U.S. patent application number 11/417666 was filed with the patent office on 2006-12-21 for vehicle seat with thermal elements.
Invention is credited to John Terech.
Application Number | 20060284455 11/417666 |
Document ID | / |
Family ID | 36649657 |
Filed Date | 2006-12-21 |
United States Patent
Application |
20060284455 |
Kind Code |
A1 |
Terech; John |
December 21, 2006 |
Vehicle seat with thermal elements
Abstract
A climate controlled seat assembly comprises a seat cushion
having an outer surface with a support portion for supporting an
occupant. A supply passage extends through the seat cushion. A
distribution system comprises at least one distribution passage
configured to distribute air along the support surface of the seat
cushion and the distribution system communicates with the supply
passage. A fluid system is in communication with the supply passage
and is configured to move air between the distribution system and
the supply passage. A seat covering is positioned over the support
portion of the outer surface of the seat cushion. A heat source is
positioned between the seat covering and an inlet to the supply
passage.
Inventors: |
Terech; John; (Brownstown,
MI) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET
FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Family ID: |
36649657 |
Appl. No.: |
11/417666 |
Filed: |
May 3, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11087215 |
Mar 23, 2005 |
|
|
|
11417666 |
May 3, 2006 |
|
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Current U.S.
Class: |
297/180.14 ;
297/180.1; 297/180.13 |
Current CPC
Class: |
B60N 2/5685 20130101;
B60N 2/5692 20130101; B60N 2/5635 20130101 |
Class at
Publication: |
297/180.14 ;
297/180.1; 297/180.13 |
International
Class: |
A47C 7/74 20060101
A47C007/74 |
Claims
1-30. (canceled)
31. A method for thermally conditioning a space adjacent a seat
assembly that includes a seat cushion that defines a support
surface and a seat covering that covers the support surface of the
seat cushion, the method comprising: activating a heating element
positioned within the seat assembly beneath the seat covering;
activating a fluid module that includes a fluid supply device and a
thermoelectric element; and directing heated air from the fluid
module to a space adjacent the seat assembly through a distribution
system formed at least partially in the seat cushion; and after a
period of time, deactivating the heating element.
32. A method as in claim 31, wherein activating a heating element
further comprises activating a resistive heater.
33. A method as in claim 31, further comprising generating heat
within a space generally beneath the seat covering of the seat
assembly.
34. A method as in claim 31, further comprising generating heat
within a space generally beneath the seat covering of the seat
assembly and generally above the seat cushion of the seat
assembly.
35. A method as in claim 31, wherein the step of activating the
fluid module begins after the heating element has been
activated.
36. A method for thermally conditioning a space adjacent a seat
assembly that includes a seat cushion that defines a support
surface and a seat covering that covers the support surface of the
seat cushion, the method comprising: during a heating mode,
activating a heating element positioned within the seat assembly to
heat the space adjacent the seat assembly; and during a cooling
mode, directing cooled air from a fluid module that includes a
thermoelectric unit and a fluid transfer device to the space
adjacent the seat assembly through a distribution system formed at
least partially in the seat cushion to cool the space adjacent the
seat assembly.
37. A method for thermally conditioning a space adjacent a seat
assembly that includes a seat cushion that defines a support
surface and a seat covering that covers the support surface of the
seat cushion, the method comprising: during a first mode, directing
heated air from a fluid module that includes a thermoelectric unit
and a fluid transfer device to the space adjacent the seat assembly
through a distribution system formed at least partially in the seat
cushion to heat the space adjacent the seat assembly; and during a
second mode, activating a heating element positioned within the
seat assembly between the seat covering and the fluid module and
directing heated air from the fluid module through the distribution
system to heat the space adjacent the seat assembly.
Description
PRIORITY INFORMATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/087,215, filed on Mar. 23, 2005, the entire
contents of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to temperature control. More
specifically, this invention relates to temperature control of a
seat.
[0004] 2. Description of the Related Art
[0005] Temperature modified air for environmental control of living
or working space is typically provided to relatively extensive
areas, such as entire buildings, selected offices, or suites of
rooms within a building. In the case of vehicles, such as
automobiles, the entire vehicle is typically cooled or heated as a
unit. There are many situations, however, in which more selective
or restrictive air temperature modification is desirable. For
example, it is often desirable to provide an individualized climate
control for an occupant seat so that substantially instantaneous
heating or cooling can be achieved. For example, an automotive
vehicle exposed to the summer weather, where the vehicle has been
parked in an unshaded area for a long period, can cause the vehicle
seat to be very hot and uncomfortable for the occupant for some
time after entering and using the vehicle, even with normal air
conditioning. Furthermore, even with normal air-conditioning, on a
hot day, the occupant's back and other pressure points may remain
sweaty while seated. In the winter, it is highly desirable to have
the ability to warm the seat of the occupant quickly to facilitate
the occupant's comfort, especially where the normal vehicle heater
is unlikely to warm the vehicle's interior as quickly.
