U.S. patent application number 11/263642 was filed with the patent office on 2006-07-20 for molded layer for a seat insert.
This patent application is currently assigned to W.E.T. Automotive Systems AG. Invention is credited to Corina Alionte, Goran Bajic, Shaun Howick, Syed Iqbal, Ed Marlovits, Peter Nagele, Madalina Onica, Zoran Panic, Angelika Riedi, Jody Van Horne.
Application Number | 20060158011 11/263642 |
Document ID | / |
Family ID | 36590687 |
Filed Date | 2006-07-20 |
United States Patent
Application |
20060158011 |
Kind Code |
A1 |
Marlovits; Ed ; et
al. |
July 20, 2006 |
Molded layer for a seat insert
Abstract
The present invention includes a ventilated seat for a vehicle
having at least one ventilated component. The ventilated component
has a cushion, a trim surface and an insert located beneath the
trim surface of each ventilated component. The insert includes at
least two layers, at least one of which is a molded layer. The at
least two layer define an open space, that may include a spacer.
The seat also includes an air mover assembly that is in fluid
communication with the open space and servers to blow air to or
draw air from the insert.
Inventors: |
Marlovits; Ed; (Windsor,
CA) ; Onica; Madalina; (Windsor, CA) ; Iqbal;
Syed; (Windsor, CA) ; Van Horne; Jody;
(Windsor, CA) ; Panic; Zoran; (Windsor, CA)
; Alionte; Corina; (Windsor, CA) ; Nagele;
Peter; (Windsor, CA) ; Riedi; Angelika;
(Windsor, CA) ; Bajic; Goran; (Windsor, CA)
; Howick; Shaun; (Windsor, CA) |
Correspondence
Address: |
DOBRUSIN & THENNISCH PC
29 W LAWRENCE ST
SUITE 210
PONTIAC
MI
48326
US
|
Assignee: |
W.E.T. Automotive Systems
AG
|
Family ID: |
36590687 |
Appl. No.: |
11/263642 |
Filed: |
October 31, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60624254 |
Nov 2, 2004 |
|
|
|
Current U.S.
Class: |
297/180.1 |
Current CPC
Class: |
A47C 7/02 20130101; A47C
7/74 20130101; B60N 2/5635 20130101 |
Class at
Publication: |
297/180.1 |
International
Class: |
A47C 31/00 20060101
A47C031/00 |
Claims
1. A ventilated seat for a vehicle, comprising: a vehicle seat
having at least one ventilated component having a cushion and a
trim surface; an insert located beneath the trim surface of each
ventilated component, the insert includes a first layer and a
second layer, at least one of which is a molded layer, defining an
open space; an air mover assembly in fluid communication with the
open space.
2. The seat of claim 1 wherein the molded layer is a fluid barrier
layer.
3. The seat of claim 1 wherein the molded layer is a flow control
layer.
4. The seat of claim 1 further comprising a spacer material located
between the first and second layers.
5. The seat of claim 1 wherein the insert further comprises and
extension.
6. The seat of claim 1 further comprising a duct that extends
through the cushion.
7. The seat of claim 6 wherein a bellows provides fluid
communication between the air mover assembly and the insert.
8. The seat of claim 7 further comprising an air impermeable trim
surface.
9. The seat of claim 7 further comprising an air permeable trim
surface.
10. The seat of claim 9 wherein the air mover assembly comprises a
plurality of fans.
11. The seat of claim 10 further comprising at least one
thermoelectric device.
12. The seat of claim 11 further comprising a heater located
between the trim surface and the insert.
13. The seat of claim 1 wherein the insert is attached to the
cushion.
14. The seat of claim 1 wherein the insert is attached to the trim
surface.
15. The seat of claim 1 wherein the insert comprises an edge sealed
bag.
16. The seat of claim 1 wherein the molded layer is injection
molded.
17. The seat of claim 1 wherein the molded layer is
thermoformed.
