GB2632384A

GB2632384A - A vehicle seat sub-assembly and method

Info

Publication number: GB2632384A
Application number: GB2417137.3A
Authority: GB
Inventors: Ozcan Zafer
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2021-05-27
Filing date: 2021-05-27
Publication date: 2025-02-05
Anticipated expiration: 2041-05-27
Also published as: GB202417137D0; GB2632384B

Abstract

A sub-assembly 12 for a vehicle seat has a fan support 14 integrally embedded by overmolded into a molded rigid seat support 13B, with a first air distribution manifold 20 proximal to the fan support 14, and a second air distribution manifold 24 connected in series to the first air distribution manifold 20 via air passages 22,26. The molded seat support 13B may be foam e.g. expanded polypropylene, with an overmolded reinforcement (18, fig. 4) that secures the fan support 14. The assembly can be a vehicle bench seat base with a compressible cushion 13A, and second air manifold 24 can have smaller air passages 25A,25B aligned with a perforated seat trim 36.

Description

A VEHICLE SEAT SUB-ASSEMBLY AND METHOD

TECHNICAL FIELD

The present disclosure relates to a vehicle seat sub-assembly and to a corresponding method of manufacture. In particular, but not exclusively it relates to a ventilated seat base comprising an integral overmolded fan support structure.

BACKGROUND

Some vehicles are offered with luxury equipment such as ventilated seats. A ventilated vehicle seat refers to a vehicle seat which is able to cool its occupant with ambient or refrigerated air. The ventilated vehicle seat permits air exchange between an air-permeable seat trim and internal air chambers within the vehicle seat. The air chambers may be in fluid communication with the vehicle cabin via a fan. The fan can be operated in a push configuration to draw ambient or refrigerated air from inside the vehicle cabin and into the seat, or in a pull configuration to draw ambient air away from the seat/occupant and into the vehicle cabin (or outside the vehicle).

Ventilated seats are typically thick and heavy, requiring ample packaging space. Ventilation equipment, such as fans, may be positioned below the seat but this could result in the seat having to be taller. A heavy, bulky seat frame may integrate some ventilation equipment.

SUMMARY OF THE INVENTION

It is an aim of the present invention to provide an improved sub-assembly for mounting ventilation components within a vehicle. The invention is as defined in the appended independent claims.

According to an aspect of the invention there is provided a sub-assembly for a vehicle seat, the sub-assembly comprising: a molded seat support; and a fan support structure, wherein the fan support structure is overmolded into the molded seat support.

An advantage of integrating the fan support structure and fan within the molding of the seat base is reduced vehicle packaging requirements.

In some examples, the sub-assembly is configured as a vehicle rear seat base.

In some examples, the fan support structure is integral with the molded seat support.

In some examples, the fan support structure is at an inset position relative to a B-surface of the sub-assembly.

In some examples, the fan support structure is located within a fan cavity of the molded seat support, wherein the B-surface of the molded seat support is shaped to define the fan cavity.

In some examples, the molded seat support comprises a foam material.

In some examples, the foam material comprises expanded polypropylene.

In some examples, the molded seat support comprises overmolded reinforcement, and wherein the reinforcement secures the fan support structure.

In some examples, the sub-assembly comprises a first air distribution manifold proximal to the fan support structure, and a second air distribution manifold fluidly connected in series to the first air distribution manifold via an air passage arrangement. An advantage of small numerous air passages is airflow uniformity and comfort because the air passages are difficult to feel through the seat.

In some examples, the air passage arrangement comprises a plurality of air passages leading to the second air distribution manifold.

In some examples, the second air distribution manifold connects the plurality of air passages to a greater plurality of smaller air passages aligned with a perforated seat trim.

The described air distribution manifolds provide a comfortable yet not overly-thick seat base that ensures: a desired hip point location is respected due to minimal packaging requirements; seat ventilation is distributed over a wide seat area; and the seat base does not feel inconsistently firm.

In some examples, the sub-assembly comprises a fan secured to the fan support structure.

According to an aspect of the invention there is provided a seat base comprising the subassembly.

In some examples, the seat base is configured as a vehicle bench seat base.

According to an aspect of the invention there is provided a vehicle seat comprising the subassembly or the seat base.

According to an aspect of the invention there is provided a vehicle comprising the subassembly, or the seat base, or the vehicle seat.

According to an aspect of the invention there is provided a method of making a sub-assembly for a vehicle seat, the method comprising: providing a fan support structure; and molding a seat support so that material of the seat support overmolds the fan support structure.

