# Patent

## Title
Automotive vehicle seat insert

## Abstract

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

## Background
CLAIM OF PRIORITY
This application is a continuation of application Ser. No. 11/043,600 filed on Jan. 26, 2005 now U.S. No. 7,052,091 which is a continuation of 10/434,890 filed on May 9, 2003, now U.S. Pat. No. 6,893,086 which claims benefit of filing date Dec. 13, 2002 of provisional application no. 60/433,270, and which also claims benefit of filing date Jul. 3, 2002 of provisional application no. 60/393,815. This application is also a continuation of and claims the benefit of priority to PCT published application WO 04/005068 published Jan. 15, 2004.


FIELD OF THE INVENTION
The present invention relates generally to automotive vehicle seats, and more particularly to an insert for providing heating, cooling, ventilation or a combination thereof to a seat of an automotive vehicle.
BACKGROUND OF THE INVENTION
For many years the transportation industry has been concerned with designing seats for automotive vehicles that provide added comfort to occupants in the seats. Various innovations in providing seating comfort are discussed in U.S. Pat. Nos. 6,064,037; 5,921,314; 5,403,065; 6,048,024 and 6,003,950, all of which are expressly incorporated herein by reference for all purposes. In addition, other innovations in providing seating comfort are discussed in U.S. patent application Ser. No. 09/619,171, filed Jul. 19, 2000, titled “Ventilated Seat Having a Pad Assembly and a Distribution Device”; U.S. patent application Ser. No. 09/755,505, filed Jan. 5, 2001, titled “Ventilated Seat”; and U.S. patent application Ser. No. 09/755,506, filed Jan. 5, 2001, titled “Portable Ventilated Seat”, each of which are expressly incorporated herein by reference for all purposes. In the interest of continuing such innovation, the present invention provides an improved seating system, insert for a seat or both, which are preferably suitable for employment within or as part of an automotive vehicle seat and which assist in providing comfort control to an occupant in the seat.
SUMMARY OF THE INVENTION
According to the present invention, there is disclosed a seat insert, a method of forming the seat insert and a ventilated seat that is preferably suitable for an automotive vehicle. The insert preferably includes a forward layer, a rearward layer and a middle layer, although greater or fewer layers may be included. When included, the forward layer typically includes a first barrier sub-layer, a heater sub-layer, a plurality of openings or a combination thereof. In preferred embodiments, the first barrier sub-layer is formed of a plastic material, the heater sub-layer is formed as a lay-wire heater or both.
The rearward layer, when included, has a second barrier sub-layer, an opening or both. In a preferred embodiment, the second barrier sub-layer is formed of a plastic material like the first barrier sub-layer. The middle layer typically includes a spacer sub-layer defining an open space. In a preferred embodiment, the spacer sub-layer is formed of interwoven polymeric strand material. An air mover (e.g., a blower) is attached to the insert and is preferably at least partially disposed within the at least one opening of the rearward layer, although not required. The air mover is in fluid communication with the plurality of openings in the forward layer, the open space of the spacer sub-layer or both.
During formation of the insert, the first barrier sub-layer is preferably sealingly attached to the second barrier sub-layer about a periphery of the insert, although other attachments may be employed. The blower is preferably configured to pull air through the plurality of openings in the forward layer and through the open space of the spacer sub-layer, but it may also push air through these areas.
When assembled to a seat (e.g., a vehicle seat), the seat preferably includes a seat cushion component and a seat backrest component. At least one of the components is typically ventilated by the insert and each ventilated component typically includes an air-permeable trim surface at occupant contact areas of the seat. The insert is preferably located beneath the trim surface of each ventilated component.



BRIEF DESCRIPTION OF THE DRAWINGS
The features and inventive aspects of the present invention will become more apparent upon reading the following detailed description, claims and drawings, of which the following is a brief description:
FIG. 1 is a blown up perspective view of a seat insert in accordance with an exemplary aspect of the present invention;
FIG. 2 is a flow diagram for producing seat inserts in accordance with an exemplary aspect of the present invention;
FIG. 3 is a partially cut-away elevational view of the seat insert of FIG. 1 after assembly of the insert;
FIG. 4 is a sectional view of the insert of FIGS. 1 and 3 taken along line 4—4 in FIG. 3;
FIG. 5 is a perspective view of an exemplary blower suitable for application in the insert of the present invention; and
FIG. 6 is a sectional view of the insert attached in an exemplary manner to a seat of an automotive vehicle according to the present invention.



