Pneumatic pump

A vehicle seat in accordance with the present disclosure includes a seat bottom, a seat back, and an occupant comfort system. The occupant comfort system includes a pneumatic pump and a pneumatic bladder. The pneumatic pump provides a stream of pressurized air to the pneumatic bladder to inflate the pneumatic bladder.

BACKGROUND

The present disclosure relates to a pneumatic pump, and particularly to a pneumatic pump for use in a vehicle seat. More particularly the present disclosure relates a pneumatic pump that includes a motor.

SUMMARY

According to the present disclosure, a vehicle seat in accordance with the present disclosure includes a seat bottom and a seat back. At least one pneumatic bladder is provided in the vehicle seat. A pneumatic pump may be used to inflate the pneumatic bladder.

In illustrative embodiments, the pneumatic pump includes a fluid-driving system, a fluid regulator, and a pump housing. The fluid-driving system may be configured to receive an airflow from an environment outside of the pneumatic pump and pressurize and communicate the airflow to the pneumatic bladder. The fluid regulator may control the flow of air from the environment to the pneumatic bladder by restricting air flow under certain conditions. The pump housing may provide an internal space for the fluid-driving system and the fluid regulator.

In illustrative embodiments, the fluid driving system includes a motor, an actuator plate, and a plurality of vertically extending diaphragms. The motor may be configured to rotate about a central axis. The actuator plate may be angled relative to a horizontal axis that is perpendicular to the central axis. The actuator plate may be positioned so that one portion of the actuator plate compresses the plurality of diaphragms and another portion of the actuator plate expands the plurality of diaphragms as the motor rotates.

In illustrative embodiments, the fluid driving system may include a motor, a first actuator plate, a second actuator plate, and a plurality of radially extending diaphragms. The motor may be configured to rotate about a central axis. The first actuator plate may be coupled to the motor and positioned along a first axis spaced apart from the central axis. The second actuator plate may be coupled to the motor and positioned along a second axis spaced apart from the central axis and opposite the first axis. The first and second actuators may compress and expand a first diaphragm and an opposite, second diaphragm as the motor rotates about the central axis and moves the first and second actuator plates.

DETAILED DESCRIPTION

A first embodiment of a pneumatic pump18in accordance with the present disclosure is shown inFIGS. 1-12. The pneumatic pump18is configured to provide compressed streams of air to one or more pneumatic bladders included in an occupant comfort system while minimizing packaging space and noise emission. A second embodiment of a pneumatic pump218in accordance with the present disclosure is shown inFIGS. 13-24. A third embodiment of a pneumatic pump318in accordance with the present disclosure is shown inFIGS. 25-34.

A vehicle seat10, in accordance with the present disclosure, includes a seat bottom12, a seat back14, and an occupant comfort system16as shown inFIG. 1. The seat bottom12is coupled to a vehicle floor for selective movement back and forth relative to the vehicle floor. The seat back14is coupled to the seat bottom12to move relative to the sea bottom. The occupant comfort system16includes one or more pneumatic bladders24which are supplied pressurized air by a pneumatic pump18to maximize comfort of an occupant resting on the vehicle seat10as suggested inFIG. 1. The pneumatic pump18provides pressurized air selectively to the pneumatic bladders24with low noise, small size, and efficient operation.

A first embodiment of pneumatic pump18in accordance with the present disclosure is shown inFIGS. 2-12. The pneumatic pump18includes a pump housing26, a fluid-driving system28, and a fluid regulator30as shown inFIG. 2. The pump housing26is formed to include an internal space25therein. The fluid regulator30and the fluid-driving system28are located in the pump housing26as shown inFIG. 3. The fluid-driving system28moves within the pump housing26to draw an airflow15from the environment and inject a pressurized airflow17into the at least one pneumatic bladder24. The fluid regulator30is configured to open and receive the airflow15from an environment outside of the pump housing26and then communicate the pressurized airflow17into the at least one pneumatic bladder24as shown inFIG. 3.

The fluid-driving system28includes a hollow cylindrical actuator having an angled top surface, a motor38coupled to the actuator, a diaphragm system40and an actuator plate42as shown inFIGS. 3 and 4. The motor38is configured to rotate about a central axis A. The diaphragm system40is spaced apart radially and arranged to surround the motor38in the internal space25and is coupled to the actuator plate42. The actuator plate42is driven by the motor38to cause the diaphragm system40to draw in air and pressurize the air.

The diaphragm system40includes a diaphragm ring50and a plurality of diaphragms52as shown inFIGS. 3 and 4. The diaphragm ring50is arranged to extend around and surround the motor38. The diaphragm ring50is configured to support and position the plurality of diaphragms52so that the plurality of diaphragms52remains in fluid communication with the fluid regulator30. The plurality of diaphragms52is coupled to the fluid-driving system28. The plurality of diaphragms52are arranged to extend downwardly toward the fluid regulator30.