[0006] For such reasons, there have been various types of
individualized temperature control systems for vehicle seats. Such
temperature control systems typically include a distribution system
comprising a combination of channels and passages formed in the
back and/or seat cushions of the seat. A thermal module thermally
conditions the air and delivers the conditioned air to the channels
and passages. The conditioned air flows through the channels and
passages to cool or heat the space adjacent the surface of the
vehicle seat.
[0007] There are, however, drawbacks with existing temperature
control systems for seats. For example, in particularly adverse
conditions, it may take the conditioned air a long period of time
to noticeably heat the seat. In addition, while climate control
systems that use thermal modules provide many advantages, they are
relatively expensive and thus may not be suitable for all
applications.
[0008] Thus, there is a need for an improved temperature control
apparatus for a climate control system for seats.
SUMMARY OF THE INVENTION
[0009] Accordingly, one embodiment of the present invention
involves a climate controlled seat assembly that includes a seat
cushion having an outer surface. A supply passage extends through
the seat cushion. The supply passage comprises an inlet. A
distribution system comprises at least one distribution passage
configured to distribute air along the support surface of the seat
cushion. The distribution system communicates with the supply
passage. A fluid system is connected to the inlet of the supply
passage and is configured to move air between the distribution
system and the supply passage. A seat covering is positioned over
the outer surface of the seat cushion. A heat source is positioned
between the seat covering and the inlet to the supply passage.
[0010] Another embodiment of the present invention comprises a
method for thermally conditioning a space adjacent a seat assembly
that includes a seat cushion that defines a support surface and
seat covering that covers the support surface of the seat cushion.
A fluid supply system is activated. The air from the fluid supply
system is directed to a space adjacent the seat assembly through a
distribution system formed at least partially in the seat cushion.
A heating element that is positioned within the seat assembly
between the seat covering and the fluid supply device is
activated.
[0011] Another embodiment of the present invention comprises a
method of assembling a climate controlled seat assembly. A seat
cushion is provided. The cushion has a support surface for
supporting an occupant and a distribution system for distributing
air along the support surface of the seat cushion. A heating unit
is positioned on the seat cushion. At least a portion of the
heating unit is covered with a seat covering. The seat covering is
coupled to the seat cushion.
[0012] Another embodiment of the present invention comprises a seat
assembly having a seat cushion with a front or top side configured
to support an occupant and a rear or bottom side that generally
opposes the front or top side. Fluid passages extend through from
the rear or bottom side of the seat cushion to the front or top
side of the seat cushion. A fluid delivering device is configured
to move fluid within the fluid passages. The fluid delivering
device is on the rear or bottom side of the seat cushion. A thermal
element is on the front or top side of the seat cushion.
[0013] Another embodiment of the present invention relates to a
seat assembly that comprises a seat cushion having a fluid
distribution system extending therethrough. A fan is configured to
move air within the distribution system. The assembly also
comprises a resistive heater.
[0014] Another embodiment of the present invention relates to an
insert for a seat assembly having a seat cushion and a climate
control system. The insert includes a channel-shaped body that is
configured to be positioned within a corresponding recess formed
the seat cushion. A covering layer is positioned generally over the
body to form distribution passages. A thermal element is coupled to
the covering layer.
[0015] Further features and advantages of the present invention
will become apparent to those of ordinary skill in the art in view
of the detailed description of preferred embodiments which follow,
when considered together with the attached drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of a vehicle seat assembly,
which includes a climate control system that is configured in
accordance with a preferred embodiment of the present
invention;
[0017] FIG. 2 is a side view of the vehicle seat assembly of FIG.
1;
[0018] FIG. 2A is a cross-sectional view of the vehicle seat
assembly of FIG. 1 taken along line 2A-2A of FIG. 2;
[0019] FIG. 2B is a cross-sectional view of the vehicle seat
assembly of FIG. 1 taken along line 2B-2B of FIG. 2;
[0020] FIG. 3 is a front view of the vehicle seat assembly of FIG.
1 with a covering of the seat vehicle assembly removed;
[0021] FIG. 3A is an exploded, side perspective view of a backrest
of the vehicle seat assembly of FIG. 1;
[0022] FIG. 4 is a schematic illustration of the vehicle seat
assembly and climate control system of FIG. 1;
[0023] FIG. 5A is a cross-sectional view of a backrest of a
modified embodiment of a vehicle seat assembly;
[0024] FIG. 5B is a cross-sectional view of a seat of a modified
embodiment of a vehicle seat assembly;
[0025] FIG. 6A is a cross-sectional view of a backrest of another
modified embodiment of a vehicle seat assembly; and
[0026] FIG. 6B is a cross-sectional view of a seat of an additional
modified embodiment of a vehicle seat assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] FIGS. 1 and 2 illustrate an exemplary embodiment of a seat
assembly 30 that comprises a seat portion 32 and a backrest portion
34. The seat assembly 30 includes a climate control system 36,
which will be described in more detail below with reference to
FIGS. 2A-4.