DETAILED DESCRIPTION OF THE INVENTION
The present invention is predicated upon providing an insert suitable for placement within an automotive vehicle seat to provide heating, cooling, ventilation or a combination thereof to an occupant in the seat. The insert will include at least one layer, but preferably includes multiple (e.g., three) layers and each of the layers may include one or more sub-layers. For example, one of the layers preferably incorporates a heater or heater sub-layer into the insert. One or more of the layers also preferably incorporates a plastic film sub-layer for assisting in lamination of the layers, for providing a gas barrier or both. It is also preferable for one or more of the layers to provide a spacer sub-layer for providing open space within the insert. Additionally, a blower may be incorporated into the insert for providing fluid flow through the insert.
Referring to FIGS. 1 and 3–5, there is illustrated an exemplary insert 10 suitable for placement within a seat of an automotive vehicle. The insert 10 preferably includes a plurality of layers that may be separate but are preferably attached to each other to form the insert. In the embodiment shown, the insert 10 includes a first or forward layer 14 (e.g., the layer of the insert configured to be closest an occupant of the seat), a second or middle layer 16 and a third or rearward layer 20 (e.g., the layer of the insert configured to be furthest from the occupant of the seat).
It is preferred that one of the layers 14, 16, 20 includes a heater. In the embodiment depicted, the forward layer 14 includes a heater sub-layer 26, which is preferably laminated to a gas barrier sub-layer 28 (e.g., a film, a textile or otherwise) although such film is not necessarily required. Various different types of heaters are suitable for incorporation into a car seat and it is contemplated that any of such heaters may be incorporated into the insert 10 of the present invention. Such heaters typically incorporate flexible electrical heating elements that are preferably thin, flat, non-obtrusive or a combination thereof. As examples, a lay-wire heater, a carbon fiber heater, a positive thermal coefficient (PTC) heater, a thermoelectric heater or the like, which are typically supported with a backing (e.g., a cloth or fabric type backing) may be used within the insert. In a preferred embodiment, the heater sub-layer 26 is a carbon fiber type heater with a backing (e.g., a nonwoven layer). One exemplary preferred heater is sold under the tradename CARBOTEX® and commercially available from W.E.T Automotive Systems, Inc. in Germany and/or FTG Fraser-Technik GmbH, Schleizer Strasse 56–58, D-95028 Hot/Saale, Germany. An example of such a heater is disclosed in U.S. Pat. No. 6,064,037, issued May 16, 2000, herein expressly incorporated by reference for all puposes.
When included, the barrier sub-layer 28 is typically formed of a plastic or polymeric material that softens or melts upon exposure to heat to assist the sub-layer 28 to adhere to one or more other layers or sub-layers. Alternatively, the barrier sub-layer 28 may be formed of fabrics, woven materials (e.g, goretex or microfibers), nylon, closed pore foam or other materials. Preferably, the barrier sub-layer 28 is substantially impermeable to fluids and particularly air such that the sub-layer 28 can assist in forming an air barrier as will be described further herein. Dimensionally, for a film barrier sub-layer, it is preferable for the film thickness to be about 0.1 mm to about 2.0 mm thick and more preferably about 0.7 mm to about 1.0 mm thick. Of course, it is contemplated that the film sub-layer 28 may have a variable thickness and may be outside of the aforementioned ranges.
The first layer 14 may also include one or more buffer sub-layers, one or more adhesives or adhesive sub-layers, one or more tape sub-layers, one or more porous foam layers or a combination thereof. Adhesive may be supplied in layers, drops or in a variety of other configurations. Preferably, the buffer layer is at least partially formed of an insulating material.
In the preferred embodiment depicted, the first layer 14 includes two adhesive sub-layers 34, one strip of tape 36 and one buffer sub-layer 38. The adhesive sub-layers 34 are preferably formed of a hot melt adhesive although not necessarily required. The adhesive may be provided as a web or otherwise and may be continuous or non continuous (e.g., may be applied in drops, dabs or the like). The adhesive sub-layers may include polyamides, polyesters, elastomers, urethanes, olefin polymers or a combination thereof. Moreover, the adhesives may be formulated as desired for particular processing parameters or conditions. Preferably, the adhesive sub-layers are substantially free of anti-blocking solutions, blowing additives, process contaminants or the like which might interfere with adhesive performance. As an example, one suitable hot melt adhesive is commercially available as a non-woven web under the tradename SPUNFAB® from Spunfab, Ltd. 175 Muffin Lane, Cuyahoga Falls, Ohio 44223.
The buffer sub-layer 38 in the embodiment depicted is a layer of gauze which is capable of protecting the heater layer 20 although various alternative protective materials may be used such as cloth, fleece or the like. The tape 36 is preferably tacky on two sides.
According to an alternative embodiment, it is contemplated that the first layer 14 may also include an air-permeable layer (not shown) between buffer sub-layer 38 and an occupant of the seat. The air-permeable layer, which may be any one of a variety of air-permeable materials (such as reticulated foam, for example) may be able to help distribute air under the occupant.
