U.S. patent application number 11/824260 was filed with the patent office on 2007-11-01 for convective seating and sleeping systems.
Invention is credited to Steve Feher.
Application Number | 20070251016 11/824260 |
Document ID | / |
Family ID | 38664745 |
Filed Date | 2007-11-01 |
United States Patent
Application |
20070251016 |
Kind Code |
A1 |
Feher; Steve |
November 1, 2007 |
Convective seating and sleeping systems
Abstract
A convective seating and sleeping system with a plenum for use
as a mattress, cushion or as part of seat or other structure to
deliver air flow to a user or users. The convective cushion
includes a modular plenum made of removable pockets and a
thermocouple to provide control data to selectively control the
temperature and/or quantity of the air delivered to the cushion.
The cushion includes the use of tubular spacer material. The
cushion has deep styling lateral and longitudinal pleats and air
flow structures around the pleats to provide a controlled air flow
to the cushion. The invention includes an improved Stirling cycle
heat pump with magnetic bearing structures and relative humidity
controls and an improved thermoelectric heat pump that selectively
controls the relative humidity of the air delivered to the cushion.
The cushion can be activated and operated by remote operation from
a telecommunications device.
Inventors: |
Feher; Steve; (Honolulu,
HI) |
Correspondence
Address: |
LAUSON & SCHEWE LLP
1600 ROSECRANS AVENUE 4TH FLOOR
FOURTH FLOOR
MANHATTAN BEACH
CA
90266
US
|
Family ID: |
38664745 |
Appl. No.: |
11/824260 |
Filed: |
June 29, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11225605 |
Sep 13, 2005 |
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11824260 |
Jun 29, 2007 |
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11024073 |
Dec 28, 2004 |
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11225605 |
Sep 13, 2005 |
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Current U.S.
Class: |
5/713 ; 165/240;
455/39 |
Current CPC
Class: |
A47C 7/748 20130101;
A47C 21/044 20130101; A47C 7/744 20130101; A47C 21/048 20130101;
A47C 31/006 20130101; A47C 7/74 20130101 |
Class at
Publication: |
005/713 ;
165/240; 455/039 |
International
Class: |
A47C 27/08 20060101
A47C027/08 |
Claims
1. A convective cushion comprising: a plenum defined by a bottom
surface secured around a perimeter to a generally air permeable top
surface and containing a modular air flow structure therein, said
top surface adapted for convective air flow delivered from said
modular air flow structure; an air inlet in fluid communication
with the air flow structure; a power unit having a blower in fluid
communication with the air inlet for delivering air of a
selectively variable temperature and quantity to the modular air
flow structure through the air inlet; and wherein said modular air
flow structure comprises a plurality of removable pockets, each of
said pockets containing a plurality of air permeable tubular spacer
material arranged in a generally parallel configuration therein,
and wherein positioning said plurality of pockets within said
plenum is adapted to deliver said air of a selectively variable
temperature and quantity from said air inlet to the top surface of
the plenum.
2. The convective cushion of claim 1 further comprising a mattress
adjoining the bottom surface of the plenum and having a first end
and a second end opposite said first end, wherein said air inlet
comprises an air duct configured within said mattress at said first
end.
3. The convective cushion of claim 2 wherein said mattress further
comprises an air outlet duct at the second end of said
mattress.
4. The convective cushion of claim 4 further comprising a face
plate attached to at least a portion of an outer surface of the
blower.
5. The convective cushion of claim 1 further comprising a
thermocouple adapted to provide control data to said power unit to
selectively control the temperature of air delivered to said air
inlet.
6. The convective cushion of claim 5 wherein the control data
comprises temperature data from the plenum.
7. The convective cushion of claim 5 wherein the control data
comprises temperature data from the air produced by the blower.
8. The convective cushion of claim 1 further comprising a
thermocouple adjacent to the plenum and adapted to provide control
data to said power unit to selectively control the temperature of
air delivered to said air inlet wherein the control data comprises
temperature data from a cover placed adjacent to the top surface of
the plenum.
9. The convective cushion of claim 1 wherein said power unit
further comprises a Stirling cycle heat pump and a blower control
potentiometer, said blower control potentiometer adapted to control
the flow of air delivered to the air inlet by said blower
independent of the temperature change of the air.
10. The convective cushion of claim 1 wherein said power unit
further comprises a Stirling cycle heat pump and a double pole
double throw switch adapted to control the flow of air delivered to
the air inlet by said blower independent of the temperature change
of the air.
11. A convective cushion comprising: a plenum defined by a bottom
surface secured around its perimeter to a generally air permeable
top surface and containing a plurality of air permeable tubular
spacer material therein, the longitudinal axes of the tubular
spacer material arranged in a mutually parallel configuration; an
air inlet in fluid communication with the tubular spacer material,
said air inlet adapted to deliver selectively variable temperature
air from a power unit having a blower to the tubular spacer
material; and wherein said plenum includes at least one pleat
through said plenum, said pleat extending in the direction of the
longitudinal axes of the tubular spacer material and along the
plenum, whereby the air from the air inlet is delivered to said top
surface through said tubular spacer material.
12. The convective cushion of claim 11 wherein said plenum is
anchored to a base by wire and hooks.
13. A convective cushion comprising: a plenum defined by a bottom
surface secured around its perimeter to a generally air permeable
top surface and containing a plurality of air permeable tubular
spacer material therein, the longitudinal axes of the tubular
spacer material arranged in a mutually parallel configuration; an
air inlet in fluid communication with the tubular spacer material,
said air inlet adapted to deliver selectively variable temperature
air from a power unit having a blower to the tubular spacer
material; and wherein said plenum includes at least one pleat
through said plenum, said pleat extending in a lateral direction
relative to the longitudinal axes of the tubular spacer material
along the plenum, whereby the air from said air inlet is delivered
to said top surface through said tubular spacer material.
14. The convective cushion of claim 13 wherein the bottom surface
of the plenum is anchored to a base by wire and hooks.
15. The convective cushion of claim 13 further comprising an air
outlet and including a series panel flow structure between said air
inlet and the air outlet, whereby at least a portion of the air
delivered to the air inlet flows through said series panel flow
structure to said air outlet.
