Seat assembly having an air plenum member

Abstract

A seat assembly includes a seat cushion having a recess, and an air plenum member disposed in the recess for routing air through at least a portion of the seat cushion. The air plenum member has a first portion that comprises foam, and a second portion that is attached to the first portion and that comprises a polyolefin sheet. The seat assembly further includes a cover layer covering the air plenum member and the seat cushion.

1 . A seat assembly comprising: 
 a seat cushion having a recess;    an air plenum member disposed in the recess for routing air through at least a portion of the seat cushion, the air plenum member including a first portion that comprises foam, and a second portion that is attached to the first portion and that comprises a polyolefin sheet; and    a cover layer covering the air plenum member and the seat cushion.    
     
     
         2 . The seat assembly of  claim 1  wherein the polyolefin sheet comprises polypropylene.  
     
     
         3 . The seat assembly of  claim 1  wherein the polyolefin sheet comprises polypropylene fibers.  
     
     
         4 . The seat assembly of  claim 1  wherein the polyolefin sheet comprises a polypropylene film.  
     
     
         5 . The seat assembly of  claim 1  wherein the first portion is a bottom portion of the air plenum member, and the second portion is a top portion of the air plenum member.  
     
     
         6 . The seat assembly of  claim 1  wherein the second portion is heat staked to the first portion such that a seal is formed along at least a portion of a junction of the first and second portions.  
     
     
         7 . The seat assembly of  claim 1  wherein the second portion has multiple apertures for passing air through the second portion.  
     
     
         8 . The seat assembly of  claim 1  wherein the foam of the first portion is air-impermeable.  
     
     
         9 . A seat assembly comprising: 
 a seat cushion having a recess;    an air plenum member disposed in the recess for routing air through at least a portion of the seat cushion, the air plenum member including a first portion that comprises foam, and a second portion that comprises a plastic sheet heat staked to the first portion such that the second portion is fused with the first portion, thereby forming a seal along at least a portion of a junction of the first and second portions; and    a cover layer covering the air plenum member and the seat cushion.    
     
     
         10 . The seat assembly of  claim 9  wherein the second portion comprises polypropylene.  
     
     
         11 . The seat assembly of  claim 9  wherein the second portion comprises polypropylene fibers.  
     
     
         12 . The seat assembly of  claim 9  wherein the second portion comprises a polypropylene film.  
     
     
         13 . The seat assembly of  claim 9  wherein the second portion comprises polyethylene.  
     
     
         14 . The seat assembly of  claim 9  wherein the first portion is a bottom portion of the air plenum member, and the second portion is a top portion of the air plenum member.  
     
     
         15 . A method of making a seat assembly, the method comprising: 
 positioning together first and second portions of an air plenum member, the first portion comprising foam and the second portion comprising a plastic sheet;    heat bonding the second portion to the first portion such that a seal is formed along at least a portion of a junction of the first and second portions;    positioning the air plenum member in a recess of a seat cushion; and    positioning a cover layer over the air plenum member and the seat cushion;    wherein the air plenum member is configured to route air through at least a portion of the seat cushion.    
     
     
         16 . The method of  claim 15  wherein the second portion comprises polypropylene.  
     
     
         17 . The method of  claim 15  wherein the second portion comprises polypropylene fibers.  
     
     
         18 . The seat assembly of  claim 15  wherein the second portion comprises a polypropylene film.  
     
     
         19 . The method of  claim 15  wherein the second portion comprises polyethylene.  
     
     
         20 . The method of  claim 15  wherein the first portion is a bottom portion of the air plenum member, and the second portion is a top portion of the air plenum member.