[0028] When an occupant sits in the seat assembly 30, the
occupant's seat is located generally in a seat area 40 of the seat
portion 32 and at least a portion of their legs are supported by a
thigh area 42 of the seat portion 32. In this embodiment, a rear
end 44 of the seat portion 32 is coupled to a bottom end 46 of the
backrest portion 34. When the occupant sits in the seat assembly
30, the occupant's back contacts a front surface 48 of the backrest
portion 34 and the occupant's seat and legs contact a top surface
50 of the seat portion 32. The surfaces 48, 50 cooperate to support
the occupant in a sitting position. The seat assembly 30 can be
configured and sized to accommodate occupants of various size and
weight.
[0029] In the illustrated embodiment, the seat assembly 30 is
similar to a standard automotive seat. However, it should be
appreciated that certain features and aspects of the seat assembly
30 described herein may also be used in a variety of other
applications and environments. For example, certain features and
aspects of the seat assembly 30 may be adapted for use in other
vehicles, such as, for example, an airplane, a boat, or the like.
Further, certain features and aspects of the seat assembly 30 may
also be adapted for use in stationary environments, such as, for
example, a chair, a sofa, a theater seat, a mattress, and an office
seat that is used in a place of business and/or residence. Other
configurations of the seat assembly 30 are also anticipated, such
as, for example, bench seating.
[0030] With continued reference to FIGS. 1 and 2, the backrest
portion 34 has a front side 54, a rear side 56, a top side 58 and a
bottom side 60. The backrest portion 34 includes a pair of sides
57, 59 extending between the top side 58 and bottom side 60 for
providing lateral support to the occupant of the seat assembly 30.
A lumbar region 62 of the backrest portion 34 is generally
positioned between the sides 57, 59 of the backrest portion 34 near
the seat portion 32.
[0031] In a similar manner, the seat portion 32 has a front side
64, a rear side 66, a top side 68 and a bottom side 70. The seat
portion 32 also includes a pair of sides 69, 71, which extending
from the rear side 66 and the front side 64 for providing lateral
support to the occupant of the seat assembly 30. In one embodiment,
the seat assembly 30 is secured to a vehicle by attaching the
bottom side 70 of the seat portion 32 to the floor of a
vehicle.
[0032] FIG. 2A is a cross-sectional view of a portion of the
backrest portion 34. As shown, the backrest portion 34 is generally
formed by a cushion 72, which is covered with an appropriate
covering material 74 (e.g., upholstery, leather or vinyl). The
cushion 72 is usually supported on a metallic or plastic frame (not
shown). In some embodiments, springs may be positioned between the
frame and the cushion 72. The frame provides the seat assembly 30
with structural support while the cushion 72 provides a soft
seating surface. The covering material 74 provides an aesthetic
appearance and soft feel to the surface of the seat assembly 30.
The seat portion 32 of FIG. 2B may be constructed in a similar
manner as the backrest portion 34 as shown in FIG. 2A.
[0033] FIG. 3 illustrates the seat assembly 32 with the covering 74
removed thereby exposing the cushion 72. The cushion 72 can be a
typical automotive seat cushion foam or other types of materials
with suitable characteristics for providing support to an occupant.
Such materials include, but are not limited to, closed or
open-celled foam.
[0034] As shown in FIGS. 3 and 3A, the backrest portion 34 of the
seat assembly 30 is provided with a backrest fluid distribution
system 76A. The distribution system 76A comprises an inlet passage
78A that extends through from the front side 54 to the rear side 56
of the seat cushion 72. (See also FIG. 2A). The distribution system
76A also includes at least one, and often, a plurality of channels
80A, which extend from the inlet passage 78A. As mentioned above,
the cushion 72 may be formed from a typical automotive cushion
material, such as, for example, an open or closed-cell foam. In one
embodiment, the cushion 72 is made of foam that is pre-molded to
form the passage 78A and/or the channels 80A. In another
embodiment, the passage 78A and/or the channels 80A may be formed
by cutting foam out of the seat cushion 72.
[0035] With particular reference to FIG. 3A, in the illustrated
embodiment, an insert or liner 150 may be positioned within the
channels 80A, 80B for distributing the air. As shown, the insert
150 generally comprises a body 152, which includes a plurality of
channels or plenums 154 with a generally U-shaped cross-section.
The insert 150 is configured to fit generally with the channels 80A
formed in the cushion 72. The plenums 154 extend from a duct 156
that extends through the inlet passage 78A. The periphery of the
plenums 154 and duct 156 includes a flange 158 that extends
generally parallel to the surface of the cushion 71. See FIG. 2A.
The insert 150 is preferably formed of a moisture resistant, closed
cell foam, which is configured to limit seepage of air into the
cushion 72. However, in other embodiments, the insert 150 can be
formed from other materials, such as, for example, molded plastic.