One of the layers 14, 16, 20, preferably the middle layer 16, includes a spacer sub-layer 48 formed of a spacer material. The spacer material may be provided as a variety of synthetic materials such as plastic or polymeric materials, padding and stuffing materials, lining and carrier materials or the like. Preferably, the spacer material creates a sub-layer 48 that functionally provides open space within the sub-layer while remaining at least partially pliable or flexible between the first and third layers 14, 20. As one example, the spacer sub-layer may be provided as a plurality of rubber, foam plastic or other members or fibers. The members or fibers are preferably spaced apart from each other to provide open space therebetween while still being close enough together to provide cushion and support. As another example the spacer sub-layer 48 may be formed of a 3-dimensional spacer fabric structure or material.
In the preferred embodiment depicted, the middle layer 16 includes only the spacer sub-layer 48, however, it is contemplated that additional sub-layers (e.g., adhesive sub-layers) or other materials (e.g., adhesives) may be incorporated into the middle layer 16. The particular sub-layer 48 shown is formed of polymeric (e.g., polyester) strand material that is interwoven to provide opposing honeycomb structures 56 (e.g., fabric panels), which are interconnected by several additional polymeric strand materials to provide open space 58 between the structures 56 while still providing cushion and support. As an example, one preferred material is sold under the tradename 3MESH® and is commercially available from Müller Textil GmbH, Germany or Müller Textiles, Inc., Rhode Island, USA.
In another of the layers 14, 16, 20 of the insert 10, preferably the rearward layer 20, there is included an outer protective or buffer sub-layer and another barrier sub-layer. In the embodiment shown, one integrated sub-layer 62 provides the both the barrier sub-layer 66 and the outer protective sub-layer 68 although they may be provided separately. The barrier sub-layer 66 for the rearward layer 20 may be the same or different than the barrier sub-layer 28 of the forward layer 14.
Preferably, the protective sub-layer 68 is formed of a fleece material, however, various other materials may be used such as gauze, cloth, fabric or the like. It is also preferable for the rearward layer 20 to include an adhesive or adhesive sub-layer 70 similar to or the same as those discussed in relation to the forward layer 14. According to a preferred embodiment, the adhesive sub-layer 70 is provided integrally with the integrated sub-layer 62.
In a highly preferred embodiment, an attachment component 72 is included in one of the layers 14, 16, 20. The attachment component 72 shown in FIG. 1 is a frame member that preferably defines an opening or through-hole 74. It is contemplated that the frame member may be in a variety of configurations (e.g., annular, rectangular, square, geometric or otherwise) and may be formed of a variety of preferably rigid or semi-rigid materials (metal, plastic or the like).
Notably, several of the materials of the various layers and sub-layers of the insert 10 may be environmentally friendly. For example, and without limitation, the materials of the spacer sub-layer 48, the buffer and protective sub-layers 38, 68 and the barrier sub-layers 28, 66 may be recyclable.
Assembly
Generally, for forming a vehicle seat insert according to the present invention, it is contemplated that the various layers and sub-layers of the insert as described above may be combined in a variety of sequences and according to a variety of protocols and technique. Thus, the order in which the various layers and sub-layers are combined and the techniques of combining should not in any way limit the present invention unless such order or techniques is specifically claimed. Moreover, it is also contemplated that there may be greater or fewer layers and that each layer may include greater or fewer sub-layers.
According to a preferred method, the sub-layers of the front or first layer and the third or rearward layer are each laminated separately followed by laminating the front layer to the rearward layer with the middle layer in between. Referring to FIGS. 1 and 2, the first layer 14 is formed according to a preferred method by feeding the various sub-layers 38, 26, 28 to a laminator 80 (e.g., a belt and roller laminator).
Although the manner in which the sub-layers 38, 26, 28 are fed to the laminator 80 may be varied, the preferred embodiment has the buffer sub-layer 38 and one of the adhesive sub-layers 34 as the outer sub-layers on the outer sides of the first layer 14. The barrier sub-layer 28 and the heater sub-layer 26 are directly inside of the outer sub-layers and, as shown, the other adhesive sub-layer 34 is between the barrier sub-layer 28 and the heater sub-layer 26. Preferably, the tape 36 is integrated into the first layer 14 between the buffer sub-layer 38 and the heater sub-layer 26 such that the tape 36 may be used to form a pocket for securing a wire harness 40 to the insert 10. It is also preferable for some amount of adhesive to be applied between and adhere the buffer sub-layer 38 and the heater sub-layer 26 to each other.
During the lamination process, it may be preferable for the laminator 80 to expose various portions of the first layer 14 to different temperatures. For the embodiment illustrated, it is preferred that the laminator 80 expose a first side of the first layer 14 (e.g., the side that includes the buffer sub-layer 38 and the heater 26) to a higher temperature while exposing a second opposite side of the first layer 14 (e.g., the side having the film sub-layer 28 and outermost adhesive sub-layer 34) to a lower temperature. Depending upon the materials used, the difference between the higher and lower temperatures is preferably between about 5° C. and about 150° C., more preferably between about 10° C. and about 100° C. and even more preferably between about 20° C. and 80° C. In this manner, the central adhesive sub-layer 34 of the first layer 14 is exposed to higher temperatures and is induced to more substantially melt and adhere the barrier sub-layer 28 to the heater sub-layer 26. At the same time, the outermost adhesive sub-layer 34 of the first layer 14 is maintained at a lower temperature than the central adhesive sub-layer 34 thereby avoiding excess melting of the outermost adhesive sub-layer 34.