18. A ventilated seat, comprising: a perforated seating surface for
supporting a seat occupant; a mixing region, at least partially
defined by a molded layer, disposed under the seating surface for
combining ambient air with a cooled fluid; an air mover assembly
for providing ambient air to the mixing region, for providing
temperature conditioned air to the mixing region, for removing the
combined ambient air and temperature conditioned air, and
combinations thereof; and a temperature conditioning device for at
least adjusting the temperature of the air from ambient.
19. The seat of any of the preceding claims, wherein the
temperature conditioning device is a thermoelectric device.
20. The seat of any of the preceding claims, wherein the mixing
region is at least partially disposed in the spacer.
Description
CLAIM OF PRIORITY
[0001] The present application claims the benefit of U.S.
application 60/624,254, filed on Nov. 2, 2004 and is incorporated
by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to improved trim bag insert
for use in heating, cooling, ventilation and dehumidification of
seats, and more particularly, of vehicle seats.
BACKGROUND OF THE INVENTION
[0003] For many years the transportation industry has been
concerned with designing seats for automotive vehicles that provide
added comfort to occupants in the seats. Various innovations in
providing seating comfort are discussed in U.S. Pat. Nos.
6,893,086; 6,872,882; 6,869,139; 6,857,697; 6,828,528; 6,676,207;
6,619,736; 6,439,658; 6,164,719; 6,064,037; 5,921,314; 6,064,037;
5,921,314; 5,403,065; 6,048,024 and 6,003,950, all of which are
expressly incorporated herein by reference. In addition, other
innovations in providing seating comfort are discussed in U.S.
Publication No. 2002/0096931, filed Jan. 5, 2001, titled
"Ventilated Seat"; U.S. Pat. No. 6,629,724, issued Oct. 7, 2003,
titled "Portable Ventilated Seat"; U.S. Patent Publication
2004/0070236, filed Oct. 8, 2003, titled "Automotive Vehicle
Seating Comfort System", U.S. Patent Publication 2005/0067862,
filed: Apr. 12, 2004, titled "Ventilated Seat"; and U.S. Patent
Publication 2005/0066505, filed: Apr. 12, 2004, titled "A Method
For Ventilating A Seat", each of which are expressly incorporated
herein by reference for all purposes.
[0004] In the interest of continuing such innovation, the present
invention provides an improved insert and system for a seat, which
are preferably suitable for employment within or as part of an
automotive vehicle seat and which assist in providing comfort
control to an occupant in the seat.
SUMMARY OF THE INVENTION
[0005] The present invention includes a ventilated seat for a
vehicle having at least one ventilated component. The ventilated
component has a cushion, a trim surface and an insert located
beneath the trim surface of each ventilated component. The insert
includes at least two layers, at least one of which is a molded
layer. The at least two layer define an open space, that may
include a spacer. The seat also includes an air mover assembly that
is in fluid communication with the open space and servers to blow
air to or draw air from the insert.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] In the drawings:
[0007] FIG. 1 shows an exploded view of one embodiment of an insert
that may include a molded layer according to the present
invention.
[0008] FIG. 2 shows an insert that may include a thermoformed layer
according to the present invention.
[0009] FIG. 3 shows a molded layer according to one embodiment of
the present invention.
DETAILED DESCRIPTION
[0010] Transportation vehicle seats may comprise at least one
ventilated component such as a seat component, a backrest
component, a bolster, an armrest, a headrest or the like. Each
ventilated component may provide heating, cooling, ventilation or
combinations thereof to the occupant, and comprises a seat cushion
and a trim surface to cover the seat, as well as a thermal change
insert. The present invention relates to a molded layer for
incorporation into a thermal change insert.
[0011] The thermal change insert will include at least one layer,
but preferably includes multiple (e.g. three) layers and each of
the layers may be a monolayer or a plurality of layers (e.g. a
laminate). The plurality of layers need not be attached to each
other but preferably are. More preferably, the layers are attached
to each other at least at their edges to form an edge-sealed bag,
although this is not necessarily the case. The layers of the insert
are typically co-extensive, although partial layers that are not
co-extensive with the other layers or the insert may be suitable in
certain instances.
