Patent Description:
Seat construction is a primary differentiator among seating classes. While seats in premium seating classes are spaced and actuated for complex adjustment, economy class seats are typically configured with minimal backrest recline. In addition, premium class seats may be equipped with heating and/or cooling systems, while economy class seats suffer from trapped and stagnant air and consequential discomfort and overheating accompanying prolonged sitting in a constant sitting position. While attempts have been made to address seat ventilation issues, all such attempts to date have focused on premium class seat constructions and systems delivering conditioned air to the seat.

Accordingly, what is needed is a mechanically simple, robust and economical solution for ventilating a seat without significant modification to the existing seat construction, and without having to draw conditioned air from the vehicles air conditioning system.

To achieve the foregoing, according to a first aspect, the present invention provides a ventilated seat assembly according to claim <NUM> and a corresponding method according to claim <NUM>.

International patent application <CIT> discloses a climate controlled seat assembly including a thermoelectric device having a main side and a waste side for generating a conditioned fluid stream and a waste fluid stream respectively, a fluid distribution system for distributing the conditioned fluid stream towards an occupant seated on the climate controlled seat assembly and for gathering and pulling fluid from around the occupant and directed this gathered fluid away from the occupant.

International patent application <CIT> discloses a climate controlled seat assembly including an outer frame and one or more layers of fabric. A panel member attached to the opposite side of the frame defines an inner space located between the panel member and the fabric. One or more channels attached to or formed, in part, by the panel member are in fluid communication with an opening in the panel member and a plurality of orifices located on the channels. Air from a fluid module or other device enters the channels and is discharged through the orifices in the direction of the fabric. The air passes through the fabric and reaches an occupant situated on the seating assembly.

United States patent <CIT> B1discloses an air cell support system for vehicle seat and mattress applications includes an air cell constructed from facing sheets of flexible material that are sealed along their marginal edges. One of the sheets is impermeable and the other of the sheets is perforated to direct air from the air cell for ventilating an occupant support surface while providing a source of pressure for inflating the air cell.

United States patent <CIT> discloses a climate control device including a first and a second thermal module. The first module is configured to provide climate conditioned air to a first portion of a seat. The second module is configured to provide climate conditioned air to a second portion of the seat. A control system is provided for controlling the climate control device.

United States patent application <CIT> discloses a seat air conditioner applied to a seat disposed in a vehicle interior space and includes a seat back portion which supports an upper body side of a user and a seat cushion portion that supports a lower body side of the user. The seat air conditioner includes multiple air flow ducts provided in at least one of the seat back portion or the seat cushion portion and define an air flow passage for air to be blown out from the seat or air to be drawn into the seat.

European patent application <CIT> discloses an air conditioned seat device having a support member, an air blower, a skin configured to form a seating surface, an air layer member, and an air-impermeable sheet member. The support member is provided with a duct for air. The air blower takes in air from the outside and passes the air through the duct. The skin passes air sent from the air blower. The air layer member, provided between the support member and skin, temporarily stores air supplied from the duct to form an air layer. The sheet member covering the air layer member is provided with an air flow-out opening configured to induce air to flow out from the air layer.

United States patent application <CIT> discloses a climate controlled seat assembly including a seat having a seat cushion, a backrest having a backrest cushion, and a headrest having a headrest cushion. The headrest cushion includes at least one fluid passageway extending at least partially therethrough. A thermoelectric device is in fluid communication with the at least one fluid passageway. A fluid transfer device that is in fluid communication with the at least one fluid passageway is coupled to the headrest such the thermal module moves with the headrest as it is moved with respect to the backrest.

In some embodiments, the ventilated seat assembly comprises a perforated dress cover positioned over the cushion assembly.

In some embodiments, the assembly further includes at least one valve or baffle for controlling air flow through the first length of tubing and the second length of tubing.

In some embodiments, the cushion assembly, in the ventilated seat assembly, is a backrest cushion including at least one of a lumbar target region, a side bolstertarget region, and a headrest target region, and the conduit network includes at least one of a first conduit for delivering air to the lumbar target region, a second conduit for delivering air to the side bolster target region, and a third conduit for delivering air to the headrest target region.

In some embodiments, the air mover, in the ventilated seat assembly, serves a single ventilated seat assembly and is positioned below or behind the at least one structural frame element.

