Patent Publication Number: US-10773618-B2

Title: Air channel thermocomfort foam pad

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional of U.S. application Ser. No. 15/832,577, filed on Dec. 5, 2017, entitled “AIR CHANNEL THERMOCOMFORT FOAM PAD,” the disclosure of which is hereby incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure generally relates to a foam pad, and more particularly to a molded air channel thermocomfort foam pad. 
     BACKGROUND OF THE DISCLOSURE 
     Properly ventilated seating assemblies are becoming more important as the need for prolonged travel increases. Maintaining the posterior of an occupant at a comfortable temperature creates a more pleasant and comfortable ride. 
     SUMMARY OF THE DISCLOSURE 
     According to one aspect of the present disclosure, a method of making a cushion assembly includes forming a first foam pad with a plurality of air cooling columns through the first foam pad. The plurality of air cooling columns terminate at a topper pad. A second foam pad is operably coupled with the first foam pad to define a non-linear flow channel between the first foam pad and the second foam pad. The non-linear flow channel is in fluid communication with the air cooling columns. An air mover is operably coupled to the non-linear flow channel to move air within the air cooling columns. 
     According to another aspect of the present disclosure, a method of making a cushion assembly includes forming a first foam pad with a plurality of air cooling columns through the first foam pad. The plurality of air cooling columns includes a first air column and a second air column. The plurality of air cooling columns terminate at a topper pad. A second foam pad is operably coupled with the first foam pad to define a flow channel between the first foam pad and the second foam pad. The flow channel is in fluid communication with the air cooling columns, exits a top portion of the first air column, and enters a lower portion of the second air column. An air mover is operably coupled to the flow channel to move air within the air cooling columns 
     Embodiments of the first and second aspects of the present disclosure, as set forth in the preceding paragraphs, can include any one or a combination of the following features:
         forming the non-linear flow channel to include a vertical portion and a horizontal portion;   blowing the air through the non-linear flow channel from the air mover to an air exhaust;   forming a recessed periphery about the plurality of air cooling columns, proximate the topper pad;   forming the topper pad to be substantially porous;   forming the plurality of air cooling columns to include a first air column and a second air column, wherein the non-linear flow channel exits a top portion of the first air column and enters a lower portion of the second air column;   forming the plurality of air columns so that the air flows turbulently through the plurality of air columns;   forming the plurality of air columns to include at least three columns aligned linearly;   forming the flow channel to include a vertical portion and a horizontal portion; and   blowing the air through the flow channel from the air mover to an air exhaust.       