16. The convective cushion of claim 13 further comprising an air
outlet and including a parallel panel flow structure between said
air inlet and the air outlet, whereby at least a portion of the air
delivered to the air inlet flows through said parallel panel flow
structure to said air outlet.
17. The convective cushion of claim 15 further comprising a
headrest and said air outlet is attached to said headrest.
18. A convective cushion comprising: a plenum defined by a bottom
surface secured around a perimeter to a generally air permeable top
surface and containing an air flow structure therein, said top
surface adapted for convective air flow delivered from the air flow
structure to the top surface; an air inlet in fluid communication
with the air flow structure; a power unit having a blower in fluid
communication with the air inlet for delivering air of a
selectively variable temperature and quantity to the air flow
structure through the air inlet; wherein the power unit comprises a
free piston Stirling cycle heat pump configured to provide
reciprocal movement of a piston within a cylinder in a sealed
housing during operation, and comprising a magnetic bearing
permanent magnet and pole assembly secured to the cylinder and
adapted to interact magnetically with a magnetic ring insert on the
piston so as to substantially maintain the piston and magnetic ring
insert on center within the cylinder during the reciprocal movement
of the piston.
19. The convective cushion of claim 18 wherein the air flow
structure comprises tubular spacer material.
20. The convective cushion of claim 18 further comprising
ferrofluid within a first gap between the magnetic bearing
permanent magnet and the magnetic ring insert on the piston.
21. The convective cushion of claim 18 wherein said Stirling cycle
heat pump further comprises a stator pole and a piston driver coil
assembly and having ferrofluid within a second gap between the
stator pole and the piston driver coil assembly.
22. A method for remote control of a convective cushion in a
vehicle, the steps comprising: providing a receiver, the receiver
in communication with a controller that selectively controls the
operation of a power unit and blower in fluid communication with
the convective cushion to control the delivery of air from the
blower to the convective cushion; transmitting a control signal to
the receiver from a telecommunications unit located remotely from
the vehicle to activate delivery of air from the blower to the
convective cushion.
23. The method of claim 22 wherein said telecommunications unit is
a mobile telephone.
24. The method of claim 22 wherein said telecommunications unit
includes a pager.
25. The method of claim 22 wherein the convective cushion comprises
tubular spacer material within said convective cushion.
26. The method of claim 22 wherein the control signal provides
information to select operating modes of the power unit and the
blower.
27. The method of claim 26 wherein the operating modes include
selectively variable temperature of the air delivered to the
convective cushion.
28. The method of claim 26 wherein the operating modes include
selectively variable quantity of the air delivered to the
convective cushion.
29. The method of claim 22 wherein the step of transmitting a
control signal activates the operation of a variable temperature
steering wheel in the vehicle.
30. A convective cushion comprising: a plenum defined by a bottom
surface secured around a perimeter to a generally air permeable top
surface and containing an air flow structure therein, said top
surface adapted for convective air flow delivered from the air flow
structure to the top surface; an air inlet in fluid communication
with the air flow structure; a power unit comprising a blower in
fluid communication with the air inlet for delivering air of a
selectively variable temperature and quantity to the air flow
structure through the air inlet; wherein the power unit comprises a
free piston Stirling cycle heat pump adapted for reciprocal
movement of a piston within a cylinder to produce a cold end of a
sealed housing during operation and having a reheater and a master
controller to control the operation of the free piston Stirling
cycle heat pump and reheater such that the master controller
selectively activates and controls the reheater to control the
relative humidity of cooled air from the blower to be delivered to
the air inlet.
31. The convective cushion of claim 30 wherein the air flow
structure comprises tubular spacer material.
32. The convective cushion of claim 30 wherein the master
controller controls the operation of the reheater in response to
data from a hygrometer.
33. The convective cushion of claim 30 wherein the master
controller controls the operation of the reheater in response to
data from an air temperature sensor.
34. The convective cushion of claim 30 wherein the master controls
selectively controls the reheater so that a desired relative
humidity is maintained for a desired air temperature.
35. The convective cushion of claim 30 wherein the master
controller selectively controls the reheater until a desired
temperature is maintained at a desired relative humidity.
36. The convective cushion of claim 30 wherein the reheater is
configured to further heat the heated air to be delivered from the
blower to the air inlet.
37. The convective cushion of claim 30 whereby the power unit
further comprises an auxiliary fan and a reheater air duct adjacent
to the reheater and configured such that the auxiliary fan draws
ambient air into the reheater air duct so as to transfer heat from
the ambient air to the cooled air from the blower and thereby
control the relative humidity of air from the blower to be
delivered to the air inlet.
38. A convective cushion comprising: a plenum defined by a bottom
surface secured around its perimeter to a generally air permeable
top surface and containing tubular spacer material therein, said
top surface adapted for convective flow of air delivered from the
tubular spacer material to the top surface and wherein the plenum
is divided into a first section and a second section by a divider,
said divider configured to provide a substantially air impermeable
barrier within the plenum between said first section and said
second section; a first air inlet in fluid communication with the
tubular spacer material within the first section; a second air
inlet in fluid communication with the tubular spacer material
within the second section; and a power unit having at least two
independently controlled outputs such that a first output is in
fluid communication with the first air inlet for delivering air of
a selectively variable temperature to the first air inlet for the
first section and a second output is in fluid communication with
the second air inlet for delivering air of a selectively variable
temperature to the second air inlet for the second section.
39. The convective cushion of claim 38 further comprising an air
outlet for the outlet of at least a portion of the air delivered to
the plenum.
40. The convective cushion of claim 38 wherein the power unit
comprises a Stirling cycle heat pump.
41. The convective cushion of claim 38 wherein the power unit
comprises a thermoelectric heat pump.
42. The convective cushion of claim 38 wherein the tubular spacer
material has been cut to length along a cut line after a film is
secured on and adjacent to said cut line to thereby limit the
unraveling of fibers of the tubular spacer material along said cut
line.
43. The convective cushion of claim 42 wherein the film is applied
to the tubular spacer material with an adhesive.