In some embodiments, the cushion assembly is sealed on at least one side facing away from a passenger contact surface of the cushion assembly.

According to a second aspect, the present invention is directed to an aircraft passenger seat assembly comprising a ventilated seat assembly according to the first aspect of the present invention wherein the backrest is a first structural element, the seat pan is a second structural element, wherein a first conduit network is embedded in the backrest cushion assembly.

In some embodiments, the seat assembly further includes a second conduit network embedded in the seat bottom cushion configured to deliver air to at least one target region of the seat bottom cushion assembly, wherein the second conduit network is coupled in fluid communication with the air mover and the controller is further operable for activating the air mover to cause air to flow through the second conduit network to the at least one target region.

In some embodiments, activation of the air mover by the controller causes air to flow through the first conduit network and the second conduit network simultaneously.

In some embodiments, the second conduit network comprises one or more lengths of tubing routed from the air mover, along passageways defined in the seat pan, and to a predetermined one of the at least one target region of the seat bottom cushion assembly.

Embodiments of the present invention can include one or more or any combination of the above aspects, features and configurations.

The present invention may be better understood when consideration is given to the following detailed description thereof. In the drawings:.

The description set forth below in connection with the appended drawings is intended to be a description of various, illustrative embodiments of the disclosed subject matter. Specific features and functionalities are described in connection with each illustrative embodiment; however, it will be apparent to those skilled in the art that the disclosed embodiments may be practiced without each of those specific features and functionalities, except those mentioned in the independent claim. The aspects, features and functions described below in connection with one embodiment are intended to be applicable to the other embodiments described below except where expressly stated or where an aspect, feature or function is incompatible with an embodiment.

Referring to the drawing figures, the present invention is directed to passenger seat constructions including an integrated seat ventilation system for improving seat comfort, and particularly, preventing the build-up of trapped and stagnant heated air. The seat constructions disclosed herein are not limited to any seat type and therefore find widespread application in all types including premium and economy class seat constructions, among crew seats and other seat types. The ventilation systems disclosed herein can be integrated into the seat construction mutually exclusive of the adjustment and other capabilities of the seat.

The seat ventilation system generally operates to move unconditioned air through a particular cushion assembly to prevent air from becoming stagnant and warm after prolonged sitting. The system includes an air mover (e.g., fan, pump, blower, etc.) mounted below or behind the seat depending on space allowance. Each seat may be equipped with its own dedicated air mover electrically activated to flow unconditioned air through the system. As compared to conventional cushion assemblies constructed of open-cell foam and closed-cell flotation foam, the present cushion construction includes spacer mesh positioned in target regions corresponding to likely contact points with the seated passenger. Air conduit such as flexible tubing delivers unconditioned air to the spacer mesh in the target regions where the flowing air is released through a porous surface such as a perforated dress cover. In some embodiments, the spacer mesh may be sealed on sides facing away from the passenger such that air flow is directed, for example, out through the perforated dress cover.

Referring to <FIG>, a non-limiting example of a seat assembly is shown at reference numeral <NUM>. The seat assembly <NUM> generally includes a backrest cushion assembly <NUM> and a seat bottom cushion assembly <NUM>. A backrest structural element <NUM> supports the backrest cushion assembly <NUM>. A seat pan <NUM> supports the seat bottom cushion assembly <NUM>. Each of the backrest structural element <NUM> and the seat pan <NUM> may be constructed from rigid materials such as composites to support their respective flexible cushion assembly. Each of the backrest cushion assembly <NUM> and the seat bottom cushion assembly <NUM> can be covered with a dress cover <NUM> for comfort, performance and aesthetics. As discussed further below, portions of the dress cover corresponding to target regions on the seat cushion assemblies are perforated to allow air to flow therethrough to the passenger.

The construction and configuration of the backrest structural element <NUM> and the seat pan <NUM> may vary. For example, the two components may be continuous across the respective back and bottom of the seat or may be skeletal elements supporting a diaphragm. The two components may be pivotally coupled such that the backrest can recline relative to the seat bottom. The components may be pivotally coupled to each other or to other frame elements such as seat spreaders. The inclination of the backrest may be adjusted and locked relative to the seat bottom. In an economy class seat construction, for example, a gas compression spring may act between the backrest and the frame and a button may be positioned in the armrest actuated to unlock the gas spring through a lever and Bowden cable arrangement, among other arrangements. In a premium class seat construction, a control panel may be electrically coupled to one or more seat actuators dedicated for driving component adjustability either alone or between discrete sitting positions. The ventilation systems disclosed herein operate mutually exclusive of a seat adjustment system.