Each diaphragm of the plurality of diaphragms52is configured to move between an expanded configuration in which air is drawn into the diaphragm through the fluid regulator30and a compressed configuration in which pressurized air is expelled from the diaphragm into the fluid regulator30. Each diaphragm52expands and contracts in series as the motor38rotates driving the fluid-driving system28. In one example, each diaphragm expands into the expanded arrangement and contracts into the contracted arrangement once during one rotation of the motor38.

The fluid-driving system28is configured to provide a reciprocating up-and-down motion that moves the diaphragm system40and the actuator plate42. The actuator includes an angled top surface44that rotates about the central axis A. As the angled top surface44rotates, the angled top surface44engages the actuator plate42to cause the actuator plate42to move to cause each diaphragm in the plurality of diaphragms52to expand and contract in series as shown inFIGS. 5-8.

The actuator plate42is formed to include a motor aperture54, a series of diaphragm mounts56, and friction reducing apertures58. The motor aperture54is configured to receive an actuator plate guide55coupled to the motor38to retain the actuator plate42in a central location relative to the motor38and the central axis A. The diaphragm mounts56are configured to couple the plurality of diaphragms52to the actuator plate42. The friction reducing apertures58are spaced circumferentially around the motor aperture54and are configured to minimize an amount of surface area contract between the actuator plate42and the angled top surface44as the motor38rotates beneath the actuator plate42so that friction is minimized.

The angled top surface44of the motor38includes an upper portion X and a lower portion Y. The central axis A is located between the upper portion X and the lower portion Y. The upper portion X is arranged to extend upwardly from the central axis A toward a top casing32of the pump housing26. The lower portion Y is arranged to extend downwardly from the central axis A toward the diaphragm ring50.

The plurality of diaphragms52includes a first diaphragm60, a second diaphragm61, a third diaphragm62, a fourth diaphragm63, a fifth diaphragm64, and a sixth diaphragm65as shown inFIG. 4. Each diaphragm60,61,62,63,64,65is equally spaced circumferentially around the actuator plate42. The angled top surface44engages actuator plate42and moves actuator plate42and each diaphragm60,61,62,63,64,65from the expanded configuration to the compressed configuration. The expanded configuration occurs when the upper portion X of the angled top surface44is aligned circumferentially with one of the diaphragms60,61,62,63,64,65. The compressed configuration occurs when the lower portion Y of the angled top surface44is aligned circumferentially with one of the diaphragms60,61,62,63,64,65. In one example, this motion occurs during one rotation of motor38as shown inFIGS. 5-8.

In one example, the motor begins at 0 degrees of rotation as shown inFIG. 5. The upper portion X of angled top surface44is aligned circumferentially with the second diaphragm61. Although not shown inFIG. 5, the lower portion Y is aligned circumferentially with the fifth diaphragm64. The upper portion X positions the actuator plate42so that the second diaphragm61is fully expanded in the expanded configuration. The lower portion Y positions the actuator plate42so that the fifth diaphragm64is fully compressed in the compressed configuration. In this arrangement, the first and sixth diaphragms60,65are moving toward the compressed configuration as the motor38rotates clockwise about the central axis A. The third and fourth diaphragms62,63are moving toward the expanded configuration as the motor38rotates clockwise about central axis A.

In the example described above, the motor rotates 90 degrees clockwise about the central axis A as shown inFIG. 6so that the motor38is rotated 90 degrees from the orientation shown inFIG. 5. The upper portion X is arranged circumferentially between the third and fourth diaphragms62,63and the lower portion Y is arranged circumferentially between the first and sixth diaphragms60,65. In this arrangement, the upper portion X and the lower portion Y position the actuator plate42so that the first, second, and third diaphragms60,61, and62are moving toward the compressed configuration as the motor38rotates clockwise about central axis A. The upper portion X and the lower portion Y position the actuator plate42so that the fourth, fifth, and sixth diaphragms63,64,65are moving toward the expanded configuration as the motor38rotates clockwise about central axis A.

As shown inFIG. 7, the motor rotates another 90 degrees clockwise along the central axis A so that the motor38is rotated 180 degrees from the orientation shown inFIG. 5. The upper portion X is aligned circumferentially with the fifth diaphragm64and the lower portion Y is aligned circumferentially with the second diaphragm61. The upper portion X positions the actuator plate42so that the fifth diaphragm64is fully expanded in the expanded configuration. The lower portion Y positions the actuator plate42so that the second diaphragm61is fully compressed in the compressed configuration. The third and fourth diaphragms62,63are moving toward the compressed configuration as the motor38rotates clockwise about the central axis A. The first and sixth diaphragms60,64are moving toward the expanded configuration as the motor38rotates clockwise about central axis A.