In some examples, the method comprises securing the fan support structure to reinforcement, wherein molding the seat support comprises overmolding the reinforcement and fan support structure.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination that falls within the scope of the appended claims. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination that falls within the scope of the appended claims, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG. 1 illustrates an example of a vehicle; FIG. 2 illustrates an example of a vehicle seat; FIG. 3 illustrates an example side cross-section through a seat base; FIG. 4 illustrates an example of a fan support structure secured to reinforcement; and FIG. 5 illustrates an example method of manufacture.

DETAILED DESCRIPTION

FIG. 1 illustrates an example of a vehicle 1 in which embodiments of the invention can be implemented. In some, but not necessarily all examples, the vehicle 1 is a passenger vehicle, also referred to as a passenger car or as an automobile. In other examples, embodiments of the invention can be implemented for other applications, such as commercial vehicles.

Conventional longitudinal, lateral and vertical axes (x, y, z) of the vehicle 1 are shown.

The Figures illustrate an example of a sub-assembly 12 for a vehicle seat 10, the sub-assembly 12 comprising: a molded seat support 13B; and a fan support structure 14 for an electrically controllable ventilation fan 30, wherein the fan support structure 14 is overmolded into the molded seat support 13B.

An overmolded product refers to a product having distinct characteristics resulting from an overmolding process. An overmolding process involves placing one or more base components into a mould, prior to molding. Then a molding step is performed, comprising inserting a molten or pliable material into the mold and allowing the material to harden in the shape of the mold. The base components become at least partially embedded within the molded material, generally in a permanent manner.

FIG. 2 schematically illustrates an example of the vehicle seat 10, in side view. The vehicle seat 10 comprises a seat base 10A on top of which an occupant can sit, and a seat back 10B against which an occupant can lean.

In the below examples, the sub-assembly 12 comprises the whole or a part of a seat base 10A of the vehicle seat 10. In other examples, the sub-assembly 12 comprises the whole or a part of a seat back 10B of the vehicle seat 10.

In some, but not necessarily all examples, the vehicle seat 10 is a rear seat of the vehicle 1.

In some examples, a rear row of seating of the vehicle 1 comprises at least a pair of vehicleseats 10 such as shown in FIG. 2, as outboard seats, and optionally a middle seat (not shown) therebetween. In an example executive seating configuration, at least the outboard seats are independently longitudinally slidable and so have individual seat bases. In an example bench seating configuration, both outboard seats and the optional middle seat share a common, wider seat base 10A.

In at least some examples, the vehicle seat 10 is a ventilated vehicle seat. In some examples, the seat base 10A is ventilated. Additionally, or alternatively, the seat back 10B is ventilated.

FIG. 3 schematically illustrates a cross-section side view of an example seat base 10A of the vehicle seat 10.

The seat base 10A comprises a sub-assembly 12. The sub-assembly 12 at least comprises a molded seat support 13B underlying a molded, softer compressible cushion 13A. The molded seat support 13B and the compressible cushion 13A are adapted to include internal air chambers 20, 22, 24, 26, 28, 32 and an internal fan 30 for ventilation.

First, the materials of the molded seat support 13B and the compressible cushion 13A are 25 described.

The molded seat support 13B can comprise a molded rigid block of material. In some examples, the molded seat support 13B comprises an expanded material. The material may be a foam-based material. Foam-based materials can be expanded into a wide variety of structural shapes. In some examples, the foam material comprises expanded polypropylene (EPP) which is a rigid, durable and lightweight material. EPP is a form of polypropylene that may be expanded using gas injection during a moulding process. EPP can have a lower density than regular polypropylene. In some examples, porous EPP (PEPP) is used for reduced noise, vibration and harshness to the vehicle cabin. In other implementations, the foam material comprises a different material.

The molded seat support 13B may be sufficiently structural to support the compressible cushion 13A during occupant usage, and may be shaped to act as an anti-submarining ramp 44 in the event of a vehicle impact whilst wearing a seatbelt. Submarining refers to an occupant sliding under the lap part of the seat belt in the event of a collision.

In some examples, the molded seat support 13B comprises a reinforced molded block of the molded material. Internal reinforcement 18 is illustrated in FIG. 4. In some examples, the molded seat support 13B may also overmold and at least partially enclose reinforcement 18 (FIG. 4), the reinforcement 18 comprising a different material with a higher Young's Modulus.