Each of the backrest cushion assembly <NUM> and the seat bottom cushion assembly <NUM> includes more than one type of material in the cushion construction. In some embodiments, the cushion assemblies may include one or more layers of open-cell foam and closed-cell flotation foam with fire-resistant layers or additives, referred to herein collectively as the "foam" portion of the cushion assemblies shown generally at reference numeral <NUM>. Cushion assemblies additionally include spacer mesh <NUM> positioned in predetermined zones of the cushion assembly referred to herein as "target regions" or "target zones. " Spacer mesh may be a three-dimensional mesh like body attached to or affixed within the foam to prevent the spacer mesh from being displaced with respect to the foam body. The spacer mesh is positioned in ventilated regions of the cushion assembly or the target regions, and the foam is positioned outside of the ventilated regions or target regions. While both the foam and spacer mesh provide comfort and support, the open-cell structure of the spacer mesh allows more air flow therethrough. Spacer mesh is positioned near or at the front of the cushion assembly in the case of the backrest, and near or at the top of the cushion assembly in the case of the seat bottom, in the target regions to direct air flow out through the perforated dress cover and across the passenger.

Target regions correspond to likely points of passenger contact or likely pressure points. Regarding the backrest cushion assembly <NUM>, target regions are provided in a lower backrest or lumbar region <NUM> and upper backrest region <NUM> and may be provided in side bolster regions <NUM> and headrest region <NUM>. Regarding the seat bottom cushion assembly <NUM>, a target region may correspond to a central region <NUM> of the seat bottom or other region. While the target regions generally correspond to passenger contact regions, target regions may also be positioned to one or more of the lateral sides and/or longitudinal ends in embodiments in which it is desired to move air through the cushion out the sides, top or bottom outside of the target areas. While the properties of the foam (e.g., polyurethane foam, soft synthetic resin foam, etc.) have better comfort performance as compared to the spacer mesh, the open-cell structure of the spacer mesh has better air flow performance as compared to the foam. Depending on the type of foam and spacer mesh, comfort differences between the two foam types may be imperceptible to the passenger, particularly when positioned beneath a seat dress cover30. Each of the foam and the spacer mesh may be formed with contouring and concave portions to conform to passenger anatomy.

Portions of the spacer mesh adjacent the foam may be sealed to prevent air leakage. In some embodiments, the faces of the spacer mesh facing away from the passenger may also be sealed such that air contained in the spacer mesh is directed out through the unsealed face toward the passenger.

The seat construction <NUM> includes a ventilation system incorporated into one or more of the backrest cushion assembly <NUM> and the seat bottom cushion assembly <NUM>. It is intended and understood that the seat assembly includes a ventilation system in one or more of the backrest and seat bottom, with additional systems optionally incorporated into the leg rest and arm rests where applicable. The multiple systems may be coupled and supplied by a single air mover assembly <NUM> for moving a volume of air through a conduit network(s). The system may optionally include a manifold assembly, which may be a part of the air mover assembly <NUM>. The manifold assembly is actuated to supply a flow of unconditioned air from the air mover assembly <NUM> to one or more of the air conduits depending on the selected target region to be ventilated.

The air mover assembly <NUM> may be positioned with the seat assembly, such as below the seat pan <NUM> or backrest structural element <NUM>, or apart from the seat assembly. In the case of a manifold assembly, the manifold assembly may be part of the air mover assembly <NUM> or may be removed therefrom and coupled in fluid communication thereto via an air conduit. The air mover assembly <NUM> is activated and actuated to provide a flow of unconditioned air.

In the case of a manifold assembly, the manifold assembly generally operates to control and distribute air flow to the conduit network <NUM>. The manifold assembly generally includes one or more outlet ports corresponding in number to the number of air conduits of the conduit network. For example, the outlet ports may include <NUM>, <NUM>, <NUM>,. n number of outlet ports corresponding to <NUM>, <NUM>, <NUM>,. n number of air conduits of the conduit network. Extra outlet ports may be included to allow for future expansion of the system. Quick connect fittings, threaded connections and the like may be used to attach the air conduits to the manifold assembly.