44. A convective cushion comprising: a plenum defined by a bottom
surface secured around a perimeter to a generally air permeable top
surface and containing an air flow structure therein, said top
surface adapted for convective air flow delivered from the air flow
structure to the top surface; an air inlet in fluid communication
with the air flow structure; a power unit comprising a blower in
fluid communication with the air inlet for delivering air of a
selectively variable temperature to the air flow structure through
the air inlet; wherein the power unit comprises a thermoelectric
heat pump and having an auxiliary fan and a reheater with an
adjacent reheater air duct such that the auxiliary fan draws
ambient air into the reheater air duct so as to transfer heat from
the ambient air to the cooled air from the blower and thereby
control the relative humidity of cooled air from the blower to be
delivered to the air inlet.
45. The convective cushion of claim 44 further comprising a
condensate wick in communication with a heat exchanger in the power
unit and the reheater.
46. The convective cushion of claim 44 wherein the reheater is
configured to further heat the heated air to be delivered from the
blower to the air inlet.
47. The convective cushion of claim 44 wherein the air flow
structure comprises tubular spacer material.
Description
RELATED APPLICATION DATA
[0001] This application is a continuation-in-part of pending
application Ser. No. 11/225,605 filed on Sep. 13, 2005 which is a
continuation-in-part of pending application Ser. No. 11/024,073
filed on Dec. 28, 2004, the disclosures of which are incorporated
herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This present invention relates to improved convective
cooling and heating of seats, mattresses, mattress pads and other
articles used as a cushioning device.
[0004] 2. Description of Related Art
[0005] There are many applications and situations where it is
desirable to provide for convective cooling or heating of various
articles including seats, mattresses and other articles used for
supporting individuals while either sitting or laying down on the
article. Many of the conventional devices that have been used
suffer from serious drawbacks. As one example, the resistance
heated type prior art mattresses and cushions do not provide for
cooling or ventilation, a major disadvantage in many parts of the
world that lack adequate air conditioning. Moreover, the
conventional devices are very inefficient and lack adequate control
to adjust the heating or cooling temperature to satisfy the needs
of the user. In addition, because of the believed negative impact
on the environment, certain materials, such as Freon used for
cooling purposes, are being phased out for use in air conditioning
systems in many countries.
[0006] In U.S. Pat. No. 6,085,369 by Steve Feher there is disclosed
a selectively cooled or heated cushion and apparatus therefore and
in U.S. Patent Publication No. 2006/0137099 also by Steve Feher,
published Jun. 29, 2006, a convective cushion with a positive
coefficient of resistance heating mode is disclosed. While each of
the Feher '369 patent and the Feher '099 application is a
substantial improvement over other known and conventional prior art
techniques, there is believed to be room for improvement in
apparatus and systems that provide selectively variable temperature
air to convective cushions in a wide variety of applications,
including home, office and in vehicles, including increasing the
overall efficiency of operation. Thus, a need exists for improved
systems and methods for convective cooling and heating of seats,
mattresses, mattress pads and other articles.
SUMMARY OF THE INVENTION
[0007] A convective seating and sleeping apparatus, systems and
methods for controlled convective cooling and heating for seats,
mattresses, mattress pads and other articles. In one or more
embodiments, the invention includes a convective cushion that
provides selectively controlled convective cooling and heating
delivered from a power unit and blower, such as a Stirling cycle
heat pump or a Peltier thermoelectric device. The invention has air
flow structures within the cushion including tubular spacer
material. The invention includes remote activation and operation of
the convective cushion by a telecommunications unit.
[0008] In one or more embodiments, the invention includes a
convective cushion having removable modular pockets that when
assembled together form the convective cushion. The pockets contain
tubular spacer material and are arranged to deliver air of a
selectively variable temperature and quantity to an air permeable
top cover. Further embodiments include the use of a divider to
create different sections within the cushion with different air
inlets to provide for two or more temperature zones on the cushion
for different users. Additional embodiments use tubular spacer
material that has been cut to length along a cut line and along a
film placed adjacent to the cut line that effectively limit the
undesired unraveling of fibers of the tubular spacer material along
said cut line.
[0009] Embodiments of the invention include the use of deep styling
pleats that run longitudinally or laterally through the convective
cushion. The invention includes a series panel air flow structure
and a parallel panel air flow structure to deliver the selectively
variable temperature air throughout the convective cushion without
the pleats interrupting the air flow. Further embodiment include
improved heating and cooling devices and their operation including
a Stirling cycle heat pump and a thermoelectric device to provide
the selectively variable temperature air to the convective
cushion.
[0010] Embodiments of the invention include an improved Stirling
cycle heat pump with a magnetic bearing powered by a permanent
magnet that eliminates the input power requirement for a gas
bearing on every stroke of the piston. One of the disadvantages of
conventional gas bearings that is overcome is the fact that, when
the conventional bearing is not energized sufficiently by the
motion of the piston, such as when the machine is being started or
stopped, the gas bearing function is significantly diminished,
allowing the piston to "land" against the piston bore. This has
been handled in the past by using a non-stick, low friction coating
on the inside of the bore and on the piston itself. Although wear
has been reduced significantly, it was not completely eliminated in
these conventional systems.
[0011] The second and most important disadvantage overcome by the
present invention is that the gas bearing requires a power input to
function. The power input is in the form of the pumping action of
the piston reciprocating in the cylinder. Part of the force applied
to the piston is used to pump the gas bearing on each stroke. As
these machines operate in the region of 60 Hertz or more, this is a
loss mechanism that reduces the efficiency of the Stirling device.
Because of the elimination of the gas bearing pumping requirement,
the Stirling device will operate more efficiently and because
piston "landing wear" on start-up and shut-down is substantially
eliminated, the reliability of the Stirling cycle device will be
improved.
[0012] Further embodiments of the invention include a Stirling
device or a Peltier type thermoelectric device that includes a
reheater and optionally a hygrometer and sensor to control the
relative humidity of cooled air delivered to the convective
cushion. Other embodiments provide for a method for remote control
of the convective cushion in a vehicle by transmitting a control
signal from a telecommunications unit located remotely from the
vehicle to a receiver in the vehicle to activate delivery of
cooling or heated air to the convective cushion or other vehicle
article such as the steering wheel.
[0013] Other and further advantages and embodiments will appear to
persons skilled in the art from the written description and the
drawings herein.
BRIEF DESCRIPTION OF THE FIGURES
[0014] FIG. 1 is a perspective view of one embodiment of the
convective cushion of the present invention.
[0015] FIG. 2 is a side elevation and section view of the
convective cushion of one embodiment of the convective cushion of
the present invention.