The sub-layers 36, 26, 28 are preferably fed to the laminator 80 from rolls or otherwise and are cut to shape to form the first layer 14 after lamination. The first layer 14 may be cut to nearly any desired shape or configuration. In the illustrated embodiment, the first layer 14 is cut to be generally rectangular and to include an extension 84 and a plurality of through-holes 86. In FIG. 1, the through-holes 86 are arranged in a generally rectangular configuration and are each substantially the same size. In FIG. 3, however, the through-holes 86 are shown in a preferred configuration as progressively becoming larger from one side of the insert 10 to another.
Referring to FIG. 3, the through-holes 86 preferably increase in size as the distance of the holes from the blower increases. This increase in size provides a more uniform flow of air throughout the insert 10. It is believed that the increase in the total cross-sectional area of through-holes 86 as the distance from the blower increases allows air to enter or exit the openings at a more uniform rate than if the cross-sectional areas of through-holes at different distances from the blower were equal. The increase in cross-sectional area can be achieved by increasing the size of the holes, the number of holes, or a combination thereof. Finally, the increase in the cross-sectional area need not be a strict progression for each and every through-hole, rather, the through-holes in a region further from the blower should have a greater cross-sectional area than the through-holes in a region closer to the blower. Through-holes 86 may also be provided in a variety of different patterns. According to one preferred embodiment, through-holes 86 are provided in a substantially “U” shaped configuration corresponding to the legs and seat of the occupant. According to an alternative embodiment, through-holes 86 may be provided in a linear or straight line pattern (for example, to correspond to the back of an occupant) or in a variety of other patterns. Such pattern may be influenced by the portion of the seat in which the insert is used and the portion of the body of the occupant nearest the insert. According to other alternative embodiments, the number, size, shape, and pattern of through-holes 86 may vary.
The rearward layer 20, like the front layer 14, is also preferably formed by attaching it sub-layers 62, 70 in a lamination process. Referring again to FIGS. 1 and 2, the barrier sub-layer 66, the protective sub-layer 68 and the adhesive sub-layer 70 are fed to a laminator 90 (e.g., a belt laminator) such that the barrier sub-layer 66 is between and attached to the adhesive sub-layer 70 and the protective sub-layer 68. Thereafter, the rearward layer 20 is cut to have a shape substantially corresponding to the first layer 14. Of course, it is contemplated that the rearward layer may be cut into a variety of other configurations as well. Preferably, the rearward layer 20 includes a through-hole 98 as shown in FIG. 3 through an extension 100 of the rearward layer 20 that corresponds to the extension 84 of the first layer 14. It is contemplated, however, that the through-hole 98 may also be formed in the forward layer 14 if desired.
Once the middle layer 16 has been appropriately cut or otherwise shaped to the proper configuration, which preferably corresponds to the forward and rearward layers 14, 20, each of the layers 14, 16, 20 are laminated together to attach the layers 14, 16, 20 to each other. As shown, the middle layer 16 may be cut to include an extension 96 corresponding to the extensions 84, 100.
In the preferred embodiment, the layers 14, 16, 20 are laminated in a stationary lamination device 104 at elevated temperatures such that the adhesive sub-layer 70 of the rearward layer 20 and the outermost adhesive sub-layer 34 of the forward layer 14 both adhere and attach the forward layer 14 and the rearward layer 20 to the middle layer 16 (e.g., the honeycomb structure). At the same time, it is preferred that the barrier sub-layer 28 of the front layer 14 and the barrier sub-layer 66 of the rearward layer 20 be adhered to one another about an outer peripheral strip 106 of the insert 10. It is also preferred that the attachment component 72 be sandwiched and attached between at least portion of the rearward layer 20 and the middle layer 16 although the attachment component may be otherwise attached (e.g., retrofit, fastened, or the like).
The strip 106 may have a width as high as four (4) centimeters or greater. Preferably, the strip is between about 0.2 cm and about 3 cm and more preferably between about 1.0 cm and 2.0 cm. Advantageously, the adhesive sub-layers 34, 70 and the outer laminated peripheral strip 106 separately and together assist in forming the insert 10 as a tightly integrated unit wherein the layers 14, 16, 20 are substantially immobile relative to each other.