[0012] The insert and the layers that make up the insert have a
seat portion and, optionally, an extension. The seat portion
generally is the area of the insert that will provide heating,
cooling, ventilation or combinations thereof to the area of the
seat used by the occupant, whether the insert is located in the
seat component, in the armrest component or elsewhere. The
extension permits components of a system that includes the insert
to be remote from the seat portion. This allows the components to
be conveniently located so that they do not interfere with the
comfort of the seat. For example, the extension permits fluid
movers and/or thermoelectric device to be located underneath the
cushion where they will not be noticeable to the occupant,
underneath being relative to the occupant side of the insert. While
typically the extension is located at the back of the seat, it may
be located on either side, in the front of the seat, on a corner or
absent altogether. Multiple extensions may also be used on an
insert.
[0013] Typically, the insert is supported by a cushion. The cushion
may include one or more ducts that extend partially or completely
through the cushion, or the cushions may be free of ducts that
extend through the cushion. A preferred cushion is a molded plastic
foam, which is preferably free of a molded or cut-out fluid
distribution ducting network, but may be adapted with a trench or
opening for passing the extension from one side of the cushion to
the another side (e.g. from top to bottom). The cushion may in turn
be supported by a seat frame. Multiple inserts may be used on a
single seat or backrest cushion, where inserts may accomplish the
same or different functions (e.g. one insert may only cool, while
another insert may both heat and cool).
[0014] In an alternative to the extension of the insert, a bellows
or other conduit may be used to provide connection between the
insert and the other components of the system. The bellows provides
similar functionality as the extension, e.g. to permit components
of the system to be conveniently located remotely from the occupant
contacts areas of the seat. The bellows or conduits may be located
in a duct extending through the cushion that supporting the insert.
Thus, the bellows may be located underneath the seat portion of the
insert or connected to an edge of the insert. As with the
extension, two or more bellows may be used in conjunction with each
insert, each in a separate duct through the cushion or the ducts
sharing one or more bellows. The bellows are preferably connected
to the insert in a relatively air tight manner, such as through a
snap-fit attachment mechanism.
[0015] The molded layer of the insert may serve several different
purposes within the insert. The molded layer may be used a flow
control layer that selectively permits air flow across the layer
through one or more through holes. Also, the molded layer may be
used as a fluid barrier that is substantially impermeable or
impermeable to air or other temperature conditioned fluid utilized
in the system. Further, different molded layers within the insert
may serve different purposes. Indeed, a single molded layer may
serve multiple purposes: acting as a fluid barrier in the seat
portion and a flow control layer in the extension.
[0016] One suitable embodiment of the insert is shown in FIG. 1.
The thermal change insert 10 comprises a seat portion 12 and an
extension 14. Layers 16, 20 and 24 are flow control layers, while
optional layer 30 may be used as fluid barrier layer. The layers
may include ports 26, 28 in the extension to provide access to the
interior of the insert (e.g. for air movement). The layers may also
include flow holes 32 to provide air movement through the insert or
from the insert through the trim surface.
[0017] Another suitable embodiment of the insert is shown in FIG.
2. The insert 50 comprises a thermoformed top layer 52 or a
thermoformed bottom layer 54 where the seat portion 56 and the
extension 58 are formed such that collapse of the extension during
installation or use is reduced because the extension is preformed
to its installed shape.
[0018] The molded layer may be a relatively planar layer without
structures on the layer, like a film or laminate, with or without
ports, flow holes or other through holes. In another embodiment,
the molded layer may include structures that interrupt an otherwise
planar layer. Such structures may include air flow conduits, walls
at the edge of the layer, walls that segment the interior of the
layer, the like and combinations thereof. In one embodiment, one or
more conduits are formed on conduits are formed on an otherwise
planar layer. In another embodiment, the edge walls may be used to
create a molded layer with depth to serve as a receptacle for other
layers of the insert (e.g. a spacer). The interior walls may be
used to create air flow conduits within the insert. For example,
interior walls may be used in combination with edge walls to create
conduits in the seat portion of the insert.