The molded seat support 13B and the reinforcement 18 form an integral structural component. In some examples, the reinforcement 18 comprises a structural wireframe as shown in FIG. 4 and described later.

The compressible cushion 13A can comprise any appropriate comfort material, such as polyurethane cushion foam. The compressible cushion 13A is molded separately from the molded seat support 13B. The compressible cushion 13A may have a lower Shore ND hardness than the molded seat support 13B.

In the illustrated example, the fan 30 is located within an internal volume of the seat base 10A, between an A-surface 16A and a B-surface 16B of the seat base 10A, to make the vehicle seat 10 easier to package within the vehicle 1. The vertical thickness of the seat base 10A therefore does not need to increase to accommodate ventilation components. This arrangement can be useful for rear vehicle seats, where rear seat headroom is constrained by a high floor and/or a low roofline. This arrangement can also be useful for front vehicle seats, for an optimal hip point position. An 'A-surface' refers to a surface in the vehicle cabin 3 that is visible to occupants, such as perforated seat trim parts. A B-surface' refers to a surface in the vehicle 1 that is not visible to occupants, such as an underside of the seat base 10A.

The fan 30 is supported by a fan support structure 14. The fan support structure 14 can function as a carrier for the fan 30. The fan support structure 14 is overmolded by and inseparable from the molded seat support 13B, to make the fan support structure 14 integral with the molded seat support 13B.

The fan support structure 14 is a base component, comprising a material different from the material of the molded seat support 13B. The fan support structure 14 may comprise one or more polymeric materials such as Polyacetal (POM), polycarbonate (PC), Acrylonitrile butadiene styrene (ABS), glass fiber-reinforced polyamide (PA), and/or similar materials. The fan support structure 14 which may be harder and more rigid than the overmolding expanded material.

The fan 30 may be removably attachable to the fan support structure 14. The fan 30 may be added after a molding process has completed.

FIG. 4 illustrates an example of the fan support structure 14, viewed from the side and slightly below, prior to molding.

In FIG. 4, but not necessarily all examples, the fan support structure 14 is a bracket comprising a central aperture 41 with which the fan 30 is aligned, to provide a fluid path through the fan 30. The fan 30 is not shown in this view because it is added later.

In FIG. 4, but not necessarily all examples, the fan support structure 14 comprises a fan fixing portion 40, such as a screw hole, to enable attachment of the fan 30 to the fan support structure 14.

In FIG. 4, but not necessarily all examples, the fan support structure 14 comprises a second fan fixing portion 42, such as a clip, configured to receive a protrusion of the fan 30, to enable the fan 30 to be further secured to the fan support structure 14.

The fan 30 can comprise corresponding features (e.g., screw hole, protrusion) configured to enable the fan 30 to be secured to the fan support structure 14.

The fan support structure 14 is positioned so that its central aperture 41 is at an inset (recess) position relative to the majority of the B-surface 16B, as shown in FIG. 3. In some examples, the B-surface 16B is molded into a complex shape that comprises a fan cavity 32 in the B-surface 16B. The fan cavity 32 is aligned with the fan 30 and the central aperture 41 of the fan support structure 14. In use, the fan 30 may be located within the fan cavity 32 and/or at the top of the fan cavity 32, so that the fan support structure 14 and optionally the fan 30 does not protrude beyond a plane defined by the majority of the surrounding B-surface 16B.

The fan cavity 32 may be fluidly connected to the vehicle cabin 3 (or outside the vehicle 1) in any appropriate way. If the fan 30 is operated in a pull configuration, air exhausted from the fan 30 may enter the fan cavity 32 and then exhaust to the vehicle cabin 3 via any appropriate path. If the B-surface 16B is directly secured to a floor pan area of the body 2 of the vehicle 1, the exhausted air may travel horizontally via channels (not shown) in the B-surface 16B to reach an appropriate venting location, such as a rear cargo area (trunk) of the vehicle 1. If the fan 30 is operated in a push configuration, the airflow direction may be opposite to that stated above.

In some examples, the fixing portion 40 on the fan support structure 14 can be positioned to be accessible from the B-surface 16B of the seat base 10A. For example, the fixing portion 40 may be aligned with the fan cavity 32. In an implementation, a fixing at the fixing portion 40 can be accessed by a tool (e.g., screwdriver) inserted through the fan cavity 32, before the seat base 10A is installed into the vehicle 1. This facilitates quick attachment of the fan 30 to the fan support structure 14 and also facilitates quick removal of the fan 30 from the fan support structure 14 for replacement or servicing.