While pre-cutting the layers 14, 16, 20 followed by laminating the peripheral edges of at least two of the layers 14, 20 have been discussed, it is contemplated that cutting of the layers 14, 16, 20 and laminating of the layers may be integrated into a single processing step. For example, it is contemplated that supplies (e.g., rolls) of each of the layers 14, 16, 20 may be provided to a machine that laminates outer edges of each of the layers 14, 16, 20 together for forming the peripheral strip 106 as the supplies continuously or intermittently provide the layer 14, 16, 20 to the machine. Thus, inserts 10 may be formed by cutting the inserts 10 with the peripheral strip 106 from the laminated layers 14, 16, 20 and such cutting may be performed by the laminating machine or by another cutting machine or device. In such an embodiment, it is contemplated that the through-holes in the forward layer 14 and the through-hole in the rearward layer may be formed prior to, during or after lamination forming the outer peripheral strip 106.
Although laminating the edges of the film together and the use of adhesive layers have been found particularly advantageous, it is contemplated that other methods of attachment may also be employed in conjunction with the laminated edges or separately. For example a robot may be employed to apply a variety of adhesives such as hot-melt, heat activated, encapsulated or other types of adhesives. In one preferred alternative, an encapsulated adhesive may be applied to a first layer followed by breaking the encapsulated adhesive in close time proximity to attaching a second layer to the first layer. In other preferred embodiments, it is contemplated that the plastic films may be fused together with other techniques such as those used for book binding. Moreover, mechanical attachments (e.g., snaps, zippers, sewing, stitching, stapling or the like) may be used alone or in conjunction with the plastic films and adhesives.
During final assembly 110, the wire harness 40 is preferably inserted within the pocket formed by the tape 36 or otherwise attached to the insert 10. Also, a blower, the housing 120 of which is shown in FIG. 5, is preferably attached to the attachment component 72 of the insert 10. In the embodiment shown, the housing 120 include flanges 124 suitable for snap-fitting the housing 120 to the attachment component 72. In this manner, the blower can be attached to the rest of the insert 10 and can be placed in fluid communication with the through-holes 86 of the first layer 14, the open space 58 of the middle layer 16 and the through-hole 98 of the rearward layer 20. Advantageously, the attachment component 72 and flanges 124 provide a unique and efficient method of attaching the blower to the insert 10. It is contemplated however, that various other methods of attachment (e.g., fasteners, sewing, mating threaded attachments, quick connects or the like) may be used to attach the blower to the insert 10. It is also contemplated that the attachment component 72 and the housing 120 and flanges 124 of the blower may be varied within the scope of the present invention.
For assembly of the insert 10 to a vehicle seat (not shown), the insert 10 is preferably connected (e.g., sewn, adhered or otherwise attached) to a portion of the seat such as the cover (e.g., a perforated leather cover) or to a cushion (e.g., foam) of the seat. In one preferred embodiment, a seat cover may be configured to include a pocket for receiving the insert 10. Alternatively, it is contemplated that hook and loop fasteners may be utilized to attach the insert 10 to portions (e.g., the cover or foam) of the seat.
The insert 10 is preferably positioned in the seat such that the first layer 14 is closer to the outer seat cover relative to the rearward layer 20 although not necessarily required. It is also preferable for an extension 139 formed by the extensions 84, 96, 100 of the layers 14, 20 to extend behind the cushion of the seat such that the blower may be attached to a portion of the frame of the vehicle seat. Preferably, the extension 139 is a tubular structure for providing fluid communication between the open space of the spacer layer 48 and the blower. Additionally, the wire harness 40, the heater sublayer 26, the blower or a combination thereof are preferably connected in signaling communication with a control unit 130 and/or each other. The control unit 130 may be separate from or integrated into the vehicle.
In one embodiment referring to FIGS. 3, 4 and 6, the insert 10 is formed with one or more (e.g., three) through-holes 140 that extend through the layers, sub-layers or both of the insert 10 such that the through-holes 140 extend entirely or substantially entirely through the insert 10. Preferably, the insert 10 (e.g., the barrier layers 28, 66) have a seal 141 about the through-holes 140 for substantially preventing direct fluid communication between the through-holes 140 and the open space 58 within the insert 10. In the embodiment depicted, the barrier sub-layers 28, 66 are attached to each other during the lamination process to form a substantially air-tight seal 141 about the through-holes 140.
Advantageously, the through-holes 140 can assist in the assembly of the insert 10 and/or a seat cover 142 to a seat 144 of an automotive vehicle. As shown, for each through-hole 140, a portion 148 (e.g., a cushion layer, a felt layer, a leather layer, combinations thereof or the like) of the seat cover 142 is extended through the through-hole 140 and is attached to foam 154 of the seat 144. In the embodiment depicted, the portion 148 is attached to the foam 154 by wrapping or otherwise attaching the portion 148 about a member 162 (e.g., a bar or wire) that is attached to (e.g., at least partially imbedded within) the foam 154. Additionally, one or more loops 166 (e.g., metal loops) are integrated with the portion 148 and are looped about the member 162 for assisting in attaching the portion 148 to the member 162.