Further details and additional embodiments of the insert 150 are
provided in co-pending U.S. patent application Ser. No. 10/853,779,
filed May 25, 2004, the entire contents of which are hereby
incorporated by reference herein. As will be described below with
reference to FIG. 2B, in a modified embodiment, the distribution
system 76A may be formed without the insert 150.
[0036] With reference back to FIG. 2A, a cover or scrim 81A is
positioned generally over the insert 150 to define distribution
passages 82A for transporting air through the seat assembly 30. The
scrim 81A includes one or more openings 84A for transporting air to
and/or from the distribution passages 82A and preferably provides
structural support to prevent or reduce the seat cover 74 from
depressing into the passages 82A. The scrim 81A preferably includes
one or more thermal elements 160A, which are preferably positioned
within the scrim 81A generally adjacent the one or more openings
84A and are configured to effect a temperature change in the space
adjacent the seat assembly 30. As will be explained in more detail
below, in the illustrated embodiment, the thermal elements 160A are
used to heat the air transported through the seat assembly and/or
heat the portions of the seat assembly adjacent the thermal
elements 160A.
[0037] The thermal elements 160A may comprise any of variety of
devices for causing a temperature change, such as, for example,
resistive heaters (e.g., resistive wires, carbon fiber based
heating elements, and carbon impregnated sheets), chemical-reaction
heaters, heat exchanges and/or Peltier thermoelectric devices. The
thermal elements 160A may be used in combination with fabrics,
foams etc. to form the scrim 81A. In another embodiment, the
thermal elements 160A may be coupled to or positioned generally
near the scrim 81A. In the illustrated embodiment, the scrim 81A is
attached to the flange 158 in a manner that limits leakage between
the scrim 81A and insert 150 thereby directing the flow of air
through the openings 84A. In one embodiment, an adhesive is used to
attach the scrim 81A to the insert 150. In other embodiments, a
heat stake or fasteners may be used.
[0038] With continued reference to FIG. 2A, an optional
distribution layer 86A is disposed between the scrim 81A and the
seat covering 74. The distribution layer 86A spreads the air
flowing through the openings 84A along the lower surface of the
covering 74. To permit airflow between the distribution layer 86A
and the spaces proximal to the front surface 48 of the backrest
portion 34, the covering 74 may be formed from an air-permeable
material. For example, in one embodiment, the covering 74 comprises
an air-permeable fabric made of natural and/or synthetic fibers. In
another embodiment, the covering 74 is formed from a leather, or
leather-like material that is provided with small openings or
apertures. In a modified embodiment, the distribution layer 86A may
be omitted or combined with the seat covering 74 and/or the scrim
81A. As mentioned above, the scrim 81A is configured to allow for
the passage of air. In the illustrated embodiment, this is
accomplished by providing the scrim 81A with small openings or
apertures. In another embodiment, the scrim 81A itself and/or the
thermal elements 160A may be generally air-permeable
[0039] With reference to FIGS. 2B and 3, the seat portion 32 of the
seat assembly 30 is also provided with a seat distribution system
76B. The seat distribution system 76B comprises an inlet passage
78B that extends from the top side 68 to the bottom side 70 of the
seat cushion 72. As with the backrest distribution system 76A, the
seat distribution system 76B also includes at least one, and often,
a plurality of channels 80B, which extend from the inlet passage
78B. These channels 80B may be configured as described above.
[0040] In the seat distribution system 76B, the portion of the
cushion 72 that forms the channels 80B is preferably treated and/or
covered with a coating, skin or other material configured such that
air flowing through the channels 80B does not significantly seep
into the cushion 72. In another embodiment, the cushion 72 may be
formed from a dense foam that does not allow for significant
seepage of air through the foam. In addition to or in the
alternative, the seat distribution system 76B may include an insert
or liner as described above with reference to FIGS. 2A and 3A.
[0041] The channels 80B are covered by a scrim or cover 81B to
define distribution passages 82B for transporting air through the
seat assembly 30. The scrim 81B is preferably configured as
described above. Accordingly, the scrim 81B includes thermal
elements 160B and one or more openings 84B for delivering air to
and/or from the distribution passages 82B. As described above, the
scrim 81B is preferably attached to the cushion 72 in a manner that
limits leakage between the scrim 81B and cushion 72. A distribution
layer 86B is optionally disposed between the scrim 81B and the seat
covering 74. As mentioned above, in a modified embodiment, the
distribution layer 86B can be omitted or combined with the seat
covering 74 and/or the scrim 81A. In addition, as with the covering
74, the scrim 81A itself may be configured such that it is
generally air-permeable and/or provided with small openings or
apertures 84B as shown in the illustrated embodiment.
