Abstract:
A ventilated vehicle seat includes a porous upper surface layer, a resinous film non-porous first layer, a non-porous second layer, and a spacer layer. The resinous film non-porous first layer is beneath the upper surface layer and includes ventilation holes. The spacer layer is between the non-porous layers for providing cushioning and for ensuring airflow in lateral, longitudinal and perpendicular directions, even when the seat is occupied. The spacer layer is fixed in position between the first layer and the second layer for preventing slipping of the spacer layer.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   The present application is a continuation of U.S. application Ser. No. 10/445,506, filed by Ekern et al. on May 27, 2003, now U.S. Pat. No. 6,840,576, entitled “Ventilated Seat,” which is a continuation of U.S. application Ser. No. 09/755,506, filed by Ekern et al. on Jan. 5, 2001, now U.S. Pat. No. 6,629,724, entitled “Ventilated Seat,” both of which are incorporated herein by reference. 

   FIELD OF THE INVENTION 
   This invention generally relates to a ventilated seat for a vehicle. More specifically, this invention relates to a portable ventilated seat for a vehicle including a top pad assembly that forms at least a seat cushion, and preferably a seat cushion and seat back, suitable for use with any vehicle seat. Air passes through the seating surface of the pad assembly by suction or forced air flow. 
   BACKGROUND OF THE INVENTION 
   When driving a car in hot weather, occupants may experience excessive sweating from contact with the vehicle seat, because the seat prevents or blocks the body&#39;s ability to radiate excess heat. To reduce sweating, the occupant may roll down the window of the vehicle, or if provided, turn on the air conditioning to allow cool air to pass through the vehicle interior. A disadvantage of both solutions is that areas of the occupant&#39;s body are in contact with the vehicle seat preventing any cooling airflow from reaching those areas. In cold weather, the reverse phenomena may occur, i.e., cold seats may be difficult to warm quickly due to occupant contact with the seat. 
   Seat covers or pads designed for placement on top of vehicle seats are known. In some cases, these seat covers or pads are made of fashion based materials that allow some air to flow therethrough, thus allowing the occupant to more readily emit heat radiated from the body during hot days or long drives and vice versa in cold weather. These devices have been made from wooden rollers, springs covered with porous sheet material and the like. A disadvantage of these seat covers is that they rely only on passive air flow and thus they do not fully resolve the issues discussed above. 
   SUMMARY OF THE INVENTION 
   Accordingly, this invention provides for a portable ventilated seat pad that overcomes the problems and disadvantages discussed above. The invention provides a non-rigid pad assembly for cooling or heating an occupant primarily through evaporative cooling or forced air heating. The invention further provides, in its most preferred embodiment, a range of different air flows, e.g., low/medium/high, by a switch coupled to a fan. 
   Briefly, the invention is a portable ventilated seat pad assembly that lays on an existing seat in a vehicle. This non-porous pad has an upper surface layer formed of a porous material, a lower surface layer and two inner layers. The first inner layer is preferably formed of a non-porous material which confronts the upper surface. This non-porous layer is provided with ventilation holes for allowing air to flow through the upper surface layer. The second inner layer is a porous material and is positioned between the first inner layer and the lower surface layer. This porous layer is preferably a spring-like cushion having top and bottom netting and an interior consisting of rigidized threads extending between the top and bottom netting. 
   A fan (vacuum or forced air) is connected to an extension or tongue provided on a bag that is formed by the first inner layer and the lower surface layer and air moves through the second inner layer into or out of the ventilation holes provided in the first inner layer and hence through the upper surface layer. A vacuum would draw interior air from the vehicle through the occupant&#39;s clothes, through the ventilated seat pad assembly and out through the vacuum device, or the reverse would occur if it were desired to use forced air to heat or cool the air leaving the pad. The pad assembly of the present invention allows the occupant&#39;s perspiration to evaporate efficiently from his skin and clothing or to warm or cool the occupant more quickly than has previously been possible. Preferably, the occupant can adjust the airflow rate through the pad to maximize comfort at any time. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Further features and advantages of the invention will become apparent from the following discussion and accompanying drawings, in which: 
       FIG. 1  is a perspective view of the ventilated pad of the preferred embodiment of the invention with a cutaway of the upper surface layer to illustrate a pattern of ventilation holes in the first inner layer; 
       FIG. 2  is a cross-sectional side view of the pad of the preferred embodiment; 
       FIG. 2A  is an exploded view of the fan area of  FIG. 2  and illustrating a noise reduction layer about the fan; 
       FIG. 3  is a side sectional view of the pad of the preferred embodiment; 
       FIG. 4  is a partial cross-sectional view of the ventilated pad showing an alternative location for the fan and fan coupling, i.e., through the seat bite line; and 
       FIG. 5  is a perspective view of a ventilated pad arrangement showing a side connection of the fan, e.g., between an inboard bolster and center console of a vehicle. 
   

   In the various FIGURES, like reference numerals are used to denote like components. 
   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention or its application or uses. 
   As shown in  FIG. 1 , the portable ventilated seat pad assembly  10  of the preferred embodiment of the invention includes a pad  12  which lays on top of a vehicle seat  44 ,  45  ( FIG. 4 ). 