As shown inFIG. 8, the motor rotates another 90 degrees clockwise along the central axis A so that the motor38is rotated 270 degrees from the orientation shown inFIG. 5. The upper portion X is arranged circumferentially between the first and sixth diaphragms60,64and the lower portion Y is arranged circumferentially between the third and fourth diaphragms61,62. The upper portion X and the lower portion Y position the actuator plate42so that the first, second, and third diaphragms60,61, and62are moving toward the expanded configuration as the motor38rotates clockwise about central axis A. The upper portion X and the lower portion Y position the actuator plate42so that the fourth, fifth, and sixth diaphragms63,64, and65are moving toward the compressed configuration as the motor38rotates clockwise about central axis A.

The motor38is configured to continue rotating another 90 degrees clockwise along the central axis A so that the motor38completes one full rotation of 360 degrees. At a rotation of 360 degrees, the motor38positions the actuator plate42at the same orientation described above regardingFIG. 5.

The angled top surface44is configured to angle the actuator plate42at an angle α of about 6 degrees from a horizontal axis B as shown inFIG. 9. The horizontal axis B is generally perpendicular to the central axis A. The upper portion X of the angled top surface44angles a first half, or portion, of actuator plate42upward relative to the central axis A at the angle α of about six degrees from horizontal axis B. The lower portion Y of angled top surface44angles a second half, or portion, of actuator plate42downward relative to the central axis A at the angle α of about six degrees from the horizontal axis B. While the angle α is illustratively about six degrees, any suitable angle may be used.

Each diaphragm60,61,62,63,64,65includes a diaphragm mount66and diaphragm housing68as shown inFIGS. 9 and 10. Each diaphragm mount66is coupled to the actuator plate42. Each diaphragm housing68is coupled to a complementary diaphragm mount66and is arranged to extend through diaphragm tubes51formed in the diaphragm ring50. Each diaphragm housing68is formed to include a compression chamber69that opens toward the fluid regulator30.

As shown inFIG. 9, the fourth diaphragm63is positioned in the expanded configuration by the actuator plate42. The compression chamber69has a maximum volume in the expanded configuration. As compression chamber is expanded by actuator plate42, airflow15is suctioned from outside pneumatic pump18, through an inlet aperture35, and into compression chamber69.

As shown inFIG. 10, the first diaphragm60is positioned in the compressed configuration by the actuator plate42. The compression chamber69has a minimum volume in the compressed configuration. As the compression chamber69is compressed by actuator plate42, the airflow is pressurized and forced out of the compression chamber69through an outlet aperture37.

The fluid regulator30includes a fluid inlet controller70and a fluid outlet controller72as shown inFIGS. 9 and 10. The fluid inlet controller70and the fluid outlet controller respond to the expansion and contraction of the plurality of diaphragms52to control airflow into and out of the compression chambers69.

The fluid inlet controller70includes an inlet ring74and inlet valves76as shown inFIGS. 4 and 9. The inlet ring74is formed to include inlet passageways75extending from the inlet apertures35to the compression chambers69. The inlet valves76extend through the inlet passageways75. One inlet valve76is configured to open as the fourth diaphragm63expands into the expanded configuration as shown inFIG. 9. The inlet valve76is configured to close and restrict flow through the inlet passageway75as the first diaphragm60is compressed into the compressed configuration as shown inFIG. 10.

The fluid outlet controller72includes an outlet valve gasket78as shown inFIGS. 4 and 9. The outlet valve gasket78is arranged to control flow into and out of outlet passageways77formed in the inlet ring74. The outlet valve gasket78is formed to include a plurality of U-shaped apertures79spaced apart circumferentially. The U-shaped apertures79define outlet flaps80that are arranged to cover outlet passageways77. One outlet flap80is configured close and restrict flow through the outlet passageway77as the fourth diaphragm63is expanded into the expanded configuration as shown inFIG. 9. The outlet flap80is configured to open and allow flow though the outlet passageway77as the first diaphragm60is compressed into the compressed configuration as shown inFIG. 10.

The pump housing26includes a top casing32and the bottom casing34as shown inFIGS. 3 and 4. The top casing32is positioned above the fluid-driving system28and forms an upper boundary for internal space25. The bottom casing34is positioned below the fluid regulator30and is formed to include a plurality of inlet apertures35spaced apart circumferentially around the bottom casing34.

The bottom casing34is shaped to define an outlet conduit82as shown inFIG. 11. The pressurized airflows17are forced into the outlet conduit82through the plurality of outlet apertures37as each diaphragm is compressed in series into the compressed configuration. The pressurized airflows17are injected out of the pneumatic pump18and into the pneumatic air bladders24through an outlet tube84coupled to the bottom casing34as shown inFIG. 12.

A plurality of posts36extend from bottom casing34toward the top casing32as shown inFIG. 4. The plurality of posts36aligns the fluid-driving system28and the fluid regulator30within the internal space25. Fasteners (not shown) may extend through the top casing32and into the posts36to couple the top casing32and the bottom casing34and house the fluid-driving system28and the fluid regulator30in the internal space25.