[0016] FIG. 3 is a schematic view of a version of a heat pump in
one or more embodiments of the convective cushion of the present
invention.
[0017] FIG. 4 is a front elevation and sectional view showing a
pleat in one embodiment of the convective cushion of the present
invention.
[0018] FIG. 5 is a front elevation and partial section view showing
the air flow for one embodiment of the convective cushion of the
present invention.
[0019] FIG. 6 is a front elevation and partial section view showing
the air flow in a further embodiment of the convective cushion of
the present invention.
[0020] FIG. 7 is a front elevation and partial section view showing
the air flow in another embodiment of the convective cushion of the
present invention.
[0021] FIG. 8 is a side elevation and partial section view of one
version of a series air flow structure for one embodiment of the
convective cushion of the present invention.
[0022] FIG. 9 is a side elevation and partial section view of one
version of a parallel flow structure for one embodiment of the
convective cushion of the present invention.
[0023] FIG. 10 is a front elevation and partial section view
illustrating an embodiment of a convective cushion for use in one
or more embodiments of the present invention.
[0024] FIG. 11 is a side elevation and partial section view of one
version of a series air flow structure with headrest for one
embodiment of the convective cushion of the present invention.
[0025] FIG. 12 is a section view of a Stirling cycle device for use
in one or more embodiments of the convective cushion of the present
invention.
[0026] FIG. 13 is a side elevation and section view illustrating
the piston, the magnetic piston ring and the magnetic bearing
permanent magnet and pole assembly in a Stirling cycle device in
one or more embodiments of the convective cushion of the present
invention.
[0027] FIG. 14 is a front elevation and section view of the piston,
magnetic piston ring and the magnetic bearing permanent magnet and
pole assembly in a Stirling cycle device in one or more embodiments
of the convective cushion of the present invention.
[0028] FIG. 15 is a schematic view of a version of mobile device
for use in one or more embodiments of the present invention.
[0029] FIG. 16 is a schematic view of a version of a heat pump in
one or more embodiments of the convective cushion of the present
invention.
[0030] FIG. 17 is a schematic view of another version of a heat
pump in one or more embodiments of the convective cushion of the
present invention.
[0031] FIG. 18 is a perspective view of a further embodiment of the
convective cushion of the present invention.
[0032] FIG. 19 is an end elevation and section view of the
convective cushion illustrated in FIG. 18 used in one or more
embodiments of the convective cushion of the present invention.
[0033] FIG. 20 is partial perspective view of one embodiment of the
tubular spacer material in one or more embodiments of the
convective cushion of the present invention.
[0034] FIG. 21 is a schematic view of one embodiment of a
thermoelectric device in one or more embodiments of the convective
cushion of the present invention.
[0035] FIG. 21 a is an end elevation view of one embodiment of a
blower for use with one or more embodiments of the thermoelectric
device of FIG. 21.
[0036] FIG. 22 is a schematic view of one embodiment of a
thermoelectric device in one or more embodiments of the convective
cushion of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0037] FIG. 1 is a perspective view of one embodiment of the
convective cushion 10 as applied to a mattress for cooling and
heating while a user is resting or sleeping. The convective cushion
10 includes a plenum 12 having a generally air permeable top
surface 14 that is secured around a perimeter 16 to a bottom
surface 18. The bottom surface 18 is in one or more embodiments
generally impermeable to air and as shown in FIGS. 1 and 2 can be
placed on a mattress 20 to make the bottom surface 18 generally
impermeable. In one or more embodiments, the mattress 20 is a foam
mattress, but the present invention includes the use of a futon,
coil spring mattresses, inflatable mattresses or other structures
made of other materials to support the plenum 12.
[0038] As shown in FIG. 1, the plenum 12 includes multiple pockets
22 made of a synthetic material woven into a mesh of approximately
4-6 strands per inch.times.4-6 strands per inch with each of the
pockets 22 separately removable as part of the plenum 12. FIG. 1
shows three pockets 22 but other quantities and sizes of pockets 22
are within the scope of the present invention.
[0039] Each of the pockets 22 contains tubular spacer material 30.
The present inventor's U.S. Pat. Nos. 6,085,369 and 6,263,530
pioneered the use of tubular spacer fabric as an air flow structure
for seats, mattresses, mattress pads and other articles of
furniture that can be sat on or laid down upon. Although one
embodiment of the invention utilizes the same tubular spacer fabric
as described in the inventor's issued U.S. Pat. Nos. 6,085,369 and
6,263,530, it is within the scope of the present invention to
utilize other air flow structures such as Muller Textile's 3 Mesh
or Strahle and Hess' assembled woven fabric and other air flow
structures, however there may be substantially reduced levels of
performance when compared to the tubular spacer fabric disclosed in
the above issued U.S. patents.
[0040] The pockets 22 secure the multiple sections of the tubular
spacer material 30 close together while still allowing air to flow
from one end of the plenum 12 to the other end of the plenum 12
through pockets 12 via the tubular spacer material 30. The pockets
22 may be arranged so that the longitudinal axes of the tubular
spacer material in the pockets 22 are all aligned to allow
substantially uninterrupted flow of air. If the pockets 22 were
made of standard cotton sheeting, as the upper and lower layers are
made, the pressure drops across the pocket walls between the
tubular spacer material 30 layers would be too high and functional
air flow within the plenum 12 would not be possible using a small,
light, cost-effective and quiet main blower.
[0041] The use of multiple pockets 22 containing tubular spacer
material 30 in one or more embodiments instead of one single
mattress sized panel allows for the tubular spacer material 30 to
be easier to handle in smaller pieces and it is generally not
feasible to launder a single mattress size piece of tubular spacer
material 30 in a standard washing machine. A single queen size
piece of tubular spacer material 30 is not impossible to handle,
but is much more difficult to handle than smaller pieces, even if
laundering by washing in a shower or bathtub or a large washtub.
For larger beds, such as King, California King, and larger, it may
be more convenient to divide the plenum 12 into more pockets 22 to
facilitate shipping, handling and laundering and these embodiments
are within the scope of the present invention also.