   As best shown in  FIGS. 2 and 3 , the pad  12  includes an upper surface layer  14 . The upper surface area  14  is preferably formed of a porous material, e.g., fabric or perforated leather. A first inner layer  16  is formed of a non-porous material, as is a lower surface layer  20 . Upper surface layer  14 , first inner layer  16 , and lower surface layer  20  are attached, for example, by sewing  18  ( FIG. 1 ), forming an air impermeable bag between the first inner layer  16  and the lower surface layer  20 . 
   An expanded, porous second inner layer  22  is located between non-porous layers  16 ,  20  and is preferably 5900 series spacer fabric available from Mueller Textil located at Wiehl, Germany. It will be described in greater detail in connection with  FIGS. 2 ,  2 A and  3 . Extending forwardly from the pad  12 , is tongue  24  ( FIGS. 1 and 2 ) coupled to a fan  26  powered by wire  27 . The fan  26  is coupled to the air space within layer  22 .  FIGS. 2 and 2A  show fan  26  coupled to an opening  28  in layer  20 . Tongue  24  can form a pocket-like structure  30  to support fan  26 . In the illustrated embodiment, a layer of any suitable sound-absorbing material  29  surrounds fan  26 . 
   Referring to  FIG. 1 , tongue  24  extends from the front side or edge of pad  12  and is an extension of the different layers of pad  12  (e.g. tongue  24  is integrally-formed with the rest of pad  12 ). Although the tongue is illustrated in  FIG. 1  as extending from the front side of pad  12 , the tongue may alternatively extend from other sides of the pad. In one embodiment, the width of the side from which tongue  24  extends is greater than the width of tongue  24 . For example, according to the embodiment illustrated in  FIG. 1 , the front side of pad  12  has a width that extends approximately between the left and right side of pad  12 , which is greater than the width of tongue  24 . 
   With reference to  FIGS. 1 ,  3  and  5 , ventilation holes  32  are provided in first inner layer  16 . Ventilation holes  32  are preferably positioned in a U-shape along the lower half of pad  12  to provide airflow about the thighs and seat of the occupant sitting on the pad  12 . Ventilation holes  32  provided in the upper seating area of the pad  12  are linear to provide good suction or forced airflow to assist in the elimination or reduction of sweating of the occupant&#39;s back. In a preferred embodiment, non-porous material  16  is formed of a laminated continuous resin-film layer  34  to a foam layer  35 , wherein the continuous layer  34  provides support about ventilation holes  32 , thereby preventing tearing of them when the occupant sits on pad  12 . 
   Lower surface layer  20  may be provided with a tacky interior layer  36  (e.g. an adhesive) for fixing the position of the porous material  22  between layers  16  and  20  and preventing slipping thereof while allowing airflow through the pad  12 . Alternatively, the porous material  22  can be stitched to either or both of layers  16  and  20 . 
   The porous material  22  is preferably formed of a spacer fabric (as described above). This spacer fabric has an upper layer of netting  38  and a lower layer of netting  40  supported by a middle layer comprised of plurality of semi-rigid threads  42 . Threads  42  extend between upper netting  38  and lower netting  40 . The porous material  22  is strong enough to provide a cushion for the occupant while ensuring airflow in all directions, i.e., laterally and longitudinally as well as perpendicular to the netting layers  38  and  40 , even when the seat is occupied. 
   With reference to  FIGS. 2 ,  4 , and  5 , fan  26  is shown attached to the pad  12  in several different locations. In one preferred embodiment, as shown in  FIG. 2 , the fan  26  is located in the tongue  24  extending between the occupant&#39;s legs. Other embodiments, as shown in  FIGS. 4 and 5 , show fan  26  under or to the side of a lower seat cushion  44 . Specifically,  FIG. 4  shows a vehicle seat cushion  44  and a seat back  45  provided with pad  12 . Attachment of the fan  26  to the pad  12  is through the bite line of the seat in  FIG. 4  and between an inboard bolster (not shown) and a center console (not shown) in  FIG. 5 . A quick connect for electrical wiring  27  to the fan  26  may be provided. Fan  26  may, for example, be powered by plugging wire  27  into a conventional cigarette lighter provided in vehicles or the wire  27  may be hard wired to the vehicle electrical system. 
   As best shown in  FIGS. 1–3 , the vehicle seat pad assembly  10  of the present invention pulls cabin air of the vehicle through the occupant&#39;s clothes and porous upper surface layer  14  when the fan is activated in a suction made. Ventilation holes  32  provide patterned openings for pulling the air away from upper surface layer  14  through the first inner layer  16 . Air then passes through the spacer material  22 . Lower surface area  20  (or upper layer  16  or both) seals about the entrance to fan  26 . 
   The coupling to fan  26  may include a separate non-air permeable seal  50 , which in turn is coupled to one or both of the air impermeable layers. 
   As fan  26  draws air away from the occupant or forces air into pad  12 , air speed may be controlled by any suitable fan speed switch, e.g., at high, medium or low speeds. 
   The foregoing discussion describes preferred and alternate embodiments of the invention. One skilled in the art will readily recognize from such discussion and from the accompanying drawings and claims that changes and modifications can be made to the invention without departing from the true spirit and fair scope of the invention.