In one embodiment, the actuator plate42is made of an acetal homopolymer resin, such as, for example, a Dupont™ DELRIN® acetal resin to minimize friction between actuator plate42and motor38. In another example, a layer of DELRIN® acetal resin may be coupled to the motor to provide the angled top surface44. In another example, any suitable material may be used to minimize friction between the actuator plate42and the motor38.

In one embodiment, a biasing spring (not shown) is used to bias the actuator plate42downward against the angled top surface44of the motor38. In other embodiments, a retainer (not shown) may be coupled to the actuator plate guide55to retain the actuator plate42against the angled top surface44of the motor38.

A second embodiment of a pneumatic pump218in accordance with the present disclosure is shown inFIGS. 13-24. The pneumatic pump218includes a pump housing226, a fluid-driving system228, and a fluid regulator230as shown inFIG. 13. Pump housing226is formed to include an internal space225therein. The fluid regulator230and the fluid-driving system228are located in the pump housing226as shown inFIG. 14. The fluid-driving system228moves within the pump housing226to draw an airflow15from an environment outside pneumatic pump18and inject a pressurized airflow17into the at least one pneumatic bladder24. The fluid regulator230is configured to open and receive the airflow15from an environment outside of the pump housing26and then communicate the pressurized airflow17into the at least one pneumatic bladder24as shown inFIG. 3.

The fluid-driving system228includes a motor238, a diaphragm system240, an actuator plate242, and a bearing driver243as shown inFIGS. 3 and 4. The motor238is configured to rotate about a central axis A. The diaphragm system240is spaced apart radially and arranged to surround the motor238in the internal space225and is coupled to the actuator plate242. The actuator plate242is driven by the bearing driver243to cause the diaphragm system40to draw in air and pressurize the air. The bearing driver243is coupled to the motor238and is configured to rotate about the central axis A with the motor238.

The diaphragm system240includes a diaphragm ring250and a plurality of diaphragms252as shown inFIGS. 3 and 4. The diaphragm ring250is arranged to extend around and surround motor238. The diaphragm ring250is configured to support and position the plurality of diaphragms252so that the plurality of diaphragms252remains in fluid communication with the fluid regulator230. The plurality of diaphragms252is coupled to the actuator plate242. The plurality of diaphragms52are arranged to extend downwardly toward the fluid regulator230.

Each diaphragm of the plurality of diaphragms252is configured to move between an expanded configuration in which air is drawn into the diaphragm through the fluid regulator30and a compressed configuration in which pressurized air is expelled from the diaphragm into the fluid regulator230. Each diaphragm252expands and contracts in series as the motor238rotates the bearing driver243. In one example, each diaphragm expands into the expanded configuration and contracts into the contracted configuration once during one rotation of the motor238.

The fluid-driving system228is configured to provide a reciprocating up-and-down motion that moves the diaphragm system240and the actuator plate242. The bearing driver243includes an upper bearing mount245, a lower bearing mount247, a bearing shaft249, and a plurality of ball bearings253that rotate about the central axis A as shown inFIG. 16. As the bearing driver243rotates, the plurality of ball bearings253engages the actuator plate242to cause the actuator plate to move. The plurality of ball bearings253is arranged on varied planes that cooperate to angle the actuator plate242relative to a horizontal axis B that is perpendicular to central axis A as shown inFIGS. 16-20. The angled actuator plate242is moved by bearing driver243to cause each diaphragm in the plurality of diaphragms252to expand and contract in series as shown inFIGS. 17-20.

As shown inFIG. 16, the bearing driver243is arranged so that the upper bearing mount245and the lower bearing mount247rotate about central axis A at the same time. To accomplish this, the bearing shaft249includes a first rib255and a second rib257that extend from the upper bearing mount245to the lower bearing mount247as shown inFIGS. 15 and 16. The ribs255,257are configured to extend into slots271,273formed in the upper bearing mount245and into slots281,283formed in the lower bearing mount247. The lower bearing mount is then coupled to the motor238so that the upper bearing mount and the lower bearing mount rotate about the central axis A at the same time.

The actuator plate242is formed to include a shaft aperture254and a series of diaphragm mounts256. The shaft aperture254is configured to receive the bearing shaft249to retain actuator plate242in a central location relative to the motor238and the central axis A. The diaphragm mounts256are configured to couple the plurality of diaphragms252to the actuator plate242.

The upper bearing mount245of the bearing driver243includes a first ball285, a second ball286, a third ball287, and a forth ball288as shown inFIG. 15. The lower bearing mount247of the bearing driver243also includes a first ball295, a second ball296, a third ball297, and a forth ball298.