[0042] As shown in FIG. 1, one or more embodiments include an air
inlet nozzle 40 to deliver air to the plenum 12. Air enters the
mattress pad through the air inlet nozzle 40 and fans out within
the tubular spacer material 30, with some of the air permeating up
through the top surface 14 of the plenum 12 as the air flows toward
an outlet at the opposite end of the plenum 12, which is shown as
air outlet vents 41 in FIG. 1. This air flow surrounds the user
underneath and to a lesser extent, on the sides, with an atmosphere
or micro-environment of cooled or heated air, depending upon which
mode is chosen. The air inlet nozzle 40 in one or more embodiments
is removable and may be removed prior to machine washing, by sewing
or otherwise attaching a small plastic adaptor to the edge of a
cloth cover, allowing the air inlet nozzle 40 to be snapped on and
off. Further embodiments of the invention include an extra layer 24
as shown in FIG. 1 which can be placed over a pocket 22 adjacent to
the air inlet nozzle 40. The extra layer 24 can provide temperature
control for the space adjacent to the air inlet nozzle 40 by
limiting air flow through the top surface 14 in the area of the
extra layer 24.
[0043] In one or more embodiments, the blower 46 delivers air to
the air inlet nozzle 40 which may include a flexible hose portion
as shown in FIG. 1, and the air delivered from the blower 46 to the
air inlet nozzle 40 is of a selectively variable temperature, a
selectively variable quantity or a selectively variable temperature
and quantity. In additional embodiments, the blower 46 includes a
decorative face plate 48 illustrated in FIG. 1 to display colors
and/or designs that a user may select to mask the blower 46, which
may be under the bed or at the end of the bed in the event it does
not fit under the bed. If under the bed, there needs to be an open
path to enable air flow to the blower 46.
[0044] In one or more embodiments, the face plate 48 which is
removable from the blower 46 and secured to the blower 46 by
plastic fittings, snap-on connectors or other securing mechanisms
that allow the face plate 48 to be removed, all of which are known
to persons skilled in the art and included within the scope of the
present invention. The face plate 48 may cover all or as shown
merely a portion of the blower 46, and be a single color such as a
neutral color or a dark color or may be a combination of colors.
The face plate 48 may be made of one or more materials including
plastic, wood or a combination of materials. The face plate 48 may
also be a design such as a wood appearing veneer as selected by the
user to present a more attractive appearing article to persons
viewing the blower 46. Embodiments of the present invention allow a
user to selectively change the face plate 48 as desired for a
variety of color, color combinations and design arrangements that
the user may wish to select.
[0045] In one or more embodiments shown in FIG. 1 and FIG. 2, a
fitted sheet 32 secures the pockets 22 together in a similar way a
fitted sheet with an elastic band fits securely onto a mattress by
gripping around the bottom edge. An outer top cover 34 may also be
sewn to the underlayer around the perimeter at the top of the
plenum 12 to further secure the pockets 22. FIG. 2 shows a closure
36 along a long side edge of the plenum 12. This closure 36 may be
made of hook and loop fastener or may be a ZIPPER running the
length of the edge. The closure 36 may also be a plastic slide,
snaps or buttons. In further embodiments, an elastic band 38 can
secure the top layer 34 to the mattress 20.
[0046] FIG. 2 shows an alternative embodiment with an air inlet
duct 42 that is molded into a foam mattress 20. The outlet air duct
44 is molded into the foam mattress 20 and allows air that does not
escape through the top surface 14 of the plenum 12, and which flows
longitudinally within and through the tubular spacer material 30,
to flow out of the cushion 10.
[0047] FIG. 3 shows a schematic view of an embodiment of the
convective cushion 10 with a thermistor or thermocouple 50. As
illustrated in FIG. 3, data from the thermistor or thermocouple 50
is communicated to a controller 52, which may be either a variable
amplitude Stirling Cycle cooler piston drive controller or Peltier
thermoelectric heat pump control circuit, to either increase or
decrease the amplitude of the Stirling Cycle piston displacement or
the power level delivered to the thermoelectric heat pump, and
hence the cooling power delivered to the cushion 10 as a function
of a preselected temperature.
[0048] In one or more embodiments, the thermistor or thermocouple
50 may be placed on the underside of the top cover 34 of the
embodiment shown in FIGS. 1 and 2 adjacent to the tubular spacer
material 30. In other embodiments of the invention, the
thermocouple 50 is placed in a seat backrest, a seat rest or may be
placed anywhere else in the conditioned air stream to provide
temperature feedback to the controller 52 and use conditioned air
temperature at any given point in the stream as a reference
temperature for the controller 52.
[0049] In further embodiments of the invention, the thermistor or
thermocouple 50 is of the miniature type in order to minimize
sensor mass and enable more rapid and sensitive reaction to changes
in cover cloth temperature.
[0050] In cooling mode, if the user is large and hot, it will take
longer for the sensor to cool down because the user's body heat
will prevent the sensor from cooling down to the temperature of the
air flowing by on the inside of the tubular spacer material 30. But
if the user is small and relatively cool, or if the user has cooled
down after sitting on the seat or lying on the mattress pad, the
sensor will begin to read more of the internal air temperature, and
this change in value can be interpreted as a signal to reduce
cooling power in order to avoid overcooling.
[0051] The embedded thermocouple or thermistor 50 is applicable to
both cooling and heating modes in the improved Peltier
thermoelectric type convective cushion 10 because heating mode is a
function of input power to the thermoelectric device and the air
flow volume through the heat pump.
[0052] Also as shown in FIG. 3, one or more embodiments include a
double pole, double throw switch 54 that is arranged to switch a
resistor 56 in and out in series with the basic main blower control
potentiometer. The basic control potentiometer controls the speed
of the main blower, which controls the cooling or heating power
delivered to the cushion 10 at a given temperature change. The
variable amplitude piston driver controller also controls the power
of the Stirling machine, but another method of control, especially
in heating mode, is to control the amount of air blown through the
cushion 10 regardless of air temperature change using the double
pole, double throw switch 54.
[0053] It can be appreciated in FIG. 3 that the trim resistor,
which drops the speed of the main blower in heating mode, is only
switched in circuit for a Stirling Cycle machine when heating mode
is selected. It is then in series with the main blower control
potentiometer, in order to maintain user control of main blower
speed and air flow within the reduced heating mode blower speed
range. Note that the double pole, double throw switch 54 is
connected to the main power switch, and that a jumper is used to
show that the two poles connect to the main switch. The diagonal
line in the double pole, double throw switch 54 in FIG. 3
represents the mechanical connection between the two poles, which
are activated by a common solenoid or other actuator.