[0042] As will be explained in more detail below, the thermal
elements 160A, 160B are used to change the temperature (e.g.,
increase) in the space or portions of the seat adjacent the
occupant of the seat assembly 30. The thermal elements 160A, 160B
are preferably used in combination with fluid flow provided through
the distribution system 76A, 76B. As explained below, when used in
combination with fluid flow, the air may be conditioned or
unconditioned before the thermal elements 160A, 160B changes its
temperautre. For example, in one embodiment, air (which can be
heated) is delivered to the distribution passages 82A, 82B through
the inlet passages 78A, 78B. The air then flows through the
openings 84A, 84B and into the distribution layers 86A, 86B. The
air is then directed through the covering 74 to a space adjacent to
the front surface 48 of the backrest portion 34 and/or the top
surface 50 of the seat portion 32. In another embodiment, the
climate control system 36 is used to remove air, which is adjacent
to the front surface 48 of the backrest portion 34 and/or the top
surface 50 of the seat portion 32. In such an embodiment, the air
is withdrawn through the covering 74 and into the distribution
layers 86A, 86B. The air is then withdrawn through the openings
84A, 84B, into the distribution passages 82A, 82B and through the
inlet passages 78A, 78B. In this manner, the air withdrawn and/or
supplied through the distribution systems 76A, 76B may be used to
supplement and/or enhance the thermal elements 160A, 160B. In one
embodiment, thermal elements 160A, 160B provide heat to the
occupant via conduction through the covering 74 and other layers of
material. In such an embodiment, the fluid flow can enhance the
thermal elements 160A, 160B by also transferring the heat generated
by the thermal elements 160A, 160B to the occupant via
convection.
[0043] Given the goal of distributing air through the cushion 72
and along the covering 74, those of skill in the art will recognize
that the distribution systems 76A, 76B for the backrest portion 34
and the seat portion 32 may be modified in several different
manners. For example, the shape and/or number of channels 80A, 80B
and/or openings 84A, 84B may be modified. In other embodiments, the
scrim 81A, 81B and/or distribution passages 82A, 82B may be
combined and/or replaced with other components configured for
similar functions. In other embodiments, the distribution systems
76A, 76B or portions thereof may be combined with each other. In
addition, various features of the distribution systems 76A, 76B of
the backrest portion 34 and seat portion 32 may be combined and/or
interchanged with each other.
[0044] FIG. 4 is a schematic illustration of the temperature
control system 36. In the illustrated embodiment, the temperature
control system 36 includes the thermal elements 160A, 160B and the
distribution systems 76A, 76B described above. The system 36 also
includes a back fluid module 92A and seat fluid module 92B. As will
be explained below, both fluid modules 92A, 92B are configured to
provide and/or remove fluid from the distribution systems 76A, 76B
described above and/or provide conditioned air (e.g., heated air)
to the distribution systems 76A, 76B. In this manner, the fluid
modules 92A, 92B provide a fluid flow to/from the seat assembly 30,
which can be used to enhance or supplement the heat provided by the
thermal elements 160A, 160B described above.
[0045] In the illustrated embodiment, the fluid modules 92A, 92B
preferably each include a thermoelectric device 94A, 94B for
conditioning (e.g., selectively healing or cooling) the fluid
flowing through the device 94A, 94B. A preferred thermoelectric
device 94A, 94B is a Peltier thermoelectric module, which is well
known in the art. The illustrated fluid modules 92A, 92B preferably
also include a main heat exchanger 96A, 96B for transferring or
removing thermal energy from the fluid flowing through the modules
92A, 92B and to the distribution systems 76A, 76B. Such fluid is
transferred to the distribution systems 76A, 76B through conduits
98A, 98B (see e.g., U.S. application Ser. No. 10/973,947, filed
Oct. 25, 2004, which is hereby incorporated by reference herein).
In the illustrated embodiments, the modules 92A, 92B also
preferably include a waste heat exchanger 100A, 100B (see FIG. 4)
that extends from the thermoelectric device 94A, 94B generally
opposite the main heat exchanger 96A, 96B. A pumping device 102A,
102B is preferably associated with each fluid module 92A, 92B for
directing fluid over the main and/or waste heat exchangers 96A,
96B, 100A, 100B. The pumping devices 102A, 102B may comprise an
electrical fan or blower, such as, for example, an axial blower
and/or radial fan. In the illustrated embodiment, a single pumping
device 102A, 102B may be used for both the main and waste heat
exchanges 96A, 96B, 100A, 100B. However, it is anticipated that
separate pumping devices may be associated with the waste and heat
exchanges 96A, 96B, 100A, 100B.
[0046] It should be appreciated that the fluid modules 92A, 92B
described above represents only one exemplary embodiment of a
device that may be used to move and/or condition the air supplied
to the distribution systems 76A, 76B. Any of a variety of
differently configured fluid modules may be used to move and/or
provide conditioned air. Other examples of fluid modules that may
be used are described in U.S. Pat. Nos. 6,223,539, 6,119,463,
5,524,439 or 5,626,021, which are hereby incorporated by reference
in their entirety. Another example of such a fluid module is
currently sold under the trademark Micro-Thermal Module.TM. by
Amerigon, Inc. In another example, the fluid module may comprise a
pump device without a thermoelectric device and/or waste heat
exchanger for thermally conditioning the air. In such an
embodiment, the pumping device may be used to remove or supply air
to the distribution system 76A, 76B. In yet another embodiment, the
fluid modules 92A, 92B, may share one or more components(e.g.,
pumping devices, thermoelectric devices, etc.) with each other
and/or with the vehicles general climate control system. In another
embodiment, a single fluid module is used to supply air to both
distribution systems 76A, 76B.