The first ball285of upper bearing mount245engages the actuator plate242on a first axis X as shown inFIGS. 17-20. The fourth ball288of the upper bearing mount245engages the actuator plate242on a second axis Y. The second ball286and the third ball287of the upper bearing mount245engage the actuator plate242on a third axis Z. The first axis X is axially above the second axis Y and the third axis Z. The second axis Y is axially below the first axis X and the third axis Z. The third axis Z is axially between the first axis X and the second axis Y as shown inFIG. 18.

The first ball295of the lower bearing mount247is arranged on an axis that complements the second axis Y. The second ball296and third ball297of lower bearing mount247are arranged on an axis that complements the third axis Z. The fourth ball298is arranged on an axis that complements the first axis X. The axis provided by balls295,296,297,298position the actuator plate at an angle relative to the horizontal axis B.

The bearing driver243is configured to angle the actuator plate242at an angle of about six degrees from the horizontal axis B as shown inFIG. 16. However, any suitable angle may be used. The first ball285of the upper bearing mount245and the fourth ball298of the lower bearing mount247are configured to angle a first half, or portion, of the actuator plate242upward relative to the central axis A at an angle of about six degrees from the horizontal axis B. The first ball295of the lower bearing mount247and the fourth ball288of the upper bearing mount245are configured to angle a second half, or portion, of actuator plate242downward relative to the central axis A at an angle of about six degrees from horizontal axis B.

The plurality of diaphragms252includes a first diaphragm260, a second diaphragm261, a third diaphragm262, a fourth diaphragm263, a fifth diaphragm264, a sixth diaphragm265, a seventh diaphragm266, and an eighth diaphragm267as shown inFIG. 15. Each diaphragm260,261,262,263,264,265,266,267is equally spaced circumferentially around the actuator plate242and the diaphragm ring250. The balls285,286,287,288and the balls295,296,297,298engage actuator plate242to move actuator plate242and each diaphragm260,261,262,263,264,265,266,267from the expanded configuration to the compressed configuration in series as bearing driver243rotates about the central axis A.

The first ball295of the lower bearing mount247is axially aligned with the fourth ball288of the upper bearing mount245. The expanded configuration occurs when the first ball295of the lower bearing mount247and the fourth ball288of the upper bearing mount245are aligned circumferentially with one of the diaphragms260,261,262,263,264,265,266,267. The compressed configuration occurs when the first ball285of the upper bearing mount245and the fourth ball298of the lower bearing mount247are aligned circumferentially with one of the diaphragms260,261,262,263,264,265,266,267. In one example, each diaphragm moves from the compressed configuration to the expanded configuration during one rotation of motor38as shown inFIGS. 17-20.

In one example, the bearing driver243begins at 0 degrees of rotation as shown inFIG. 17. The first ball285of the upper bearing mount245and the fourth ball298of the lower bearing mount247are aligned circumferentially with the sixth diaphragm265. The actuator plate242moves the sixth diaphragm265to the compressed configuration. The fourth and fifth diaphragms263,264are moving toward the compressed configuration as the bearing driver243rotates clockwise about the central axis A. The seventh and eighth diaphragms266,267are moving toward the expanded configuration as the bearing driver243rotates clockwise about central axis A.

In the example described above, the motor rotates 90 degrees clockwise about the central axis A as shown inFIG. 18so that the bearing driver243is rotated 90 degrees from the orientation shown inFIG. 17. The first ball285of the upper bearing mount245and the fourth ball298of the lower bearing mount247are aligned circumferentially with the fourth diaphragm263. The first ball295of the lower bearing mount247and the fourth ball288of the upper bearing mount245are aligned circumferentially with the eighth diaphragm267. The actuator plate242moves the fourth diaphragm263to the compressed configuration and the eighth diaphragm267to the expanded configuration. The fifth, sixth, and seventh diaphragms264,265,266are moving toward the expanded configuration as the bearing driver243rotates clockwise about central axis A.

As shown inFIG. 19, the bearing driver243rotates another 90 degrees clockwise along the central axis A so that the bearing driver243is rotated 180 degrees from the orientation shown inFIG. 17. The first ball295of the lower bearing mount247and the fourth ball288of the upper bearing mount245are aligned circumferentially with the sixth diaphragm265. The actuator plate242moves the sixth diaphragm265to the expanded configuration. The fourth and fifth diaphragms263,264are moving toward the expanded configuration as the bearing driver243rotates clockwise about the central axis A. The seventh and eighth diaphragms266,267are moving toward the compressed configuration as the bearing driver243rotates clockwise about the central axis A.

As shown inFIG. 20, the motor rotates another 90 degrees clockwise along the central axis A so that the bearing driver243is rotated 270 degrees from the orientation shown inFIG. 17. The first ball285of the upper bearing mount245and the fourth ball298of the lower bearing mount247are aligned circumferentially with the eighth diaphragm267. The first ball295of the lower bearing mount247and the fourth ball288of the upper bearing mount245are aligned circumferentially with the fourth diaphragm263. The actuator plate242moves the fourth diaphragm263to the expanded configuration and the eighth diaphragm267to the compressed configuration. The fifth, sixth, and seventh diaphragms264,265,266are moving toward the compressed configuration as the bearing driver243rotates clockwise about central axis A.

