Abstract:
An air distribution system ( 20 ) for distributing air through a vehicle component such as a vehicle seat pad ( 6 ). The system ( 20 ) includes an air distribution layer ( 4 ) defining a base area and a first layer ( 2 ) arranged on the air distribution layer ( 4 ). The first layer ( 2 ) projects beyond the base area along at least a portion of an edge thereof to form a flange ( 25 ). A side of the flange ( 25 ) facing towards the air distribution layer ( 4 ) includes an adhesion area ( 5 ). During assembly, the adhesion area ( 5 ) engages the seat pad ( 6 ) along a pad elevation ( 41 ) surrounding a portion of the recess ( 35 ) formed in the seat pad ( 6 ) to fix the air distribution system ( 20 ) within the seat pad ( 6 ).

Description:
TECHNICAL FIELD  
       [0001]     The present invention relates to an air distribution system for a vehicle component having an air distribution layer and an accompanying layer thereon. Such arrangements are employed, for example, in air-conditioned seats, to distribute air in the seating surface underneath a seat covering and thereby direct the flow towards a passenger.  
       BACKGROUND OF THE INVENTION  
       [0002]     U.S. Pat. No. 5,902,014 discloses air-conditioned seats in which a ventilating layer made of a highly porous air-permeable material is sewn between a seat pad and a covering. In another example, DE 197 26 810 provides an areal heating element between such a ventilating layer and the covering. Such seats are very costly to fabricate, since several layers must be sewn up, at least in part, successively. Such operations are time consuming and inefficient. Furthermore, positioning the ventilating layer on the pad poses difficulties in terms of accuracy.  
         [0003]     EP 1,352,780 discloses a seat in which parts of a pad of a seat are replaced by insertions of reticular material. These parts are supplied with air. This arrangement has disadvantages, too, as such parts may slip or require separate fastening elements.  
         [0004]     Accordingly, there exists a need for an improved air distribution system for ventilated components in the passenger compartment such as vehicle seats.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention provides an air distribution system that is simple to install, logistically simple to manage, and is secure in operation. In one embodiment, the invention provides an air distribution system for distributing air in a component such as a vehicle seat. The system includes an air distribution layer and a first layer arranged thereon. The first layer projects beyond the base area or perimeter of the air distribution layer to form at least one projection or flange. An adhesive is arranged on the flange on the side facing towards the air distribution layer. The air distribution system can be arranged between a seat pad and a seat cover. The pad can include a recess to accommodate the air distribution layer. The recess can also correspond in depth to the air distribution layer. Because the adhesive flange projects beyond the air distribution layer which is secured to the first layer, the unit can be easily positioned and secured to the seat pad during further manufacturing steps.  
         [0006]     The seat pad can include various pad zones separated by seat features such as depressions, elevations and/or height differences. At least one of the pad zones includes a recess substantially corresponding in size and depth to the air distribution layer. The recess can extend as far as the edge of the pad zone and be bounded along its borders by a pad elevation. The pad elevation can substantially correspond with the flange such that the adhesive area can bind to the pad elevation surrounding the recess. In this way, the air distribution system can advantageously be registered in position and fixed within the seat pad zone of interest. The seat pad zone may be a seat cushion or backrest portion of a vehicle seat.  
         [0007]     In another example, the air distribution layer can comprise at least two segments with the first layer arranged over the segments such that the segments are spaced from each other. The segments can be separated from each other within the same plane along the first layer. An electrical conductor such as a heating conductor can run from the first segment to the second segment of the air distribution layer. The conductor can be arranged at an angle with respect to the shortest path between the two segments and can also meander about its principal, angled direction to permit flexion during assembly and in operation or use of the seat.  
         [0008]     The adhesive can be provided as an adhesive layer on at least half of the flange such that at least one adhesive edge is provided around the air distribution layer. The adhesive area can comprise a self-adhesive or a knotted surface.  
         [0009]     The first layer can be formed essentially by the adhesion area and/or may include constituents such as pad material essentially covering the air distribution layer completely.  
         [0010]     In another embodiment, an areal heating element is arranged on the air distribution layer, either in the first layer or between the first layer and air distribution layer.  
         [0011]     In another example, a vehicle seat including at least one pad having a recess formed therein, and an air distribution system is provided. The air distribution system includes an air distribution layer secured to a first layer. The air distribution layer defines a base area substantially corresponding in size to the recess. The first layer projects beyond the base area along at least a portion of an edge thereof to form a flange. A side of the flange facing towards the pad includes an adhesion area. The air distribution system can also include an areal heating element arranged between the air distribution layer and the first layer. The adhesion area includes a self-adhesive or a knotted surface for engaging the pad along a pad elevation surrounding a portion of the recess.  