In some examples, the dimensions of the fan cavity 32 are large enough to enable the fan 30 to be inserted through the fan cavity 32 into contact with the fan support structure 14, so that the fan 30 can be secured to the fan support structure 14 before the seat base 10A is installed into the vehicle 1. Similarly, replacement may comprise detaching the fan 30 from the fan support structure 14 and pulling the fan 30 out through the fan cavity 32.

FIG. 3 also illustrates a non-limiting example of how the fan 30 can be fluidly connected to the ventilated A-surface 16A of the seat. FIG. 3 illustrates a plurality of air distribution manifolds 20, 24, 28 between the fan 30 and a perforated seat trim 36 comprising the A-surface 16A.

FIG. 3 illustrates a first air distribution manifold 20 proximal to the fan 30. The first air distribution manifold 20 is configured to fluidly connect the fan 30 to a plurality of air passages 22, 26 (ports). The illustrated first air distribution manifold 20 is at a surface interface between an underside of the compressible cushion 13A and a top surface of the molded seat support 13B, but could be located elsewhere. In some examples, the top surface of the molded seat support 13B is shaped as an anti-submarining ramp 44.

The plurality of air passages 22, 26 extend towards the A-surface 16A of the seat base 10A. A first plurality of the air passages 22 fluidly connect the first air distribution manifold 20 to a second air distribution manifold 24. The second air distribution manifold 24 is proximal to the A-surface 16A, that is, proximal to the perforated seat trim 36. The second air distribution manifold 24 may be provided in the compressible cushion 13A.

In some examples, the plurality of air passages 22 for the second air distribution manifold 20 are molded features of the compressible cushion 13A. The compressible cushion 13A may be molded into a shape that includes said air passages 22. In other examples, the air passages 22 are introduced after molding.

The use of a plurality of air passages 22 is more comfortable to the occupant than the use of a single larger air passage. The occupant is less likely to feel the air passages 22 through the seat 10 as they are smaller and more numerous. In some, but not necessarily all examples, more than two air passages 22 fluidly connect the first air distribution manifold 20 to the second air distribution manifold 24, of which two are visible 22A, 22B.

The second air distribution manifold 24 may be positioned to achieve best airflow performance with pressure mapping of occupant which is generally under the H-point (hip point) and upper 20 thighs.

In some examples, the second air distribution manifold 24 comprises a greater plurality of smaller air passages 25A, 25B, smaller and more numerous than the air passages 22. The smaller air passages 25A, 25B may nevertheless have a larger cross-sectional area than individual perforations in the perforated seat trim 36. The smaller air passages 25A, 25B may be aligned to the perforated seat trim 36 to enable airflow across and/or along and/or through a large area of the perforated seat trim 36.

In some examples, the second air distribution manifold 24 comprises a compressible foam layer having an array of apertures extending wholly or partially through its thickness to define the smaller air passages 25A, 25B. In the illustrated example, the smaller air passages 25A, 25B are arranged in a honeycomb structure. In the illustrated example, not all of the smaller air passages 25A, 25B are aligned with the air passages 22, therefore, the foam material may be an open cell foam material to further improve air distribution.

In some examples, there are at least twice as many, or at least five times as many smaller air passages 25A, 25B than the air passages 22. The compressibility of the foam and the use of small numerous air passages is advantageous for airflow uniformity and for comfort because they are difficult to feel through the seat.

The foam of the second air distribution manifold 24 may be a different foam than the material of the compressible cushion 13A. For example, the compressible cushion 13A may comprise a closed cell material (e.g., closed cell polyurethane) for more control, whereas the second air distribution manifold 24 may comprise an open cell material.

An additional or alternative third air distribution manifold 28 can be provided at a different location of the same seat, under the same occupant. The first air distribution manifold 20 may be fluidly connected to the third air distribution manifold 28. The third air distribution manifold 28 may have a similar construction to the second air distribution manifold 24, the third air distribution manifold 28 having its own smaller air passages 29A, 29B which may be be aligned to the perforated seat trim 36 to enable airflow across and/or along and/or through a large area of the perforated seat trim 36.. However, the third air distribution manifold 28 is positioned forward and closer to lower thighs of a seat occupant, that is, further from the seat back 10B. The first and third air distribution manifolds 20, 28 may be fluidly connected to each other by a plurality of air passages 26, of which two air passages 26A, 26B are shown. The air passages 26 may be similar to the air passages 22 described above.