[0019] Additionally, other structures may be used on the molded
layer to provide structural integrity to the insert. For example,
protrusions, buttons, bumps, mounds, wall segments or the like may
be used to support other layers of the insert while also allowing
air flow through the insert to be maintained. In one use, the
extension may be bent or folded when assembled with the other
components of the seat or otherwise deformed during use. Such
bending, folding or deformation may cause the air flow through the
insert to be reduced or eliminated due to the collapse of the
layers of the insert. By using protrusions or the like in the
extension the collapse of the extension by reduced or eliminated.
In another embodiment, protrusions or the like are utilized in the
seat portion to reduce or prevent collapse of the insert due to the
weight of the occupant or help locate the spacer material within
the insert. In one embodiment, the structures are located on the
same side as the walls that are optionally use to segment the
layer. In another embodiment, the structures are located on the
side opposite from the walls. These may be used to provide
integrity, especially for flexible portions of the layer such as
the extension. A series of ridges may be used to prevent over
bending of the extension.
[0020] One embodiment of a molded layer is shown in FIG. 3. The
molded layer 100 includes a seat portion 102 and an extension 104.
The seat portion is generally planar and includes edges walls 106
and 108. The seat portion and the extension may also include
conduits 110 to facilitate air movement to or from the seat surface
or through the insert. The area between the conduits may be filled
with a space material (not shown), as discussed herein. The
extension may also include structures 112 to help provide
structural integrity to the extension when it is bent or
folded.
[0021] The structures of the molded layer may include zigzags,
S-shapes, straight lines, concentric circles, ovals, protrusions of
circular, rectangular, diamond or other shape, or combinations
thereof. The structures may be placed in a regular pattern or
irregularly on the planar portion of the molded layer. The
structures may be placed evenly or unevenly throughout the molded
layer and/or limited to a particular area of the layer (e.g. the
extension).
[0022] Preferably, the molded layer is manufactured in a single
process step, such that the layer and the included structures are
made in one process step. Such a single reduces the complexing of
the insert manufacturing process. However, this is not necessarily
the case and structures may be made before, during or after the
rest of the layer and the components of the layer subsequently
attached together. For example, an adhesive or a welding technique
(e.g. thermal, ultrasonic or RF) may be used to attach the
components of the molded layer together.
[0023] In one preferred embodiment, the molded layer is attached to
another layer of the insert with a fluid tight seal around some or
the entire perimeter of the insert. The seal may be made by bonding
the layers together after or during manufacture of one or both of
the layers, such as by using an adhesive, thermal welding,
ultrasonic welding, RF welding or the like or combinations thereof.
In one preferred embodiment, the molded layer is attached to a
film. In one preferred embodiment, one layer is extruded while the
other layer is molded. In another embodiment, both layers are
molded and attached during curing to achieve the seal between the
layers. Alternately, the two layers may be co-molded.
[0024] The molded layer may be manufactured according to any known
molding techniques including injection molding, two part molding,
vacuum molding, thermoforming, reaction injection molding, etc. In
one embodiment, the molded layer is injection molded thus providing
a molded layer via a cost effective method. The method is
particularly preferred for inserts that do not require an
extension. Collapse of the extension from bending or deformation is
reduced or eliminated as a source of performance degradation.
[0025] In another embodiment, the molded layer is thermoformed,
which provides greater ability to define the shape of molded layer.
For example, for an insert that includes an extension,
thermoforming provides an extension that is preformed to the
assembled shape of the insert, thus reducing or eliminating the
need to bend or deform the molded layer during installation of the
insert into the seat. Thus, through thermoforming collapse of the
extension can be reduced or eliminated.