[0054] FIG. 4 shows an embodiment of the convective cushion 10 for
use in seats, beds or other articles of furniture having deep
lateral and longitudinal styling pleats. Pleats are often used by
furniture designers to enhance the appearance of the outside
surface of seats and cushions, but present a problem when one is
trying to blow air longitudinally within the tubular spacer
material 30 located just under a body cloth or leather cover for a
seat or cushion.
[0055] For example, FIG. 10 shows one of the inventor's previous
embodiments of a seat with tubular spacer material. The styling
pleat shown in FIG. 10, a surface longitudinal pleat 58, is
relatively shallow and is located superficially over the tubular
spacer material 30 layer and the depth of the pleat is defined by
the thickness of the pad between the outer cloth or leather cover
material and the tubular spacer material 30 layer.
[0056] FIG. 4 is an illustration of an embodiment of the convective
cushion 10 of the present invention in a seat with a deep
longitudinal pleat 62 running from the seat bite line, or seat
hinge point 64, to the front edge of the seatrest 66. This is
accomplished in one embodiment by dividing the tubular spacer
material 30 into two halves, with a longitudinal gap running down
the middle as shown in FIGS. 4 and 5. The longitudinal gap leaves
room for Lister wires 68 and hog rings 70 to assemble the apparatus
into a seat. One wire 68 is anchored into the foam base 72, and the
other wire is sewn into the seat cover pleat 62 in such a way as to
allow the two wires to be clamped loosely together with the hog
ring 70 shown. One or more embodiments include an optional bolster
76 which is shown in FIG. 4.
[0057] In one or more embodiments, two or more hog rings 70 are
used on each Lister wire assembly 68. The Lister wire assembly 68
pulls a cover 74 down deeply into the gap, creating a deep styling
pleat 62 that is securely anchored to the seat base foam 72.
Additional hog rings 70 may also be located along the side edges as
shown to create deep styling pleats on the sides of the cushion as
well.
[0058] FIGS. 5 and 6 show additional embodiments of the invention
with backrests. FIG. 5 shows a single longitudinal deep styling
pleat 80 in the backrest 82 that allows for air flow from the air
inlet 84 to the air outlet 86 through the tubular spacer material
30. FIG. 6 shows a multiple styling pleats 80 in the backrest 82
which allows for air flow from the air inlet 84 to the air outlet
86 through the tubular spacer material 30. FIG. 6 also illustrates
an embodiment with multiple deep pleats 62 in the seatrest 66.
Thermal efficiency between the user and the seat 60 or cushion 10
is improved or maintained by creating deep pleats without the need
for excessive padding over the tubular spacer material 30.
[0059] FIG. 7 shows an embodiment for a convective seat or cushion
with a lateral deep styling pleat 90, which cuts across the seat
cushion, effectively cutting off longitudinal internal air flow
through the tubular spacer material layers in the seat and/or
backrest 82 as shown in FIG. 7 with arrows indicating air flow.
[0060] FIG. 8 shows an embodiment of the invention with a series
panel flow structure 92 where the deep lateral styling pleats 90
define two panels as shown in FIG. 8 but other quantities of
lateral pleats 92 with more than two panels are within the scope of
the invention. Air from a heat pump such as a Stirling or Peltier
system is delivered to backrest air inlet 92a, where the air or a
portion of the air that does not permeate through to the user
travels up to the top of the panel through the tubular spacer
material 30 and then out the back side into the U shaped duct 92b,
where the air enters the upper backrest panel as shown in FIG. 8.
This air then flows internally up through the upper panel also
containing tubular spacer material 30 to the top of the panel,
where the air can exit the back of the seat 60.
[0061] FIG. 9 shows one embodiment of the invention with a parallel
panel flow structure 94. In this embodiment, air is blown into a
manifold 94a that has a number of air outlets equal to the number
of air flow panels. Air is blown simultaneously into the lower
inlets of the panels, flows up through the panels, and then vents
from the upper outlets 94b and 94c of the panels. For further
embodiments of the invention, longitudinal air flow is enabled
through adjacent panels when separated by deep styling pleats and
the invention is not limited to the particular arrangements or
number of panels, inlets and outlets shown in the Figures.
[0062] Other embodiments of the invention include seat rests that
can be configured in the same manner for lateral and longitudinal
deep pleats. An advantage of the parallel arrangement is that the
air temperature change is substantially the same in all of the
panels, whereas in the series arrangement, the temperature change
will diminish as the air flows from one panel to the next because
heat is absorbed from the user in cooling mode and is transferred
to the user in heating mode.
[0063] FIG. 11 shows a side elevation of a series type lateral
pleat air panel arrangement with a seat headrest 100 included into
the top air panel. The present invention includes a parallel
arrangement with three or more paths, including two or more lateral
pleats and panels in the seat or backrest with an additional
parallel panel for the headrest. The above embodiments for pleated
seats can also be used with portable cushions by the use of thinner
base foam layers in the cushion.
[0064] FIGS. 12-14 show an improved Stirling cycle free-piston
device 110 used in one or more embodiments of the invention. The
device 110 includes a housing 112 enclosing a sealed chamber 114
that is filed with a gas within which the moving parts are located.
The piston 116 is resiliently supported at one end by piston spring
118 for reciprocating movement of the piston 116 toward and away
from the orifice 120. The piston spring 118 may be of the helical
coil type or of the leaf type and additionally, a lever connected
to a torsion bar spring can also be used.
[0065] As shown in FIG. 12, the magnet 130 and the coil 132
surround the piston 116 for driving the piston 116 on an electric
supply from leads 134 and 136. A displacer 138 is mounted on the
opposite side of the orifice 120 that is resiliently mounted by a
displacer spring 140 for gas pressure induced movement of the
displacer 138 toward and away from the orifice 120. The operation
of the Stirling device produces a temperature reduction at the end
142 for cooling air that is delivered to the convective cushion 10
of the invention.