         [0012]     A method of assembling a ventilated vehicle seat is also provided. The method includes providing at least one vehicle seat pad having a recess formed therein, and providing an air distribution system comprising an air distribution layer secured to a first layer. The air distribution layer defines a base area substantially corresponding in size to the recess. The first layer projects beyond the base area along at least a portion of an edge thereof to form a flange, wherein a side of the flange facing towards the pad includes an adhesion area. Thereafter, the air distribution system is positioned within the recess and the flange adhesion area is engaged to the pad along a pad elevation surrounding a portion of the recess to fix the air distribution system within the seat pad.  
         [0013]     The present invention is advantages in that it provides an economical air distributing system that can be easily handled during seat manufacturing and can be accurately positioned with respect to a seat pad. Other objects and advantages will become apparent with reference to the following detailed description, taken in conjunction with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     For a more complete understanding of this invention reference should now be had to the embodiments illustrated in greater detail in the accompanying figures and described below by way of examples of the invention wherein:  
         [0015]      FIG. 1  shows a cross-sectional of a seat with an air distribution system according to one embodiment of the present invention.  
         [0016]      FIG. 2  shows a longitudinal section through the seat of  FIG. 1 .  
         [0017]      FIG. 3  shows a perspective view of a seat in an opened condition having an air distribution system according to another embodiment of the present invention.  
         [0018]      FIG. 4  shows a top view of an air distribution system according to an embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]     While the present invention is described with respect to an air distribution system for a vehicle seat, the present invention may be adapted and utilized for other ventilated components such as arm rests, door trim, armature panels as well as non-automotive seat and ventilated components applications. In the following description, various operating parameters and components re described for two embodiments. These specific parameters and components are included as examples and are not meant to be limiting.  
         [0020]      FIGS. 1 and 2  show a cross-section and longitudinal section, respectively, of a component  30  in the passenger compartment of a vehicle, in this case a seat  31 . A pad  6  is provided in the seat  31 . The pad  6 , on its side facing the passenger, comprises a recess  35 . The recess  35  is bounded by pad elevations  41 . On the side of the pad elevations  41  away from the recess  35 , depressions  7  are provided. The recess  35  and the pad elevations  41  are provided in a first pad zone  16 . A second pad zone  17  is also provided, and is formed like the first pad zone  16  such that it includes a recess  35 , pad elevations  41  and depressions  7 . Thus, the pad zones  16 ,  17  are separated from each other by depressions  7  or other variations in height. The recesses  35 ,  35 ′ can extend almost as far as the edge  37  of the pad zones  16 ,  17 , as shown. The elevations  41 , however, provide a boundary or border region  39  along at least one side of each recess  35 ,  35 ′.  
         [0021]     In the example shown, the base area of the second recess  35 ′ is displaced from that of the first recess  35 . On the seat pad  6 , an air distribution system  20  is disposed. The air distribution system  20  comprises an air distribution layer  4  and a first layer  2  arranged thereon. The air distribution layer  4  can be made up, for example, of a knit spacer (as here), rubber filaments, foam or a plurality of spirals arranged side by side, or some other material through which air can flow.  
         [0022]     The air distribution layer  4  comprises, in the present embodiment by way of example, two segments  43 ,  43 ′ separated and distanced from each other by the depression  7  ( FIG. 2 ). The size of each air distribution layer segment  43 ,  43 ′ corresponds more or less to the base area of the respective recesses  35 ,  35 ′. The thickness of the segments  43 ,  43 ′ also corresponds more or less to the depth of the recesses  35 ,  35 ′. The segments  43 ,  43 ′ are so arranged as to be accommodated in the recesses  35 ,  35 ′. The two segments  43 ,  43 ′ in the present example are of the same material and of like configuration. They may, however, e.g. to optimize pad firmness or load capacity, comprise a differential elasticity or various materials or thicknesses of material. In other words, the thickness of each segment can be greater or less than that of the corresponding recess, and the material of each segment  43 ,  43 ′ can also be different.  
         [0023]     On the air distribution layer  4 , a first layer  2  is arranged. The first layer  2  is located on the side of the air distribution layer  4  away from the pad  6 . The first layer  2  projects at least partly beyond the base area or boundary of the air distribution layer  4  to create a projection or flange  25 . The flange  25  should extend beyond at least one edge of the air distribution layer and, preferably, beyond the entire periphery of the air distribution layer. On the flange  25  so formed, an adhesion area  5  is provided. This extends, in the embodiment shown by way of example, around the segments  43 ,  43 ′ of the air distribution layer  4 . It is expediently formed by a strip of self-adhesive film. The adhesive area  5  is at least on the side of the first layer  2  facing toward the air distribution layer  4 , but can be on both sides of the first layer  2 . The first layer  2  may be made up exclusively of the adhesion area  5 . In the present example, however, it comprises a pad layer  3  of pad material.  