[0026] Preferred materials used in the molded layer may include any
suitable material. Generally, the material should be air
impermeable while being sufficiently durable to withstand use in an
automobile seat. In addition, the material should provide
dimensional stability to the layer without excessive weight.
Consequently materials that may be made thinner are preferred. In
one aspect, a foamed material is used, while in another aspect an
unfoamed material is used. Of course, combinations of materials may
be used such as in a laminate. Unformed materials are preferred for
thermoforming application. Suitable thicknesses range from a few
mils for films to several millimeters. One preferred range is
between about 2 and about 7 millimeters, while another preferred
range is about 1 mil to about 10 mils.
[0027] Some suitable materials for the molded layer include
acrylonitrile butadiene styrene (ABS), polycarbonates (PC), PC/ABS
blends, flexible or rigid polyvinylchloride, flexible or rigid
thermoplastic polyurethane, polybutylene terephthalate, polyamide,
polyethylene, polypropylene, combinations thereof and the like.
[0028] The insert may include a spacer, which may be located
between two layers of the insert. The spacer may be any structure,
material or combination of materials and/or structures that permits
fluid flow through the material while also providing a measure of
support for a seat occupant. The spacers should not collapse under
the weight of a seat occupant and maintain the fluid communication
through the spacer. As one example, the spacer may include rubber,
foam plastic or the like. In one aspect, the spacer may include a
reticulated foam.
[0029] The spacer may include a plurality of members or fibers that
are preferably spaced apart from each other to provide open space
therebetween while still being close enough together to provide
cushion and support. One preferred spacer is formed of polymeric
(e.g., polyester) strand material that is interwoven to provide
opposing honeycomb structures (e.g., fabric panels), which are
interconnected by several additional polymeric strand materials to
provide open space between the structures while still providing
cushion and support. As an example, one preferred material is sold
under the tradename 3MESH.RTM. and is commercially available from
Muller Textil GmbH, Germany or Muller Textiles, Inc., R.I.,
USA.
[0030] Another preferred spacer is formed of a polymeric material
in a helix held between two sheets of material. Preferably, the
helix is oblong in order to provide increased area on the helix for
attachment of the helix to the sheets of material. The helix may be
tightly wound such that adjacent courses of the helix touch or
loosely wound such that there is no touching of adjacent courses of
the helix. Typically, multiple helices are placed adjacent
(abutting or otherwise) to one another in order to form a spacer.
Exemplary helical material is discussed in international
applications PCT/DE04/000540 and PCT/DE04/000541, both files Mar.
17, 2004, both of which are incorporated by references.
[0031] Exemplary optional layers for the insert include those
having a heater. Various different types of heaters are suitable
for incorporation into a car seat and it is contemplated that any
of such heaters may be incorporated into the inserts of the present
invention. Such heaters typically incorporate flexible, electrical
heating elements that are preferably thin, flat, non-obtrusive or a
combination thereof. As examples, a lay-wire heater, a carbon fiber
heater, a positive thermal coefficient (PTC) heater, a
thermoelectric heater or the like, which are typically supported
with a backing (e.g., a cloth or fabric type backing) may be used
within the insert. In a preferred embodiment, the heater is a
carbon fiber type heater with a backing (e.g., a non-woven layer).
One exemplary preferred heater is sold under the tradename
CARBOTEX.RTM. and commercially available from W.E.T. Automotive
Systems, Inc. in Germany and/or FTG Fraser-Technik GmbH. An example
of such a heater is disclosed in U.S. Pat. No. 6,064,037, issued
May 16, 2000, herein expressly incorporated by reference for all
purposes. A combination heater/cooler in the form of a flexible
sheet of TEDs may be a suitable optional layer. Flexible sheet TEDs
include those discussed in U.S. Pat. No. 6,700,052, which is
incorporated by reference. Other coolers may includes those
described in U.S. provisional application 60/505,806, filed Sep.
25, 2003, which is incorporated by reference.