[0066] As shown in detail in FIGS. 13 and 14, the cylinder 150 that
surrounds the piston 116 includes a magnetic bearing permanent
magnet 152 that is sandwiched between pole pieces 154 and 156. The
pole pieces 152 and 154 focus and direct the magnetic flux and
field into the magnetic piston ring 158 embedded in the piston 116
as shown in FIG. 13. Since the piston 116 is supported at one end,
the function of the magnetic bearing is to levitate, or suspend
approximately half the total weight of the piston at the cylinder
center line and maintain it there during reciprocation.
[0067] In one or more embodiments, the piston 116 is made of a
lightweight material other than that used for the magnetic ring and
known to persons skilled in the art in order to minimize the
magnetic flux, and hence bearing size, required to levitate and
maintain the piston 116 and magnetic piston ring 158 on center
within the annular structure of the magnetic bearing assembly and
the cylinder 150 during reciprocation. The present invention
includes the use of such lightweight materials. The piston 116
moves essentially in pure reciprocating motion, with little if any
angular moment, which is ideal for a magnetic bearing, particularly
of the passive type, as described here, and does not require
auxiliary control coils or an active feedback controller to
maintain bearing and piston concentricity.
[0068] In an embodiment of the invention, a surface coating or
treatment resulting in a very low coefficient of friction is used.
For example, in the event that the Stirling device 110 is subjected
to a sharp bump or high acceleration force and the piston is
momentarily displaced within the magnetic bearing and the cylinder
bore, low friction surfaces will minimize undesirable wear during a
"hard landing" of the piston.
[0069] In one or more embodiments, a ferrofluid 160 is placed in
the magnetic circuit gap 162 between the stator pole 130 and piston
driver coil 132 as shown in FIG. 12. In one or more additional
embodiments, ferrofluid 160 is placed in the gap 164 between the
magnetic piston ring 158 (and piston 116) and the cylinder 150 with
the magnetic bearing permanent magnet 152 and pole pieces 154 and
156 and as shown in FIGS. 13 and 14.
[0070] Ferrofluid is a liquid well known to persons skilled in the
art that contains ferromagnetic particles in suspension so that the
fluid itself acquires magnetic properties and behaves as though it
is magnetic. The magnetic field of the stator magnet holds the
Ferrofluid in place, while allowing the Ferrofluid to exhibit low
viscosity and shear strength for low pumping losses due to the
reciprocating motion of the piston driver coil. The Ferrofluid 160
increases the magnetic permeability of the air gap and increases
magnetic field strength and efficiency. Another advantage of the
Ferrofluid in the air gap is that heat generated in the piston
driver coil is more efficiently conducted across the Ferrofluid to
the stator pole and then outward to the ambient environment than it
is with a gap of helium separating the piston driver coil from the
stator pole. This helps to reduce temperature rise in the piston
drive coil, which reduces electrical resistance changes as a
function of temperature and makes for increased coil insulation
life and greater reliability.
[0071] FIG. 15 is a schematic flow chart of one embodiment of the
invention to further enhance the performance and convenience of the
seat convective cushion 10 used in a vehicle. This embodiment
allows the driver, by use of a telecommunications device, such as a
telephone, mobile telephone, pager or cellular phone/text messaging
type communication system, to activate and, if desired, to select
cooling or heating mode from blocks away in order to have the
seat(s) cool down or warm up in advance, according to the weather
and the preferences of the user(s). In one or more embodiments, a
driver of the vehicle controls the cooling and heating of the
convective cushion from a much greater distance from the vehicle
than conventional "Keyless Entry" systems, which generally only
work within a 25 foot radius of the vehicle, and often do not work
well from angles approaching the vehicle from behind and to the
side.
[0072] In further embodiments, the invention allows a user to
activate and control a Variable Temperature Steering Wheel,
("VTSW"), which is the subject of the inventor's U.S. Pat. No.
5,850,7641. In additional embodiments, the VTSW may be energized
simultaneously with the vehicle seat using the present invention,
in order to provide a steering wheel grip surface temperature that
corresponds with the seat mode.
[0073] For example, in warm weather, especially with bright
sunlight impinging upon the interior surfaces of a vehicle, both
the steering wheel grip surface and seat surfaces may become
relatively very hot. It would then be desirable to cool these
surfaces down to a pleasant temperature, preferably before entering
the vehicle, to avoid heat stress.
[0074] In embodiments of the invention, both the steering wheel and
the seat can be left in cooling mode while driving in order to
maintain vehicle occupant thermal comfort while using little, if
any, conventional space air conditioning. This saves on fuel and
reduces emissions and improves vehicle performance, as vehicle air
conditioning systems typically require approximately 3-5+
horsepower, and the single convective cushion+VTSW combination
requires not more than approximately 80 watts total for the
Stirling Cycle type convective cushion with VTSW, and approximately
140-160 watts for the Peltier thermoelectric convective cushion
with VTSW. Each additional convective cushion requires
approximately 20 watts for the Stirling cycle device and
approximately 80-100 watts for the Peltier thermoelectric
device.
[0075] FIG. 16 shows embodiments of an improved heating and cooling
source device 170 with an active cooling mode re-heater 172 that
regulates the relative humidity of the heat pump output air to the
convective cushion 10 (arrows show air flow to a cushion) by
raising the temperature of cooling mode conditioned air back to, or
above, the dew point. In one embodiment shown in FIG. 16, the
device 170 includes a main heat exchanger 171 and an auxiliary heat
exchanger 173 and positive temperature coefficient (PTC) heating
element 175.
[0076] In the embodiments shown schematically in FIG. 16, the
device 170 includes a hygrometer 174 to measure relative humidity
to provide control input to a controller for controlled operation
of the re-heater 172. In further embodiments, an ambient and/or
conditioned air temperature sensor 176 is provided, which may be
integral with the hygrometer or separate, connected to the master
controller in order to provide additional control input for the
control operation of the device 170 and re-heater 172.
[0077] Cooling air that contains water in vapor form to below the
dew point precipitates a percentage of that water vapor as
condensate. The amount of condensate depends on how far below the
dew point the air is cooled. After cooling down to the dew point,
or sub-cooling below the dew point, the air can be said to be
saturated with vapor, or at 100% relative humidity, because it is
holding all of the water that is theoretically soluble in that
volume of air, as vapor, at that temperature and barometric
pressure.