[0047] In operation, fluid in the form of air can be delivered from
the fluid modules 92A, 92B, through the conduits 98A, 98B to the
corresponding distribution systems 76A, 76B. As described above,
the air flows through the passages 82A, 82B, into the openings 84A,
84B and then along the distribution layers 86A, 86B and through the
coverings 74. In this manner, conditioned or unconditioned air can
be provided to the front surface 48 of the backrest portion 34
and/or the top surface 50 of the seat assembly. As mentioned above,
the air supplied to the seat assembly may enhance or supplement the
thermal elements 160A, 160B.
[0048] In a modified embodiment, air from within the passenger
compartment of the automobile can be drawn through the covering 74,
into the distribution layers 86A, 86B and through the openings 84A,
84B. The air then can flow through the distribution passages 82A,
82B, into the inlet passages 78A, 78B and then into the conduit
98A, 98B. In this manner, the temperature control system 36 can
provide suction so that air near the surface of the seat assembly
30 is removed. As mentioned above, the air removed from the seat
assembly 30 may enhance or supplement the thermal elements 160A,
160B.
[0049] An exemplary control system 104 for the temperature control
system 36 will now be described with continued reference to FIG. 4.
As shown, the control system 104 includes a user input device 106
through which the user of the climate control system 36 can provide
a control setting or set mode for the climate control system 36.
The control setting can comprise a specific temperature setting
(e.g., 65 degrees), a more general temperature setting (e.g., "hot"
or "cold"), and/or a setting for the pumping device (e.g., "high,"
"medium," or "low"). Depending upon the desired configuration, the
input device 106 may include any of a variety of input devices,
such as, for example, dials, buttons, levers, switches, etc. The
user input device 106 may also include a user output that provides
visual or audio indicia of the control setting (e.g., an LED
display).
[0050] With continued reference to FIG. 4, the input device 106 is
operatively connected to a control module 110. The control module
110 is, in turn, operatively connected to the pumping devices 102A,
102B and the thermoelectric devices 94A, 94B of the fluid modules
92A, 92B for the backrest portion 34 and seat portion 32. The
control unit 110 is also operatively connected through control
lines (not shown) to the thermal elements 160A, 160B. Temperature
sensors 112, 124 are provided to measure the temperature of the
fluid conditioned by the thermoelectric devices 94A, 94. The
temperature sensors 112, 124 are also operatively connected to the
seat control module 110. Temperature sensors (not shown), which are
preferably located near or proximate to the thermal elements 160A,
160B may also be operatively connected to the control module
110.
[0051] In the illustrated embodiment, the control module 110 is
operatively connected to a power source 114 and a ground source 116
and includes an appropriate power control unit to provide
sufficient electrical capacity to operate one, a plurality or all
of the aforementioned devices (92B, 92B, 112, 124, 160A, 160B). In
some embodiments, the seat control module 110 also has a controller
that is configured to receive the occupant inputs from the input
device 106 and the temperature information from the temperature
sensors 112, 124. From this information, the seat control module
110 is configured to make adjustments to the operation of the
thermal elements 160A, 160B, the thermoelectric devices 94A, 94B
and/or the fluid pumps 102A, 102B according to a predetermined
logic designed to ensure occupant comfort and to protect against
system damage.
[0052] Those of skill in the art will appreciate that the seat
control module 110 can comprise a hard-wired feed back control
circuit, a dedicated processor or any other control device that can
be constructed for performing the steps and functions described
herein. In addition, the controller within the control module 110
may be combined or divided into subcomponents as deemed
appropriate. For example, it may be advantageous to divide the
control module into a first module for conditioning the backrest
portion 34 and a second control module for conditioning the seat
portion 32. See e.g., co-pending U.S. patent application Ser. No.
10/047,077, filed Jan. 31, 2005, which is hereby incorporated by
reference herein. In another embodiment, separate control modules
may be provided for the thermal elements 160A, 160B and the fluid
modules 92A, 92B. In addition, it should be appreciated that the
control system 104 represents only one exemplary arrangement of an
system for controlling the operation of the climate control system
36. Those of skill in the art will recognize in light of the
disclosure herein various other configurations for the control
system 104. In addition, one or more components of the control
module 110 may be located in various locations, such as, within one
or both of the fluid modules 92A, 92B or in a separate
location.