[0032] Suitable optional trim surfaces include seat covers that are
part of the insert or separate from the insert, but generally
separate the insert from the seat occupant. The trim surface may be
any suitable material, including but not limited to at least one
synthetic material, natural material (e.g., wool, leather or
otherwise), or combination thereof. In one embodiment the trim
surface includes perforations over at least a portion of the
seating surface through which air or other fluid may pass. In
another embodiment the cover is substantially free of perforations.
For example, perforated or non-perforated leather may be used to
separate the seat occupant from the insert, while a fleece material
may be used as part of the insert to increase moisture wicking or
otherwise provide a protective layer.
[0033] The insert of the present invention may be a separate unit
that is assembled in a space between a seat cushion and the trim
surface, integrally formed in the seat cushion, integrally formed
in the trim surface, or any combination thereof.
[0034] One or more adhesive layers may be used to assist in the
assembly of the inserts. The adhesive layers are preferably formed
of a hot melt adhesive although this is not necessarily required.
The adhesive may be provided as a web or otherwise and may be
continuous or non continuous (e.g., may be applied in drops, dabs
or the like). The adhesive sub-layers may include polyamides,
polyesters, elastomers, urethanes, olefin polymers or a combination
thereof. Moreover, the adhesives may be formulated as desired for
particular processing parameters or conditions. Preferably, the
adhesive sub-layers are substantially free of anti-blocking
solutions, blowing additives, process contaminants or the like
which might interfere with adhesive performance. As an example, one
suitable hot melt adhesive is commercially available as a non-woven
web under the tradename SPUNFAB.RTM. from Spunfab, Ltd. 175 Muffin
Lane, Cuyahoga Falls, Ohio 44223. Other techniques instead of or in
addition to adhesive may be used, such a thermal, ultrasonic, or RF
welding.
[0035] In addition to the insert, the present invention includes a
system that provides heating, cooling, ventilation or combinations
thereof. The system has an insert and one or more different
components that facilitate the operation of the insert. For
example, the system may include an air mover assembly, a
temperature conditioning device, one or more attachment components,
one or more valves, one or more sensors and/or one or more
controls. In addition, one or more conduits may be used to provide
fluid communication between components of the system such as
between the fan and the insert or between the insert and the
temperature conditioning device.
[0036] The air mover assembly provides motive force to move air
(whether conditioned, ambient, pushed, pulled and combinations
thereof) through the insert. The assembly may be used to push air
to the insert or pull air from the insert. The assembly may also be
used to both push and pull air. For example, an assembly with a fan
having at least two sets of fan blades (e.g. with vanes that are
opposite in direction) that share a common axis and form a binary
fan that is able to both push and pull air may be used. Multiple
fans may also be used in the assembly. The assembly may also
include an annular inlet, although assemblies that are free of
annular inlets are also contemplated. Included in the definition of
fan are impellers (including bidirectional impellers), blowers, or
the like. The fan also refers to devices that provide motive force
to move other fluids (e.g. liquids) through the insert. The fan may
provide a steady fluid flow, a pulsating fluid flow, an oscillating
fluid flow, or the like.
[0037] The temperature conditioning device may be any device that
heats or cools fluid. The device may be a combination of devices
where one component provides heating and another component provides
cooling. Preferably, one device or system provides both heating and
cooling. The device may be an external device such as the HVAC
system in the building or vehicle where the seat is located or an
internal device meaning that the device is not connected (other
than to a power supply) to the building or vehicle where the seat
is located. In addition to providing temperature conditioning, the
temperature conditioning device may also dehumidify the fluid (e.g.
air).
[0038] Preferably, the temperature conditioning device is a self
contained or solid state device that both cools and heats air. The
most preferred device is a peltier or thermoelectric device (TED).
TEDs are commercially available devices that provide solid state
heating and cooling by passing electricity through the device. TEDs
include a waste side and an active side, which are relative
designations depending whether warm or cool temperature conditioned
air is desired. Any supplier of TEDs would be able to provide
suitable devices for use in the present invention. The invention.
