parallel to the occupant's skin and as close as possible to the occupant's skin throughout the air travel, from the seat surface 14 perimeter to the vacuum blower 38. In embodiments, the air channel or manifold 44 is sufficiently thin and is close to the seat surface 14 to maximize turbulent air flow at the occupant's skin to achieve high moisture evaporation rates.

(38) It will also be appreciated that, although not shown, sensors, monitors and controls can be integrated into the cooling system 12 to, for example, monitor the temperature at certain locations within the system 12 and the seat 10, to monitor the blower 38 fan speed and time, monitor humidity levels and the like. Accordingly, temperature sensors such as thermocouples, humidistats, current and voltage sensors and the like can be incorporated into the system 10 as desired. As one example, thermocouples or other temperature sensors can be incorporated into the fibers 40, 42 of the seat surface.

(39) In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. It will be appreciated by those skilled in the art that the relative directional terms such as upper, lower, rearward, forward and the like are for explanatory purposes only and are not intended to limit the scope of the disclosure.

(40) All patents or patent applications referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure.

(41) From the foregoing it will be observed that numerous modification and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present film. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.