The bearing driver243is configured to continue rotating another 90 degrees clockwise along the central axis A so that the bearing driver243completes one full rotation of 360 degrees. At a rotation of 360 degrees, the bearing driver243positions the actuator plate242at the same orientation described above regardingFIG. 17.

Each diaphragm260,261,262,263,264,265,266,267includes a diaphragm mount259and diaphragm housing268as shown inFIGS. 21 and 22. Each diaphragm mount259is coupled to the actuator plate242. Each diaphragm housing268is coupled to a complementary diaphragm mount259and is arranged to extend through the diaphragm tubes251formed in the diaphragm ring250. Each diaphragm housing268is formed to include a compression chamber269that opens toward the fluid regulator230.

As shown inFIG. 21, the fifth diaphragm264is positioned in the expanded configuration by the actuator plate242. The compression chamber269has a maximum volume in the expanded configuration. As compression chamber269is expanded by actuator plate242, airflow15is suctioned from outside pneumatic pump218, through an inlet aperture235, and into the compression chamber269.

As shown inFIG. 22, the fifth diaphragm264is positioned in the compressed configuration by the actuator plate242. The compression chamber269has a minimum volume in the compressed configuration. As compression chamber269is compressed by actuator plate242, the airflow17is pressurized and forced out of the compression chamber269through an outlet aperture237.

The fluid regulator230includes a fluid inlet controller270and a fluid outlet controller272as shown inFIGS. 21 and 22. The fluid inlet controller270and the fluid outlet controller respond to the expansion and contraction of the plurality of diaphragms252to control airflow into and out of the compression chambers269.

The fluid inlet controller270includes an inlet ring274and inlet valves276as shown inFIGS. 15 and 21. The inlet ring274is formed to include inlet passageways275extending from the inlet apertures235to the compression chambers269. The inlet valves276extend through the inlet passageways275. One inlet valve276is configured to open as the fifth diaphragm264expands into the expanded configuration as shown inFIG. 21. The inlet valve276is configured to close and restrict flow through the inlet passageway275as the fifth diaphragm264is compressed into the compressed configuration as shown inFIG. 22.

The fluid outlet controller272includes an outlet valve gasket278as shown inFIGS. 15 and 23. The outlet valve gasket278is arranged to control flow into and out of outlet passageways277formed in the inlet ring274. The outlet valve gasket278is formed to include a plurality of U-shaped apertures279spaced apart circumferentially. The U-shaped apertures279define outlet flaps280that are arranged to cover the outlet passageways277. One outlet flap280is configured close and restrict flow through the outlet passageway277as the fifth diaphragm264is expanded into the expanded configuration as shown inFIG. 21. The outlet flap280is configured to open and allow flow though the outlet passageway277as the fifth diaphragm264is compressed into the compressed configuration as shown inFIG. 22.

The pump housing226includes a top casing232and the bottom casing234as shown inFIGS. 14 and 15. The top casing232is positioned above the fluid-driving system228and forms an upper boundary for internal space225. The bottom casing234is positioned below the fluid regulator230and is formed to include a plurality of inlet apertures235spaced apart circumferentially around the bottom casing234.

The bottom casing234is shaped to define an outlet conduit282as shown inFIG. 24. The pressurized airflows17are forced into the outlet conduit282through the plurality of outlet apertures237as each diaphragm is compressed in series by the actuator plate242. The pressurized airflows17are injected out of pneumatic pump218and into the pneumatic air bladders24through an outlet tube284coupled to bottom casing234as shown inFIG. 24.

A plurality of posts236extend from the inlet ring274toward the top casing232as shown inFIG. 23. The plurality of posts236aligns the fluid-driving system228and the fluid regulator230within the internal space225. Fasteners (not shown) may extend through the top casing232and into the posts236to house the fluid-driving system228and the fluid regulator230in the internal space225.

A third embodiment of a pneumatic pump318in accordance with the present disclosure is shown inFIGS. 25-34. The pneumatic pump318includes a pump housing326, a fluid-driving system328, and a fluid regulator330as shown inFIGS. 25 and 26. Pump housing326is formed to include an internal space325therein. The fluid regulator330and the fluid-driving system328are located in the pump housing326as shown inFIG. 26. The fluid-driving system328moves within the pump housing326to draw an airflow from the environment and inject a pressurized airflow into the at least one pneumatic bladder24. The fluid regulator330is configured to open and receive airflow from an environment outside of the pump housing26and then communicate pressurized airflow into the at least one pneumatic bladder24.