It shall be appreciated that, in embodiments alternative to the one depicted, a variety of materials or members such as wire, thread, stitches, fasteners, foam or the like may extend through the through-holes 140 in the insert 10 for assisting in the attachment of the seat cover 142, the insert 10 or both to the other components of the seat 144. Moreover the materials or members may be connected to the seat cover, the foam, the seat frame, other portions of the seat or vehicle or the like depending on the desired configuration. It is also contemplated that other attachment methods such as the use of alternative fastening devices may be employed in addition to or alternative to the through-holes 140. For example, hook and loop fasteners, sewing, adhesives or other fastening devices or mechanisms may be employed to locate the insert 10 relative to the seat cushion, the seat cover 142 or both.
While it is generally preferable that the layers 14, 16, 20 be substantially coextensive with each other and that the rearward and forward layers 14, 20 form a substantially continuous seal or peripheral strip 106 about the insert 10, it is contemplated that such is not the case. Thus, it is contemplated that one or more of the layers 14, 16, 20 may be less than coextensive with each other or non-existent. For example, the rearward layer 20 alone could provide a barrier sub-layer 66 that provides a sufficient pathway for receiving air from the extension 139 and guiding air through the spacer layer to the seat cover 142 or trim layers.
Operation
In operation, the insert of the present invention can preferably provide heating, cooling, ventilation or a combination thereof to an occupant of a seat having the insert. In particular, if heat is desired, electric current can be induced to travel through the heater sub-layer 26 by the control unit 130 or otherwise such that the heater sub-layer 26 can provide heat to the occupant.
Alternatively, if cooling or ventilation is desired, the blower can be operated via the control unit 130 or otherwise to pull air through the through-holes 86 in the first layer 14 of the insert 10, through the open space 58 of the middle layer 48 of the insert 10 and through the through-hole 98 of the rearward layer 20. Such air preferably flows at least partially past the occupant of the seat and through the seat cover (e.g., a perforated leather seat cover or cloth seat cover) thereby providing ventilation to the occupant and providing convective heat transfer from the occupant to the flowing air.
Although, it may be preferable for only the heater sub-layer 26 or the ventilation system to be running at one time, it is contemplated that both may be operated simultaneously. Moreover, it is contemplated that both the heater sub-layer 26 and the ventilation system may be operated at various levels (e.g., 2 or more levels of output) such as by having a blower that can operate at different levels or by having various levels of electricity flowing thought the heater sub-layer 26. It is also contemplated that the blower may push air into the open space 58 of the insert 10 as well as pulling air from the open space 58.
It is also contemplated that one or more temperature sensors (e.g., a thermostat) may be included adjacent the insert, the trim layer or the like. Preferably, any temperature sensors are near the seat cover or the insert for sensing a temperature closely related to (e.g., at or near) a temperature being experienced by an individual in the seat. Such temperature sensors may be in signaling communication with the control unit 130 such that the control unit 130 can control the blower 22, the heater layer 28 or both for attaining or maintaining a desired temperature at areas adjacent the individual and/or the temperature sensor. Moreover, the control unit 130 may be programmed with instructions for commanding the blower 22, the heater layer 28 or both to change output levels (e.g., turn on or turn off) if the temperature sensor senses a temperature above or below one or more threshold levels. An example of such programming is described in a copending patent application titled “AUTOMOTIVE VEHICLE SEATING COMFORT SYSTEM”, Ser. No. 60/428,003, filed Nov. 21, 2002 and incorporated herein by reference for all purposes.
Advantageously, the plastic film sub-layers 28, 66 respectively of the first and third layers 14, 20 provide a substantially gas-tight seal about the middle layer 16 (e.g., the spacer sub-layer 48). In this manner, gas flow to and from the open space 58 of the spacer sub-layer 48 is substantially restricted to flowing through the through-holes 86, 98 of the first and third layers 14, 20.
In a highly preferred embodiment, the through-hole 98, which may be defined by the sub-layers 66, 70 of the rearward layer 20 or by the attachment component 72, spans an area no greater than about 100 cm2 or higher, more preferably between about 15 cm2 to about 60 cm2, even more preferably between about 25 cm2 and about 40 cm2 and most preferably between about 30 cm2 and about 35 cm2 depending upon the size of the blower. Advantageously, for maintaining more efficient flow of air, the through-holes 86 on the front layer 14 may be sized to span areas, the sum of which, is substantially similar (e.g., within 20 cm2, more preferably within 10 cm2 and even more preferably within 5 cm2) to the area of the through-hole 98 in the rearward sub-layer 20. Additionally, the open space 58 of the middle layer 58 may be sized such that nearly any cross-section substantially perpendicular to airflow therethrough is also substantially similar (e.g., within 20 cm2, more preferably within 10 cm2 and even more preferably within 5 cm2) to the area of the through-hole 98 in the rearward sub-layer 20.
The preferred embodiment of the present invention has been disclosed. A person of ordinary skill in the art would realize however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.