[0053] Various components are described as being "operatively
connected" to the control unit. It should be appreciated that this
is a broad term that includes physical connections (e.g.,
electrical wires or hard wire circuits) and non-physical
connections (e.g., radio or infrared signals). It should also be
appreciated that "operatively connected" includes direct
connections and indirect connections (e.g., through additional
intermediate device(s)).
[0054] The control module 110 optionally may also be configured to
receive a signal from a vehicle control device 118 that indicates
whether the vehicle's ignition has been turned on. In this manner,
the seat control module 110 may be configured to allow operation of
the system 36 only if the vehicle's engine is running.
[0055] In one embodiment, the thermal elements 160A, 160B are
activated to heat the surfaces 48, 50 of the backrest portion 34
and seat portion 32. While the thermal elements 160A, 160B are
activated, the fluid modules 92A, 92B can provide a fluid flow to
the surfaces 48, 50 of the backrest portion 34 and seat portion 32.
The fluid may be unconditioned (e.g., not heated) and in such an
embodiment the fluid can enhance the thermal elements 160A, 160B by
promoting convection of heat from the thermal elements to the
surfaces 48, 50 of the backrest portion 34 and seat portion 32. In
another embodiment, while the thermoelectric devices 94B, 94B are
activated, the fluid modules 92A, 92B provide heated air to the
surfaces 48, 50 of the backrest portion 34 and seat portion 32. In
this manner, the fluid modules 92A, 92B supplement and enhance the
heating effect provided by the thermal elements 160A, 160B. In yet
another embodiment, the thermal elements 160A, 160B are used during
a first or initial period of time to heat the surfaces 48, 50 of
the backrest portion 34 and seat portion 32 largely through
conduction. After the first or initial period of time, the fluid
modules 92A, 92B are used to provided conditioned or un-conditioned
air to the surfaces 48, 50 of the backrest portion 34 and seat
portion 32.
[0056] The above described embodiments have several advantages. For
example, in particularly cold conditions, it may take a long period
of time to noticeably heat the seat assembly using heated air
provided by the fluid modules alone. In the above described
embodiment, because the thermal elements 160A, 160B are positioned
near the surfaces 48, 50 of the backrest portion 34 and seat
portion 32, they can provide immediate heat via conduction that can
be sensed by the occupant of the seat assembly 30. The air provided
through the distribution system 76A, 76B can enhance (e.g., through
convection) or supplement (e.g., by providing conditioned air) the
heat provided by the thermal elements 160A, 160B.
[0057] In addition, some climate control systems are relatively
expensive and thus may not be suitable for all applications. In
particular, the thermoelectric elements 94A, 94B may be too
expensive for some applications. In such applications, the fluid
modules 92A, 92B may be formed without the thermoelectric elements
94A, 94B and may be used to simply provide air to and/or remove air
from the seat surface through the distribution system 76A, 76B. In
this manner, a low cost climate control system is formed. In such a
system, the thermal elements 160A, 160B are used to selectively
control (e.g., heat) the surfaces of the seat assembly 30. The
fluid flow provided by the fluid modules 92A, 92B can used to
enhance the transfer of heat to the occupant and/or the thermal
elements 160A, 160B can be operated alone. When cooling is desired,
the fluid modules 92A, 92B can provide air flow to the seat
assembly or withdraw air from the seat surface to provide a cooling
effect.
[0058] It is anticipated that the different portions of the seat
assembly 30 (e.g., seat and backrest portions) may be controlled in
different manners and/or controlled to different temperature
settings.
[0059] FIGS. 5A and 5B illustrate portions of a distribution system
276A, 276A of a modified embodiment of a climate control system. In
FIGS. 5A and 5B, like elements to those shown in FIGS. 2A and 2B
are designated with the same reference numbers used in FIGS. 2A and
2B. In addition, only certain components of the climate control
system will be described in detail below. For those components not
described in detail, reference may be made to the detailed
description above.
[0060] As with the embodiments described above, the climate control
system generally comprises thermal elements 360A, 360B, fluid
modules (not shown) and the distribution systems 276A, 276B. In
this embodiment, the heating elements 360A, 360B are positioned
generally within or proximate to the distribution passages 82A, 82B
and/or the inlet passages 78A, 78B which are used to transport air
through the seat assembly 30. In this manner, the heating elements
360A, 360B may be used to heat the air delivered to the surfaces
48, 50 of the seat assembly 30.
[0061] With respect to the illustrated embodiment, the thermal
element 160A for the backrest portion 34 may form at least in part
a portion of the insert 150, which forms the distribution passage
82A. The air flowing through the distribution passage is heated by
the thermal element 360A and then delivered to the occupant through
the openings 84A. In a modified embodiment, the thermal element
360A may be positioned along the inner or outer surface of the
insert 150.
[0062] With respect to FIG. 5B and the seat portion 32, the thermal
elements 360B may line and/or form part of the channels 80B in the
seat cushion 72. As with the backrest 34, the thermal elements 360B
heat the air flowing through the passages 82B. In other
embodiments, the thermal elements 360B may be positioned within the
cushion 72.