The fluid-driving system328includes a motor338, a diaphragm system340, and a first actuator plate342and a second actuator plate343as shown inFIGS. 26 and 27. The motor338is configured to rotate about a central axis A. The diaphragm system340is spaced apart radially and arranged to surround the motor338in the internal space325and is coupled to the actuator plates342,343. The actuator plates342,343are driven by the motor338to cause the diaphragm system340to draw in air and pressurize the air.

The diaphragm system340includes a diaphragm ring350and a plurality of diaphragms352as shown inFIG. 27. The diaphragm ring350is arranged to extend around and surround the motor338. The diaphragm ring350is configured to support and position the plurality of diaphragms352so that the plurality of diaphragms352remains in fluid communication with the fluid regulator330. The plurality of diaphragms352is coupled to the actuator plates342,343. The plurality of diaphragms352is arranged to extend downwardly toward the fluid regulator330.

Each diaphragm of the plurality of diaphragms352is configured to move between an expanded configuration in which air is drawn into the diaphragm through the fluid regulator330and a compressed configuration in which pressurized air is expelled from the diaphragm through the fluid regulator330. Each diaphragm352expands and contracts in series as the motor338rotates driving the fluid-driving system328. In one example, each diaphragm expands into the expanded configuration and contracts into the contracted configuration once during one rotation of the motor338.

The fluid-driving system328is configured to provide a reciprocating in-and-out motion that moves the diaphragm system340and the actuator plates342,343. The fluid-driving system328further includes a first mount disk345and a second mount disk347that rotate about the central axis A. As the motor338rotates, the first mount disk345engages the first actuator plate342and the second mount disk347engages the second actuator plate to cause the actuator plates342,343to move to cause each diaphragm in the plurality of diaphragms352to expand and contract in series as shown inFIGS. 28-31.

The first actuator plate342includes a first tab349, a second tab351, and a third tab353as shown inFIG. 27. The tabs349,351,353are equally spaced circumferentially around the first actuator plate342and extend downward from the first actuator plate342.

The second actuator plate343includes a first tab355, a second tab357, and a third tab359as shown inFIG. 27. Tabs355,357,359are equally spaced circumferentially around actuator plate343and extend downward from actuator plate343.

Each tab349,351,353,355,357,359is formed to include a diaphragm mount356configured to couple the plurality of diaphragms352to the actuator plates342,343. The actuator plates342,343are also formed to include mount disk apertures354. The mount disk apertures354are configured to receive the first mount disk345and the second mount disk347so that the first actuator plate342and the second actuator plate343engage to the motor338.

The first mount disk345and the second mount disk347are configured to rotate about the central axis A along a first axis X and a second axis Y, respectfully. The first axis X is spaced apart from the central axis A on one side of the central axis A. The second axis Y is spaced apart an equal distance from the central axis A on the opposite side of the central axis A from the first axis X In this way, the first actuator plate342and the second actuator plate343move at the same time with equal and opposite motions.

The plurality of diaphragms352includes a first diaphragm360, a second diaphragm361, a third diaphragm362, a fourth diaphragm363, a fifth diaphragm364, and a sixth diaphragm365as shown inFIG. 27. Each diaphragm360,361,362,363,364,365is equally spaced circumferentially around the actuator plates342,343. The actuator plates342,342move each diaphragm360,361,362,363,364,365from the expanded configuration to the compressed configuration.

The compressed configuration occurs when the first axis X is aligned circumferentially with one of the tabs349,351,353of the first actuator plate342, and when the second axis Y is aligned circumferentially with one of the tabs355,357,359of the second actuator plate343as shown inFIGS. 28 and 30. The expanded configuration occurs when the first axis X is aligned circumferentially with one of the tabs355,357,359of the second actuator plate343, and when the second axis Y is aligned circumferentially with one of the tabs349,351,353of the first actuator plate342as shown inFIGS. 29 and 31. In one example, each diaphragm expands and compresses once during one rotation of the motor338as suggested inFIGS. 28-31.

In one example, the motor begins at 0 degrees of rotation as shown inFIG. 28. The first axis X of the first actuator plate342is aligned circumferentially with the second tab351of the first actuator plate342. The second axis Y is aligned circumferentially with the first tab355of the second actuator plate343. The first actuator plate342and the second actuator plate343are arranged so that both the first and fourth diaphragms360,363are fully compressed in the compressed configuration.

In the example described above, the motor rotates 60 degrees clockwise about the central axis A as shown inFIG. 29so that the motor38is rotated 60 degrees from the orientation shown inFIG. 28. The first axis X of the first actuator plate342is aligned circumferentially with the third tab359of the second actuator plate343. The second axis Y is aligned circumferentially with the first tab349of the first actuator plate342. The first actuator plate342and the second actuator plate343are arranged so that both the second and fifth diaphragms361,364are fully expanded in the expanded configuration.