## Claims

1. A method for manufacturing an insert and providing ventilation of a seat of an automotive vehicle, comprising the steps of
providing a first polymeric gas barrier layer having a plurality of openings, an intermediate layer including a spacer material and a second polymeric gas barrier layer wherein either the first barrier layer or the second barrier layer includes at least one opening;
laminating, by adhesion or melt seal, the first and second barrier layers about a peripheral edge of the insert for defining a peripheral strip extending along the peripheral edge and for confining the spacer material within the first and second layer so that the spacer material forms an open space within the insert wherein the spacer material remains at least partially pliable or flexible between the first and the second layers;
providing an air mover in fluid communication with the at least one opening; and
placing the plurality of openings in fluid communication with an air permeable seat cover of a seat of an automotive vehicle;
wherein the resulting area of the plurality of openings in the first layer is within 20 cm2 of the resulting area of the at least one opening.

2. The method of claim 1 further comprising a step of attaching a wire harness to the insert.

3. The method of claim 1 wherein the resulting area of the plurality of openings in the first layer is within 5 cm2 of the resulting area of the at least one opening.

4. The method of claim 1 wherein the resulting area of any cross section of air space defined by the spacer substantially perpendicular to air flow through the spacer is within 30 cm2 of the resulting area of the at least one opening.