Referring to <FIG>, the conduit network <NUM> generally includes one or more lengths of air conduit <NUM>, such as flexible air tubing, with each air conduit <NUM> extending from an outlet port of the air mover assembly <NUM> into a target region in the cushion assembly. The portions of the air conduits <NUM> within the target regions are perforated with openings <NUM> that allow air to flow out of the air conduit and into the target area spacer mesh, and in some embodiments, directed toward a front face of the cushion assembly. In some embodiments, each air conduit <NUM> is a dedicated run from one outlet port to one target region. In other embodiments, one air conduit <NUM> may supply an unconditioned flow of air to more than one target region. In yet other embodiments, one air conduit <NUM> may supply a flow of unconditioned air to a splitter, which in turn supplies multiple flows of unconditioned air to multiple air conduits <NUM> flowing unconditioned air to one or more target regions. As shown in <FIG>, air is flowed to each of the lower backrest target region <NUM>, upper backrest target region <NUM>, headrest target region <NUM>, and side bolstertarget regions <NUM> by a single air conduit <NUM>. The air conduits are embedded in the spacer mesh and <NUM> may be embedded in the foam or may be routed between the foam and the backrest element and embedded in the spacer mesh to prevent each air conduit from being displaced with respect to its respective spacer mesh target region.

Referring to <FIG>, a non-limiting example of the seat assembly <NUM> as perceived by the passenger is illustrated. The dress cover <NUM> is perforated about a lower backrest region <NUM> and about an upper backrest region <NUM> to allow air to flow out of the cushion assembly. Spacer mesh and the respective embedded air conduits are positioned in those regions beneath the dress cover, while foam is positioned outside of those regions beneath the dress cover. To the passenger, the perforations may be perceptible with close inspection, while the underlying ventilation system is not visible nor felt through the dress cover. The controller <NUM> may be located in proximity to the seat, such as within an armrest along with seat adjustability and media controls.

Referring to <FIG>, a specific seat construction is illustrated. In this seat construction, passages <NUM> are formed in a frontside of the structural frame element <NUM> and are recessed from a front planar face of the element. Each passage <NUM> has a depth corresponding to substantially a thickness of an air conduit <NUM> routed therethrough. The passages <NUM> are shaped and directed from an air conduit entry point of the element to a target region in one of the aforementioned target regions, among others. As illustrated, the air conduits <NUM> are constructed from rigid tubing section joined together with connectors <NUM> for providing directional changes. Each air conduit <NUM> is open at its distal end within the target region and/or is provided with at least one opening along its length in the target region to distribute air flow uniformly throughout the respective target region.

Referring again to <FIG>, a controller <NUM> is operable for activating the air mover <NUM> and actuating the optional manifold assembly to cause unconditioned air to flow through the conduit network(s). The controller may be operatively coupled to or an integral part of a passenger seat control interface. The control interface may be located on the seat assembly or in proximity thereto. The control interface may be collocated with the seat control features such that all seat comfort controls are provided in the same passenger device. Ventilation system controls include activating the air mover and may include, but are not limited to, one or more of adjusting air mover output, selecting a target region(s) to be ventilated, etc. Each passenger control interface may be networked with a master crew controller capable of overriding each individual seat controller. For example, all ventilation systems may be deactivated during taxi, takeoff and landing and permitted to be selectively activated during flight.

The seat ventilation systems disclosed herein may further include at least one sensor positioned in the seat assembly coupled with the controller <NUM> and operable for activating the ventilation assembly in response to a sensed condition to provide automatic ventilation in response to exceeding a predetermined threshold condition, such as a predetermined threshold temperature in one of the target regions to automatically and proactively avoid passenger discomfort. Each sensor may be a device or a subsystem capable of detecting condition changes within the seat assembly and with a processor within or in communication with the controller. The system sensors relay information to the processor where processing logic analyzes the data received to control the ventilation system. The processor may be a component of a server, such as a digital computer also including input/output (I/O) interfaces, a network interface, a data store, and memory. The components may be communicatively coupled via a local interface such as one or more buses or other wired or wireless connections. The local interface may have additional elements such as controllers, buffers (caches), drivers, repeaters, and receivers, among others, to enable communications. Further, the local interface may include address, control, and/or data connections to enable appropriate communications among the components.