[0063] Accordingly, with the thermal elements 360A, 360B generally
positioned within the seat cushion 72 between the seat cover 74 and
the backside 56 or under side 70 of the seat assembly 30, the
thermal elements 360A, 360B can heat the air delivered by the fluid
module to the seat assembly 30. It should be appreciated that in a
modified embodiment one or more thermal elements (not shown) can be
provided near or adjacent the front or top surface of the seat. In
such an embodiment, the thermal elements can be provided within the
scrim 81A, 81B as described above with reference to FIGS. 2A and
2B.
[0064] FIGS. 6A and 6B illustrate portions of a distribution system
1076A, 1076B other modified embodiments of a climate control
system. In FIGS. 6A and 6B, like elements to those shown in FIGS.
2A and 2B are designated with the same reference numbers used in
FIGS. 2A and 2B. In addition, only certain components of the
climate control system will be described in detail below. For those
components not described in detail, reference may be made to the
detailed description above.
[0065] As with the embodiments described above, the climate control
system generally comprises thermal elements 1160A, 1160B, fluid
modules (not shown) and the distribution systems 1076A, 1076B. With
reference to FIG. 6A, in this embodiment, the distribution system
1076A for the backrest portion 34 includes at least one and
preferably a plurality of channels 1080A, which are positioned
generally on the rear side 56 of the seat cushion 72. At least one
and preferably a plurality of through passages 1075A extend from
the channels 1080A to the front side 54 of the cushion 72. The
passages 1075A are covered by a cover or scrim 81A, distribution
layer 86A and covering 74, which can be arranged and/or combined as
described above with reference to FIGS. 2A and 2B. In the
illustrated embodiment, the thermal elements 1160A are positioned
within the scrim 81A near the openings 84A. An insert 1150 as
described above may be provided within the channels 1080A and/or
the passages 1075A. A rear covering 1002 with an inlet 1004 is
provided for defining distribution passages 82A and connecting the
distribution passages 82A to a fluid module. In addition, it should
be appreciated that in a modified embodiment one or more thermal
elements (not shown) can be provided within or near the channels
1080A or passages 1075A as described below with reference to FIG.
6B.
[0066] FIG. 6B illustrates the distribution system 1076B for the
seat portion 32. As with the backrest portion 34 shown in FIG. 6A,
the distribution system 1076B includes a least one and preferably a
plurality of channels 1080B, which are positioned generally on the
bottom side 60 of the seat cushion 72. At least one and preferably,
a plurality of through passages 1075B extend through from the
channels 1080B to the top side 54 of the cushion 72. The passages
1075B are covered by a cover or scrim 81B, distribution layer 86B
and covering 74, which can be arranged and/or combined as described
above with reference to FIGS. 2A and 2B. A bottom covering 1002
with an inlet 1004 is provided for defining distribution passages
82B and connecting the distribution passages 82B to a fluid
module.
[0067] In this embodiment, the heating elements 1160B are
positioned generally within or proximate to the distribution
passages 82B as formed by the channels 1080B and/or through
passages 1075B, which are used to transport air through the seat
assembly 30. In addition, the distribution system 1076B of this
embodiment does not include an insert. However, as mentioned above,
it should be appreciated that certain components and features of
the distribution systems 1076A, 1076B for the seat and cushion
portions 32, 34 may be exchanged and/or combined. For example, the
seat portion 32 may include an insert and/or the thermal elements
can positioned within the scrim. In addition, it should be
appreciated that in a modified embodiment one or more thermal
elements (not shown) can be provided near or adjacent the top
surface of the seat. In such an embodiment, the thermal elements
can be provided within the scrim 81B as described above with
reference to FIG. 2B.
[0068] To assist in the description of the disclosed embodiments,
words such as upward, upper, downward, lower, vertical, horizontal,
upstream, and downstream have been used above to describe the
accompanying figures. It will be appreciated, however, that the
illustrated embodiments can be located and oriented in a variety of
desired positions.
[0069] In the above description, various components are described
as being associated with the "back" or "seat" cushion. In modified
embodiments, it should be appreciated that the subcomponents of the
back and seat cushions may be reversed and/or made to the same. In
still other embodiments, the various components of the illustrated
embodiments may be combined and/or may be applied to different
zones of a seat, such as, for example, a top and bottom portion of
a backrest portion. In other embodiments, the features of the back
and seat cushions may be applied to different zones of an occupant
area that are to be thermally conditioned, such as, for example,
back and rear seat assemblies or left and right seat
assemblies.
[0070] Although the foregoing description of the preferred
embodiments has shown, described, and pointed out certain novel
features, it will be understood that various omissions,
substitutions, and changes in the form of the detail of the
apparatus as illustrated, as well as the uses thereof, may be made
by those skilled in the art without departing from the spirit of
this disclosure. Consequently, the scope of the present invention
should not be limited by the foregoing discussion, which is
intended to illustrate rather than limit the scope of the
invention.
* * * * *