In some examples, the first air distribution manifold 20 is implemented differently than the second and third air distribution manifolds 24, 28, for example, as a sealed bag. The sealed bag comprises fluid connections to the air passages 22, 26 and to the fan 30.

Overall, FIG. 3 shows that in a pull configuration of the fan 30, air enters the second and third air distribution manifolds 24, 28 from the perforated seat trim 36, then passes to the plurality of air passages 22, 26, then passes to the first air distribution manifold 20, then passes through the fan 30 to the fan cavity 32, and finally exhausts out of the seat base 10A. In a push configuration, the airflow direction is in the opposite direction.

The described air distribution manifolds 20, 24, 28 provide a comfortable yet not overly-thick seat base 10A with several advantageous attributes: a desired hip point location is respected; seat ventilation is distributed over a wide seat area; and the seat base 10A does not feel inconsistently firm. Integration of the fan 30 with the seat base 10A is also advantageous for vehicle packaging. It would be appreciated that air could be distributed in various other ways than that shown.

FIGS. 4 and 5 relate to the manufacture of the molded seat support 13B, and how the fan support structure 14 can be overmolded. In these examples, but not necessarily all examples, the fan support structure 14 is secured to and supported by the reinforcement 18 of the seat support 13B in addition to being supported by the molded material of the molded seat support 13B. This enables the fan support structure 14 to be positioned accurately prior to molding.

FIG. 4 shows, in addition to the fan support structure 14, reinforcement 18 in the form of a structural frame. The illustrated structural frame is a wireframe for weight minimisation. The wireframe reinforcement 18 may comprise a metallic wireframe. It would be appreciated that a different kind of reinforcement 18 could be provided in other examples. The wireframe reinforcement 18 may comprise a plurality of rigid wires, secured to each other to form a wireframe that takes the approximate shape of the seat base 10A. The wires may be secured to each other by welds, for example. The shape of the wireframe reinforcement 18 may be configured to provide approximately homogeneous strength properties across a majority of a plan area of the molded seat support 13B and/or across its depth.

The reinforcement 18 is configured to be overmolded. When overmolded, most of the reinforcement 18 becomes embedded but parts of the reinforcement 18 may optionally protrude from at least the B-surface 16B of the seat base 10A to enable the molded seat support 13B to be secured to the body 2 of the vehicle 1 and/or to the seat back 10B.

The illustrated fan support structure 14 comprises a reinforcement fixing 38 configured to secure the fan support structure 14 to the reinforcement 18. The reinforcement fixing 38 may comprise a hook, a clip, or any other suitable equivalent. If the reinforcement 18 is a wireframe, the reinforcement 18 may comprise an additional wire 43 positioned to engage with the reinforcement fixing 38 of the fan support structure 14.

FIG. 5 illustrates an example method of manufacture 50 of the sub-assembly 12. At block 52, the method 50 comprises providing the fan support structure 14. For example, the fan support structure 14 may be a pre-manufactured part provided into a mold.

At block 54, the method 50 comprises securing the fan support structure 14 to the reinforcement 18. For example, as shown in FIG. 4, the reinforcement fixing 38 of the fan support structure 14 may be engaged with the reinforcement 18. Alternatively, the fan support structure 14 may be loosely placed in the mold or only temporarily secured for molding.

In addition, other components to be overmolded may be placed in the same mold. For example, if the seat base 10A is configured to provide electronic components such as receptacles (e.g., Universal Serial Bus receptacles), an attachment structure for receiving a fascia and the electronic components may be overmolded in the same step.

At block 56, the method 50 comprises molding the seat support 13B so that the material of the seat support 13B overmolds the fan support structure 14 and the optional reinforcement 18 and any other components to be overmolded.

Then, the seat base 10A can be finished by adding the compressible cushion 13A and the air distribution manifolds 20, 24, 28 on top of the seat support 13B, and wrapping the combination with seat trim 36 which is tensioned and secured to the B-surface 16B of the molded seat support 13B.

It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Although embodiments of the present invention have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the invention as claimed.

For example, the fan support structure 14 may be integrated with the seat back 10B for a ventilated seat back.

Features described in the preceding description may be used in combinations other than the combinations explicitly described.

Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not.

Although features have been described with reference to certain embodiments, those features may also be present in other embodiments whether described or not.

Whilst endeavoring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

This disclosure further relates to the following numbered clauses: Clause 1. A sub-assembly for a vehicle seat, the sub-assembly comprising: a molded seat support; and a fan support structure, wherein the fan support structure is overmolded into the molded seat support.