     These and other aspects, objects, and features of the present disclosure will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a front perspective view of a seat cushion assembly of the present disclosure; 
         FIG. 2  is a front elevational view of a first foam pad of the seat cushion assembly of  FIG. 1  taken at area II; 
         FIG. 3  is a front elevational cross-sectional view of the first foam pad of the seat cushion assembly of  FIG. 2  with air cooling columns; 
         FIG. 4  is a front elevational view of a second foam pad of the seat cushion assembly of  FIG. 1  taken at area V; 
         FIG. 5  is a front elevational cross-sectional view of the second foam pad of the seat cushion assembly of  FIG. 4  with upwardly extending columns; 
         FIG. 6  is a front elevational cross-sectional view of a seat cushion assembly of the present disclosure; 
         FIG. 7  is a front elevational view of an upper foam pad of the seat cushion assembly of  FIG. 6  with a plurality of air cooling columns; 
         FIG. 8  is a rear elevational view of the upper foam pad of the seat cushion assembly of  FIG. 7 ; 
         FIG. 9  is a front elevational view of a second foam pad of a seat cushion assembly of the present disclosure; and 
         FIG. 10  is a rear elevational view of the second foam pad of the seat cushion assembly of  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in  FIG. 1 . However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. 
     Traditional expanded polypropylene (EPP) pads used for cushion assemblies are difficult to cool within seating assemblies. Adding cooling holes for ventilation in an EPP pad can result in failures of these cushion assemblies. These failures typically result from point loading or abuse loading that results high tensile stresses that occur at the bottom of an EPP pad or the cushion assembly. As a result, an improved construction that can better manage point loading or abuse loading would prove beneficial. 
     Referring to the embodiment generally illustrated in  FIGS. 1-10 , reference numeral  10  generally designates a seat cushion assembly that includes a first foam pad  12  defining at least one air cooling column  14  disposed therethrough. A topper pad  16  is disposed over the first foam pad  12  and the at least one air cooling column  14 . A second foam pad  18  is disposed below the first foam pad  12 . The second foam pad  18  and the first foam pad  12  define a flow channel  20  in fluid communication with the at least one air cooling column  14 . An air mover  22  moves air from an air intake  24  of the flow channel  20  to an air exhaust  26  of the flow channel  20 . 
     With reference now to  FIGS. 1 and 2 , the seat cushion assembly  10  is disposed in a seat  28  of a seating assembly  30  and may be used in any vehicle, such as a car, a truck, a van, etc. It is also contemplated that the concept set forth in this disclosure may be utilized in a front or forward position of the vehicle as well as a rear or rearward position of the vehicle. The seat cushion assembly  10 , as illustrated, includes a seat base  32  that is positioned on rail slides  34  to allow fore and aft movement of the seat cushion assembly  10  relative to the vehicle. The seat  28  is operably coupled with the seat base  32  and is movable relative thereto, as set forth in further detail below. In addition, a seatback  36  of the seating assembly  30  includes a lower lumbar region  40  and an upper thoracic region  42  as well as a head restraint  44 . Each of the components of the seatback  36  may be configured for adjustability to properly support the weight of different sized occupants inside the vehicle. 
     With reference now to  FIGS. 2 and 3 , one aspect of the seat cushion assembly  10  is illustrated taken at area II of  FIG. 1 . Specifically, the first or upper foam pad  12  is illustrated. The upper foam pad  12  is configured to provide support to the buttocks of an occupant, and is also configured to provide cooling to the buttocks of the occupant. Two air cooling columns  14  are illustrated in area II. However, it will be understood that any number of air cooling columns may be present through the upper foam pad  12 . As shown in  FIG. 3 , the air cooling columns  14  are open at a top portion thereof and include a recessed periphery  50  that aids in cooling an occupant. A bottom portion  52  of the first foam pad  12  includes enlarged recesses  54  that, together with the second foam pad  18 , define the flow channels  20 . It will be understood that the first foam pad  12  may take on a variety of shapes and constructions, and that the illustrated construction is exemplary. 
     With reference now to  FIGS. 4 and 5 , the second or lower foam pad  18  is illustrated. The second foam pad  18  includes upwardly extending columns  60  configured to protrude into the recesses  54  of the first foam pad  12 . The second foam pad  18  includes a top portion thereof that defines cavities  62 . The cavities  62  and the columns  60  of the first and second foam pads  12 ,  18  together define the flow channel  20 . As with the first foam pad  12 , the second foam pad  18  may take on a variety of shapes and constructions and is not limited to the construction as set forth in  FIGS. 4 and 5 . 
     With reference now to  FIG. 6 , the seat cushion assembly  10  that is made up by the topper pad  16 , the first foam pad  12 , and the second foam pad  18  is illustrated. The topper pad  16  is generally porous in construction so that fluid or air can pass through the topper pad  16 . It will be understood that air may be drawn into or blown out of the topper pad  16 . The air mover  22  pushes air through the air intake  24  of the flow channel  20 . The air mover  22  may be a blower that forces air from the air intake  24  of the flow channel  20  to the air exhaust  26  of the flow channel  20 . In the illustrated embodiment, the air intake  24  is oriented in a horizontal direction relative to the seat cushion assembly  10 . However, it will be understood that the air intake  24  may also be oriented in a vertical direction relative to the seat cushion assembly  10 . The air mover  22  pushes air into the air intake  24  of the flow channel  20  until the air reaches the first vertical air cooling column  14 . The air may then move in a turbulent fashion, generally in the direction of arrows  61 , cooling the topper pad  16 , and consequently, cooling the occupant. Air is also forced into a first internal transfer portion  63  of the flow channel  20 . The first internal transfer portion  63  includes a first lateral portion  64  that connects with a second lateral portion  66  by way of a vertical portion  68 . The flow of fluid, which may be air, is generally laminar as the fluid passes through the first internal transfer portion  63 . However, the flow of fluid is generally turbulent within the first and second air cooling columns  14 . It will be understood that this construction is exemplary and that other constructions may also be utilized. Air, which is still somewhat cool, but which has received some heat gain from the first air cooling column  14 , is then driven into the second air cooling column  14 , to cool the topper pad  16 , and consequently, the occupant, at a location proximate the second air cooling column  14 . Air is also forced along the back portion of the air cooling column  14  and into a second internal transfer portion  72  that includes a first lateral portion  74  that connects with a second lateral portion  76  by way of a vertical portion  78 . The warmed air ultimately exits the seat cushion assembly  10  through the air exhaust  26 . 
     With reference now to  FIGS. 7 and 8 , one example of the upper foam pad  12  is illustrated. The upper foam pad  12 , as shown in  FIG. 8 , illustrates a plurality of air cooling columns  14 . In addition, a bottom side  80  of the upper foam pad  12  includes the plurality of air cooling columns  14 , which are in fluid connection via grooves  82  that form a portion of the flow channels  20 . Each of the grooves  82  is in communication with an air mover hole, which defines the air intake  24 . It will be understood that the air mover  22  may draw air from the topper pad  16  of the seat cushion assembly  10 , or may push air toward the topper pad  16  of the seat cushion assembly  10 . 
     With reference now to  FIGS. 9 and 10 , the second foam pad  18  is illustrated. The second foam pad  18  is similar in construction to the first foam pad  12 , but lacks air cooling columns  14  that are in communication with the topper pad  16 . However, a top side  90  of the second foam pad  18  does include a plurality of grooves  92  that, together with the grooves  82  of the top foam pad  12 , define the flow channels  20 . As with the grooves  82  of the first foam pad  12 , the grooves  92  of the bottom foam pad  18  are ultimately in communication with the air mover hole at a rear portion of the seat cushion assembly  10 . Attachment features are disposed below the second foam pad  18  and are configured to secure the second foam pad  18  to an underlying seating suspension assembly. 
     It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. 
     For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated. 
     It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations. 
     It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting. 
     It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.