         [0024]     Additionally, an areal heating element  12  is arranged on the first layer  2 . The pad layer  3  and the heating element  12  may be bonded, sewn, knitted or knotted to each other. The segments  43 ,  43 ′ and the first layer  2  are so arranged on each other that the segments  43 ,  43 ′ are covered over their entire area in the pad zones  16 ,  17  and so that the first layer  2  extends as far as the base of the depression  7  between the two pad zones  16 ,  17 . This depression  7  in the present case is a relaxation pit. The adhesion area  5  adheres to the elevations  41  defining the boundary of each recess  35 ,  35 ′. In this way, a stepless transition between the elevations  41  and the air distribution layer  4  is ensured, and the air distribution layer  4  is firmly and undisplaceably fixed when placed within the corresponding recess.  
         [0025]     The air distribution system  20 , particularly in the air distribution layer  4 , provides a low flow resistance air current along the air distribution layer, i.e., transverse to the air distribution layer. In addition, it has a high vapor transmissivity and/or air transmissivity perpendicular to the air distribution layer  4 .  
         [0026]     The air distribution system  20  is covered by a seat covering  1 . The seat cover  1  may be pasted on the pad  6  and the air distribution system  20 . In the present example, however, it is stitched along the depressions  7 .  
         [0027]      FIG. 3 , in another embodiment by way of example, shows a seat  31 , a pad  6  having a recess  35  and an air distribution system  20 . The components are substantially similar to the first embodiment, however, the air distribution layer  4  comprises only one segment  43 .  
         [0028]     In the recess  35 , a passage  47  is provided for accommodating an electric connection cable  9  of the air distribution system  20 . The passage  47  extends from the base of the recess  35  through the pad  6  and emerges from the pad  6  again in a suitable place, e.g. on the reverse or face of the pad  6 .  
         [0029]     In the recess  35 , an opening  49  is provided as well. This serves for passage of air and connects the air distribution layer  4  to the surroundings of the seat  31 . Expediently, therefore, air travels as directly and rectilinearly as possible to the side of the pad  6  away from the air distribution system  20 .  
         [0030]     In the opening  49 , a blower or fan  8  is provided. The fan  8  serves to supply air to the air distribution system  20  or aspirate air from the system  20 .  
         [0031]     It will be apparent that the air distribution system  20  comprising the air distribution layer  4 , the first layer  2  with adhesion area  5  and the other functional elements such as the electric heating element  12  will form a coherent, simply handled component. This component may simply be fitted into the recess  35 , held in place by the adhesion area  5 , and then may be permanently secured during subsequent operations.  
         [0032]      FIG. 4  shows another example of an air distribution system  20  corresponding to the first embodiment. In the top view, electrical conductors  11  are shown, leading from the first segment  43  of the air distribution layer  4  to the second segment  43 ′. These electric conductors  11  are fixed on the first layer  2 . They do not extend linearly or on the shortest path from one segment to the other. Rather, their principal direction is at an angle to the shortest possible connection, and they meander about that principal direction. In this way, the conductors  11  acquire sufficient freedom of motion to bridge relaxation pits or other depressions  7  and seams without being damaged by overextension or stress under load. The invention is not limited to seats. In adapted form, it may for example be provided also for arm rests, door trim and armature panels.  
         [0033]     The air distribution system  20  may alternatively comprise a moist, interstorage layer, e.g. a fleece of active carbon particles. Further, the air distribution system may be fitted with sensors, fans or other functional elements. Also, pad distribution elements or multi-zone foams may be arranged thereon. Molded parts of rubber filament are especially suitable for the seat level.  
         [0034]     Another fastening alternative can be provided by foaming parts of an adhesive shield into the pad and providing the corresponding parts on the adhesion area of the air distribution system, and/or making the first layer a textile, bondable material. The adhesion area  5  of the first layer  2  will then interlock with the pad  6  rather than bond thereto in the case of an adhesive. As used herein, however, the term adhesion contemplates both bonding and material interlocking.  
         [0035]     In operation, the air distribution system of the present invention provides assembly advantages over prior art vehicle seat assembly processes. In particular, the air distribution system  20  comprising the air distribution layer  4  and first layer  2  having an adhesive flange  25  can be easily handled by assembly operators. Further, because the seat pad recess  35  substantially corresponds in size to the air distribution layer  4 , the air distribution layer  4  can easily and accurately be located on the vehicle seat pad  6 . In addition, the adhesive flange  25  secures the air distribution system  20  to the pad  6  during further upholstery operations. In this way, it is ensured that the air distribution system will not shift or otherwise become dislocated during final assembly.  
         [0036]     While the invention has been described in connection with one or more embodiments, it is to be understood that the specific mechanisms and techniques which have been described are merely illustrative of the principles of the invention, numerous modifications may be made to the apparatus described without departing from the spirit and scope of the invention as defined by the appended claims.