As shown inFIG. 30, the motor rotates another 60 degrees clockwise along the central axis A so that the motor338is rotated 120 degrees from the orientation shown inFIG. 28. The first axis X of the first actuator plate342is aligned circumferentially with the third tab353of the first actuator plate342. The second axis Y is aligned circumferentially with the second tab357of the second actuator plate343. The first actuator plate342and the second actuator plate343are arranged so that both the third and sixth diaphragms362,365are fully compressed in the compressed configuration.

As shown inFIG. 31, the motor rotates another 60 degrees clockwise along the central axis A so that the motor38is rotated 180 degrees from the orientation shown inFIG. 28. The first axis X of the first actuator plate342is aligned circumferentially with the first tab355of the second actuator plate343. The second axis Y is aligned circumferentially with the third tab351of the first actuator plate342. The first actuator plate342and the second actuator plate343are arranged so that both the first and fourth diaphragms360,363are fully expanded in the expanded configuration.

The motor338is configured to continue rotating another 180 degrees clockwise along the central axis A so that motor338completes one full rotation of 360 degrees. At a rotation of 360 degrees, the motor38positions the actuator plates342,343at the same orientation described above regardingFIG. 28. Each of the diaphragms will have compressed and expanded once after 360 degrees of rotation, following the sequence described in the example above.

Each diaphragm360,361,362,363,364,365includes a diaphragm mount366and diaphragm housing368as shown inFIGS. 32 and 33. Each diaphragm mount366on the second, fourth, and sixth diaphragms361,363,365is coupled to the first actuator plate342. Each diaphragm mount366on the first, third, and fifth diaphragms360,362,364is coupled to the second actuator plate343. Each diaphragm housing368is coupled to a complementary diaphragm mount366and is arranged to extend outward through the diaphragm tubes341formed in the diaphragm ring350. Each diaphragm housing368is formed to include a compression chamber369that opens toward the fluid regulator330.

As shown inFIG. 32, the fifth diaphragm364is positioned in the expanded configuration by the second actuator plate343. The compression chamber369has a maximum volume in the expanded configuration. As the compression chamber369is expanded by the second actuator plate343, the airflow15is suctioned from outside pneumatic pump318, through an inlet aperture335, and into the compression chamber369.

As shown inFIG. 33, the fifth diaphragm364is positioned in the compressed configuration by the second actuator plate343. The compression chamber369has a minimum volume in the compressed configuration. As the compression chamber369is compressed by the second actuator plate343, the airflow17is pressurized and forced out of the compression chamber369through an outlet aperture337.

The fluid regulator330includes a fluid inlet controller370and a fluid outlet controller372as shown inFIGS. 32 and 33. The fluid inlet controller370and the fluid outlet controller372respond to the expansion and contraction of the plurality of diaphragms352to control airflow into and out of the compression chambers369.

The fluid inlet controller370includes inlet valves376as shown inFIGS. 27 and 32. The inlet valves376extend through inlet passageways375. One inlet valve376is configured to open as the fifth diaphragm364expands into the expanded configuration as shown inFIG. 32. The inlet valve376is configured to close and restrict flow through the inlet passageway375as the fifth diaphragm364is compressed into the compressed configuration as shown inFIG. 33.

The fluid outlet controller372includes an outlet ring374an outlet valves378as shown inFIGS. 27 and 32. The outlet valves378are arranged to control flow into and out of the outlet passageways377formed in the outlet ring374. One outlet valve378is configured close and restrict flow through the outlet passageway377as the fifth diaphragm364is expanded into the expanded configuration as shown inFIG. 9. The outlet valve378is configured to open and allow flow though the outlet passageway377as the fifth diaphragm364is compressed into the compressed configuration as shown inFIG. 33.

The pump housing326includes a top casing332and the bottom casing334as shown inFIGS. 26 and 27. The top casing332is positioned above the fluid-driving system328and forms an upper boundary for the internal space325. The bottom casing334is positioned below the fluid regulator330and is formed to include a plurality of inlet apertures335spaced apart circumferentially around the bottom casing334.

The top casing332is shaped to define an outlet conduit382as shown inFIG. 34. The pressurized airflows17are forced into outlet conduit382through the plurality of outlet apertures337as each diaphragm352is compressed into the compressed configuration. The pressurized airflows17are injected out of pneumatic pump318and into the pneumatic air bladders24through an outlet tube384coupled to the top casing332.

The occupant comfort system16, as shown inFIG. 1, includes the pneumatic pump18, a pump controller20, a manifold22, and at least one pneumatic bladder24. The pneumatic pump18is configured to provide an airflow to inflate the at least one pneumatic bladder24as directed by the pump controller20. The pump controller20is configured to control pneumatic pump18and manifold22to either inflate or deflate the at least one pneumatic bladder24. The at least one pneumatic bladder24is contained within vehicle seat10and is configured to receive the airflow from pneumatic pump18to inflate and support the occupant in the preferred position. The at least one pneumatic bladder24may be used to provide additional support, provide a massaging effort, or act as actuator moving other components.