The processor is a hardware device for executing software instructions such as collation algorithms. The processor may be any custom made or commercially available processor, a central processing unit (CPU), an auxiliary processor among several processors associated with the server, a semiconductor-based microprocessor (in the form of a microchip or chip set), or generally any device for executing software instructions. When the server is in operation, the processor is configured to execute software stored within the memory, to communicate data to and from the memory, and to generally control operations of the server pursuant to the software instructions. The I/O interfaces may be used to receive user input from and/or for providing system output to one or more devices or components such as the described or inferred sensors, an aircraft network, and flight crew devices. I/O interfaces may include a serial port, a parallel port, a small computer system interface (SCSI), a serial ATA (SATA), a fibre channel, Infiniband, iSCSI, a PCI Express interface (PCI-x), an infrared (IR) interface, a radio frequency (RF) interface, and/or a universal serial bus (USB) interface.

A network interface may be used to enable the server to communicate on a network, such as the Internet, a wide region network (WAN), a local region network (LAN) such as the secure aircraft network, and the like, etc. The network interface may include address, control, and/or data connections to enable appropriate communications on the network. A data store may be used to store data. The data store may include any of volatile memory elements (e.g., random access memory (RAM, such as DRAM, SRAM, SDRAM, and the like)), nonvolatile memory elements (e.g., ROM, hard drive, tape, CDROM, and the like), and combinations thereof. In one example, the data store may be located internal to the server such as, for example, an internal hard drive connected to the local interface in the server. Additionally, in another embodiment, the data store may be located external to the server such as, for example, an external hard drive connected to the I/O interfaces (e.g., SCSI or USB connection). In a further embodiment, the data store may be connected to the server through a network, such as, for example, a network attached file server.

The software in memory may include one or more software programs, each of which includes an ordered listing of executable instructions for implementing logical functions. The software in the memory includes a suitable operating system (O/S) and one or more programs. The operating system essentially controls the execution of other computer programs, such as the one or more programs, and provides scheduling, input-output control, file and data management, memory management, and communication control and related services. The one or more programs may be configured to implement the various processes, algorithms, methods, techniques, etc. described or inferred herein.

Claim 1:
A ventilated seat assembly (<NUM>) with active air circulation, comprising:
at least one structural frame element (<NUM>);
a cushion assembly (<NUM>, <NUM>) supported by the at least one structural frame element (<NUM>);
a conduit network (<NUM>) embedded in the cushion assembly (<NUM>, <NUM>) configured to direct air to at least one target region of the cushion assembly (<NUM>, <NUM>);
an air mover (<NUM>) coupled in fluid communication with the conduit network (<NUM>); and
a controller (<NUM>) operable for activating the air mover (<NUM>) to cause unconditioned air to flow through the conduit network (<NUM>) to the at least one target region;
wherein
the at least one structural element (<NUM>) is a backrest, the cushion assembly (<NUM>) is a backrest cushion comprising a spacer mesh (<NUM>) component and a foam (<NUM>) component, and wherein the backrest cushion includes a lower target region near a lumbar region (<NUM>) of the backrest and an upper target region near a headrest region (<NUM>) of the backrest;
the spacer mesh (<NUM>) is positioned in the lower target region and in the upper target region, and wherein the foam (<NUM>) is positioned outside of the lower target region and the upper target region; and
the conduit network (<NUM>) includes a first length of tubing extending from the air mover (<NUM>) to the lower target region and a second length of tubing extending from the air mover (<NUM>) to the upper target region, each of the first length of tubing and the second length of tubing being embedded in the spacer mesh (<NUM>) and having at least one opening for releasing unconditioned air into their respective target region;
and/or wherein
the at least one structural frame element (<NUM>) is a seat pan (<NUM>), the cushion assembly (<NUM>) is a seat bottom cushion, the cushion assembly (<NUM>) includes a spacer mesh (<NUM>) component in the at least one target region and a foam (<NUM>) component outside of the at least one target region, and the conduit network (<NUM>) includes at least one length of tubing embedded in the spacer mesh (<NUM>) component and having at least one opening for releasing unconditioned air into the at least one target region.