Clause 2. The sub-assembly of claim 1, wherein the fan support structure is integral with the molded seat support.

Clause 3. The sub-assembly of claim 2, wherein the fan support structure is at an inset position relative to a B-surface of the sub-assembly.

Clause 4. The sub-assembly of claim 3, wherein the fan support structure is located within a fan cavity of the molded seat support, wherein the B-surface of the molded seat support is shaped to define the fan cavity.

Clause 5. The sub-assembly of any preceding claim, wherein the molded seat support comprises a foam material.

Clause 6. The sub-assembly of claim 5, wherein the foam material comprises expanded polypropylene.

Clause 7. The sub-assembly of any preceding claim, wherein the molded seat support comprises overmolded reinforcement, and wherein the reinforcement secures the fan support structure.

Clause 8. The sub-assembly of any preceding claim, comprising a first air distribution manifold proximal to the fan support structure, and a second air distribution manifold fluidly connected in series to the first air distribution manifold via an air passage arrangement.

Clause 9. The sub-assembly of claim 8, wherein the air passage arrangement comprises a plurality of air passages leading to the second air distribution manifold.

Clause 10. The sub-assembly of claim 9, wherein the second air distribution manifold connects the plurality of air passages to a greater plurality of smaller air passages aligned with a perforated seat trim.

Clause 11. The sub-assembly of any preceding claim, comprising a fan secured to the fan support structure.

Clause 12. A seat base comprising the sub-assembly of any preceding claim.

Clause 13. The seat base of clause 12, configured as a vehicle bench seat base.

Clause 14. A vehicle seat comprising the sub-assembly of any one of clauses 1 to 11 or the seat base of clause 12 or 13.

Clause 15. A vehicle comprising the sub-assembly of any one of clauses 1 to 11, or the seat base of clause 12 or 13, or the vehicle seat of clause 14.

Clause 16. A method of making a sub-assembly for a vehicle seat, the method comprising: providing a fan support structure; and molding a seat support so that material of the seat support overmolds the fan support structure.

Clause 17. The method of claim 16, comprising: securing the fan support structure to reinforcement, wherein molding the seat support comprises overmolding the reinforcement and fan support structure.

Claims

CLAIMS1. A sub-assembly for a vehicle seat, the sub-assembly comprising: a molded seat support; a fan support structure, wherein the fan support structure is overmolded into the molded seat support; and a first air distribution manifold proximal to the fan support structure, and a second air distribution manifold fluidly connected in series to the first air distribution manifold via an air passage arrangement.
2. The sub-assembly of claim 1, wherein the fan support structure is integral with the molded seat support.
3. The sub-assembly of claim 2, wherein the fan support structure is at an inset position relative to a B-surface of the sub-assembly.
4. The sub-assembly of claim 3, wherein the fan support structure is located within a fan cavity of the molded seat support, wherein the B-surface of the molded seat support is shaped to define the fan cavity.
5. The sub-assembly of any preceding claim, wherein the molded seat support comprises a foam material.
6. The sub-assembly of claim 5, wherein the foam material comprises expanded polypropylene.
7. The sub-assembly of any preceding claim, wherein the molded seat support comprises overmolded reinforcement, and wherein the reinforcement secures the fan support structure.
8. The sub-assembly of any preceding claim, wherein the air passage arrangement comprises a plurality of air passages leading to the second air distribution manifold.
9. The sub-assembly of claim 9, wherein the second air distribution manifold connects the plurality of air passages to a greater plurality of smaller air passages aligned with a perforated seat trim.
10. The sub-assembly of any preceding claim, comprising a fan secured to the fan support structure.
11. A seat base comprising the sub-assembly of any preceding claim.
12. The seat base of claim 11, configured as a vehicle bench seat base.
13. A vehicle seat comprising the sub-assembly of any one of claims 1 to 10 or the seat base of claim 11 or 12.
14. A vehicle comprising the sub-assembly of any one of claims 1 to 10, or the seat base of claim 11 or 12, or the vehicle seat of claim 13.
15. A method of making a sub-assembly for a vehicle seat, the method comprising: providing a fan support structure; molding a seat support so that material of the seat support overmolds the fan support structure; and providing a first air distribution manifold proximal to the fan support structure, and a second air distribution manifold fluidly connected in series to the first air distribution manifold via an air passage arrangement.
16. The method of claim 15, comprising: securing the fan support structure to reinforcement, wherein molding the seat support comprises overmolding the reinforcement and fan support structure.