The TED may be combined with any useful heat dissipation device;
e.g. heat sinks, heat exchangers, fans, heat pipes or the like. A
refrigeration absorption system may also be used as a temperature
conditioning device.
[0039] The attachment component is a frame member that preferably
defines a location for the attachment of the air mover assembly,
temperature conditioning device, a conduit, a bellows or other
component to the insert. It is contemplated that the frame member
may be in a variety of configurations (e.g., annular, rectangular,
square, polygonal or otherwise) and may be formed of a variety of
preferably rigid or semi-rigid materials (e.g. metal, plastic or
the like). In some aspects, the attachment component also helps
define a port. In one preferred embodiment, the attachment
component cooperates with structures and/or materials (e.g. snap
fit fasteners) on the fan, the temperature conditioning device or
other components to connect the device or component to the
attachment component.
[0040] One or more valves may be used to redirect fluid flow
through the system to make use of unused energy (i.e. the fluid is
hotter than ambient) or energy capacity (i.e. the fluid is colder
than ambient) in the fluid. For example, the valves may be used to
vent fluid to ambient to dispose of un-needed energy stored in the
fluid. The valves may also be used to redirect fluid to components
of the system (e.g. the temperature conditioning device) to either
warm or cool such components. In addition, a valve may be used to
optionally recirculate fluid within system to create a closed or
partially closed system.
[0041] A variety of sensors may be included in the system such as
temperature sensors, humidity sensors, current sensors, occupant
detection sensor, weight sensors or the like. Sensors may be placed
throughout the system. For example, temperature sensors may be
place within the spacer, between spacers, between the spacer and
the molded layer or other optional layer (e.g. reticulated foam or
seat cover), near the temperature conditioning device, near the
fan, and combinations thereof.
[0042] One or more controllers may be used to receive inputs from
the sensors or a used control device, to issue instructions to the
fan and temperature conditioning device, and/or to otherwise
coordinate the operation of the system.
[0043] The insert with a molded layer may be incorporated into a
larger seat system for providing heating, cooling, ventilation,
etc. to a vehicle occupant by way of the occupant's seat. Several
such systems are known and the present molded layer insert may be
used as an additional component of such systems or they may be used
as a substitute for one or more of the components of such
systems.
[0044] For example, the molded layer insert may be added on to the
seats of U.S. Pat. Nos. 6,786,541; 6,629,724; 6,840,576, 6,869,140,
and related applications and patents or to the seats of U.S. Patent
Publication 2004-0189061. In addition, the molded layer insert may
used in combination with the seats of U.S. Pat. Nos. 6,893,086;
6,869,139; 6,857,697; 6,676,207; 6,619,736; 6,604,426; 6,439,658;
6,164,719; 5,921,314, and related applications and patents, or U.S.
Patent Publications 2005-0173950; 2005-0161986; 2005-0140189;
2005-0127723; 2005-0093347; 2005-0085968; 2005-0067862;
2005-0067401; 2005-0066505; 2004-0169028, and related applications.
All patents and publications are hereby incorporated by
reference.
[0045] The seat system comprises at least one of a seat or
backrest, armrest, bolster or like component, having a cushion, a
thermal change insert and a trim surface. In one embodiment, an air
mover assembly is utilized to provide temperature conditioned air
to the seat, which may be used convectively or conductively heat or
cool the seat or occupant.
[0046] In one embodiment, temperature conditioned air may be blown
across the occupant through a permeable trim surface from the seat
cushion thus providing convective heating or cooling to the seat
and occupant. As shown in U.S. Pat. Nos. 6,869,139 and 6,857,697,
the cushion may contain a passageway through the cushion for
circulating temperature conditioned air to the seat surface through
the insert. A variety of other optional features disclosed in these
patents may be included in the seat systems of the present
invention, such as sub-passageways, deflectors, air-impermeable
linings or coating or the like. For example, an insert with
through-holes may be placed over the sub-passageways to moderate or
direct the air blown on the occupant. A molded layer may be used as
a flow control layer or as a fluid barrier layer. A certain amount
of conductive cooling may also be achieved through the use of this
system.