5. The method of claim 1 wherein the air mover is attached to an extension of the insert and the insert is free of any heater.

6. The method claim 1 wherein the first and second layers are adhesively bonded together with a hot melt adhesive.

7. The method of claim 1 wherein the air mover is adapted to pull air through the openings in the first layer and the open space.

8. The method of claim 1, further comprising a heater layer wherein the spacer material is formed with rubber, foam, plastic or fibers and the heater layer includes a positive thermal coefficient (PTC) heater.

9. A method for manufacturing an insert and providing ventilation of a seat of an automotive vehicle, comprising the steps of
providing a first polymeric gas barrier layer having a plurality of openings, an intermediate layer including a spacer material and a second polymeric gas barrier layer wherein either the first barrier layer or the second barrier layer includes at least one opening;
laminating, by adhesion or melt seal, the first and second barrier layers about a peripheral edge of the insert for defining a peripheral strip extending along the peripheral edge and for confining the spacer material within the first and second layer so that the spacer material forms an open space within the insert wherein the spacer material remains at least partially pliable or flexible between the first and the second layers;
providing an air mover in fluid communication with the at least one opening; and
placing the plurality of openings in fluid communication with an air permeable seat cover of a seat of an automotive vehicle;
wherein the resulting area of any cross section of air space defined by the spacer substantially perpendicular to air flow through the spacer is within 30 cm2 of the resulting area of the at least one opening.

10. The method of claim 9 wherein the strip has a width between about 1.0 cm and 2.0 cm.

11. The method of claim 9 further comprising adhesively securing the insert to a foam cushion of the seat.

12. The method of claim 9 wherein the first barrier layer is formed of a fabric.

13. The method of claim 9 wherein the first barrier layer is part of a forward layer of the insert and the forward layer of the insert includes an adhesive layer.

14. The method of claim 9 wherein the resulting area of the plurality of openings in the first layer is within 10 cm2 of the resulting areas of the at least one opening.

15. A method for manufacturing an insert and providing ventilation of a seat of an automotive vehicle, comprising the steps of
providing a first gas barrier layer having a plurality of openings and a second gas barrier layer wherein either the first barrier layer or the second barrier layer includes at least one opening;
laminating, by adhesion or melt seal, the first and second barrier layers about a peripheral edge of the insert for defining a peripheral strip extending along the peripheral edge and for forming an open space within the insert wherein the peripheral strip has a width between 0.2 cm and about 3.0 cm;
providing an air mover in fluid communication with the at least one opening; and
placing the plurality of openings in fluid communication with an air permeable seat cover of a seat of an automotive vehicle;
wherein the resulting area of the plurality of openings in the first layer is within 20 cm2 of the resulting area of the at least one opening.

16. The method of claim 15 wherein the strip has a width between about 1.0 cm and 2.0 cm.

17. The method of claim 15 wherein each of the plurality of through-holes are substantially the same size.

18. The method of claim 15 wherein the insert includes an extension extending toward the air mover.

19. The method of claim 15 further comprising adhesively securing the insert to a foam cushion of the seat.

20. The method of claim 15 wherein the first barrier layer is formed of a fabric.

21. The method of claim 15 wherein the first barrier layer is part of a forward layer that also includes a polymeric layer, an adhesive layer or both.

22. The method of claim 15 wherein the first barrier layer is adhered to the second barrier layer at the peripheral strip.

23. The method of claim 15 further comprising forming a buffer layer over the first barrier layer.

24. The method of claim 15 further comprising forming an air permeable layer over the first barrier layer wherein the air permeable layer is a foam.

25. The method of claim 15 wherein the resulting area of the plurality of openings in the first layer is within 10 cm2 of the resulting area of the at least one opening.

26. The method of claim 15 wherein the resulting area of the plurality of openings in the first layer is within 5 cm2 of the resulting area of the at least one opening.

27. The method of claim 15 further comprising associating a thermoelectric heater with the insert.

28. The method of claim 15 wherein the resulting area of any cross section of air space defined by the space substantially perpendicular to air flow through the spacer is within 10 cm2 of the resulting area of the at least one opening.

29. The method of claim 15 wherein the insert is free of any heater.

30. The method of claim 15 wherein the first gas barrier layer, the second gas barrier layer or both are formed of closed pore foam.

31. The method of claim 15 wherein the first layer, the second layer or both have a thickness of 0.1 mm to 2.0 mm.