[0047] In another embodiment, conductive heating or cooling may be
provided to the occupant occupant by providing temperature
conditioned air to the insert such that the air is not blown across
the occupant. For example, through the use of an air impermeable
trim surface, temperature conditioned air is circulated to an
molded layer insert having an open space is located underneath the
impermeable trim surface, with air blown or drawn into the insert
for the purpose of conductively heating or cooling the insert and
thus the occupant.
[0048] In another embodiment, conductive and convective heating or
cooling may be provided to the occupant. The temperature
conditioned air may be combined with ambient air drawn across the
occupant and into the seat. Here, ambient air is drawn through the
trim surface and into a mixing region underneath the trim surface
where the ambient air is combined with the temperature conditioned
air. The mixed air is then circulated away from the seat either to
be exhausted or to be recirculated back to the evaporator and/or
the mixing region. The ambient air provides convective cooling (or
heating), while the temperature conditioned air provided conductive
cooling or heating. A plurality of air movers may be used to draw
ambient air into the mixing region and to provide temperature
conditioned to the mixing region, whether by blowing or drawing. In
one embodiment, the mixing region is an open space contained in a
molded layer insert. Examples of seats comprising mixing regions
include U.S. Patent Publication 2005-0067862 and 2005-0066505.
[0049] Temperature conditioned air may be generated through
connection to the HVAC system of the vehicle, through a
self-contained system or through a combination of systems.
Self-contained system included those that are not connected to the
HVAC system of the vehicle and may include thermoelectric devices,
absorption refrigeration systems or components, heating elements,
and combinations thereof.
[0050] In addition, the molded layer insert may be combined with
other systems or devices to provide temperature regulation to an
occupant. For example, heating elements may be utilized to provide
heating to the vehicle seat. In one embodiment, the heating element
is provided between the trim surface and the seat cushion or insert
of the seat. In another embodiment, the heating element is
incorporated into the insert, whether incorporated on the molded
layer or not. While not preferred but still acceptable,
thermoelectric devices may be used to provide heating to the
vehicle seat, particularly if the thermoelectric device is
otherwise utilized in the vehicle and generates waste energy that
may be recaptured for use in temperature control of the seat.
[0051] The present invention also relates to methods of heating,
cooling and ventilating a vehicle seat. The methods comprise
circulating temperature conditioned air through a system that
comprises an insert having at least one molded layer.
[0052] It will be further appreciated that functions or structures
of a plurality of components or steps may be combined into a single
component or step, or the functions or structures of one-step or
component may be split among plural steps or components. The
present invention contemplates all of these combinations. Unless
stated otherwise, dimensions and geometries of the various
structures depicted herein are not intended to be restrictive of
the invention, and other dimensions or geometries are possible.
Plural structural components or steps can be provided by a single
integrated structure or step. Alternatively, a single integrated
structure or step might be divided into separate plural components
or steps. In addition, while a feature of the present invention may
have been described in the context of only one of the illustrated
embodiments, such feature may be combined with one or more other
features of other embodiments, for any given application. It will
also be appreciated from the above that the fabrication of the
unique structures herein and the operation thereof also constitute
methods in accordance with the present invention.
[0053] The explanations and illustrations presented herein are
intended to acquaint others skilled in the art with the invention,
its principles, and its practical application. Those skilled in the
art may adapt and apply the invention in its numerous forms, as may
be best suited to the requirements of a particular use.
Accordingly, the specific embodiments of the present invention as
set forth are not intended as being exhaustive or limiting of the
invention. The scope of the invention should, therefore, be
determined not with reference to the above description, but should
instead be determined with reference to the appended claims, along
with the full scope of equivalents to which such claims are
entitled. The disclosures of all articles and references, including
patent applications and publications, are incorporated by reference
for all purposes.
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