[0078] The greater the drop in temperature for a given starting
water vapor content, or relative humidity, the more condensate will
be precipitated out of the air when that air is cooled. The greater
the subsequent rise in temperature, (re-heat), the lower the
relative humidity of that air will be because some of the water
that was originally entrained in the air as water vapor has been
removed as condensate, and as the temperature of that air rises
it's capacity for holding water vapor increases again. However,
since some of the water vapor that was originally entrained in that
air has been precipitated out as condensate, the relative humidity
of that air is now lower.
[0079] One procedure is to first drop the conditioned air
temperature enough, if the starting relative humidity is higher
than desired, to get rid of some of the water vapor, then raise it
enough to reduce its relative humidity, (relative humidity is
simply the amount of water vapor contained in a given unit volume
of air divided by the theoretical maximum amount of water vapor
that can be contained in that volume of air at that given
temperature and barometric pressure), without heating it up beyond
the ideal or desired comfort temperature. This process is desired
to provide true air conditioning, wherein the relative humidity of
the environment is controlled in addition to the temperature.
[0080] In one or more operating embodiments of the invention, a
basic operational logic includes the following:
[0081] 1. If the hygrometer, (relative humidity gauge or sensor),
senses relative humidity below 50%, for example, (or any other
desired relative humidity), at any output air temperature, the
re-heater is not energized.
[0082] 2. The re-heater is not energized in heating mode, unless
ambient temperature is so low that it is necessary or
desirable.
[0083] 3. If re-heat is necessary in either cooling mode or heating
mode, the controller energizes the re-heater on a curve until the
desired relative humidity is reached for a given selected air
temperature, or until the selected temperature is maintained at a
predetermined relative humidity.
[0084] In further embodiments, a condensate trap (not shown) may be
provided, however it is in one or more embodiments simply a small
volume container with a small aperture that allows condensation
produced in the main heat exchanger to drain out without allowing
ambient air to leak into the cooling mode air stream. This can be
accomplished in one or more embodiments by using a drain hole of
approximately 0.10-0.20'' diameter plugged with a short length of
wicking material (not shown) that blocks air flow while wicking
liquid into the condensate trap chamber. The wick can also be
extended in length and extended to reach to surface of the
auxiliary heat exchanger in order to provide some evaporative
cooling to the auxiliary heat exchanger, reducing its temperature
and thereby increasing the coefficient of performance ("COP") of
the Stirling heat pump device by reducing the overall temperature
change between the cold and hot sides.
[0085] In additional embodiments of the invention, the re-heater
172 is configured to provide heated air for a heating mode that
delivers heated air to the convective cushion 10 in addition to
re-heat in a cooling mode as described above.
[0086] FIG. 17 illustrates another embodiment of an improved free
piston Stirling cycle heat pump device 170 wherein the auxiliary
fan 180 is ducted to provide heated air to the reheater 172 to
control the relative humidity of the air to be delivered to a
convective cushion 10 (outlet arrows in FIG. 17 show air flow to a
cushion).
[0087] In cooling mode, the Stirling Cycle heat pump cools air that
is drawn through the main heat exchanger 171, (main heat exchanger
171 as also shown in FIG. 16). This cooled air is also blown
through the passive cooling mode re-heater central heat exchanger
on its way to the cushion. Simultaneously, the auxiliary fan 180
draws ambient air, via the re-heater air duct 182, in the direction
of the arrows shown in FIG. 17 through duct 182, through the
annular passive re-heater heat exchanger fins. Thus, heat from
ambient air is transferred to the cooled air raising the
temperature of the cooled air and lowering the relative humidity of
the cooled air, while simultaneously lowering the temperature of
the ambient air that is then drawn through the auxiliary heat
exchanger.
[0088] In addition to lowering the relative humidity of the cushion
air, other functions that may be provided include:
[0089] 1. The thermal transfer efficiency of heat from the
auxiliary heat exchanger 173 to the ambient air is increased
because reducing the temperature of the ambient air increases the
temperature change between the auxiliary heat exchanger and the
ambient air.
[0090] 2. Because of increased thermal transfer efficiency, and a
lower auxiliary heat exchanger temperature, the total heat pump
temperature change from hot side to cold side is reduced,
increasing the COP of the Stirling heat pump device, which
increases the energy efficiency of the Stirling Cycle heat pump
device. In one or more embodiments, a positive temperature
coefficient ("PTC") device 175 and heat exchanger 171 shown in FIG.
17 for heating mode can also be eliminated by attaching positive
temperature coefficient elements 175 to the passive cooling mode
reheater and energizing these PTC elements 175 when heating mode is
desired. The auxiliary fan 180 is not energized during heating
mode, so there is no air flow through the outer section of the
passive reheater to reduce its efficiency in heating mode.
[0091] FIGS. 18 and 19 illustrate another embodiment of the
invention that can be used by more than one sleeper or sleepers
simultaneously. As shown in FIG. 18, the plenum 12 includes a
divider 190 that divides the plenum into sections, which can be two
sections as shown in FIG. 18 or more than two sections depending on
the needs of the user or users. Each of the sections can have a
separate inlet for delivering an air flow to the section and as
shown in FIG. 18, a first air inlet nozzle 192 and second inlet
nozzle 194 are provided in the embodiment with two sections. In
further embodiments, each of the sections includes an outlet vent
shown as air outlet vent 196 and air outlet vent 198 in the
embodiment illustrated in FIG. 18 to allow air flow out of the
sections.
[0092] The divider 190 is relatively impermeable to air and extends
from the top surface 14 to the bottom surface 18 as shown in FIG.
19 to prevent substantial lateral mingling of separate air streams
supplied by a heat pump, which may be a thermoelectric heat pump
with two separate cooled or heated air outputs or a Stirling Cycle
heat pump with two separate cooled or heated air outputs. These
heat pumps with two air outputs are not shown in FIG. 18 because
they are well known to persons skilled in the art and are
essentially single output devices doubled up to create two
independently adjustable heat pumps. A purpose of the dual air flow
structure and system is to allow the sleepers to have different
temperature settings.
[0093] In embodiments of the invention, the divider 190
substantially prevents lateral mixing or mingling of the different
air flows, such as from air inlet nozzle 192 and second inlet
nozzle 194 as shown in FIG. 18. There is potential for some lateral
air mixing between that portion of the air in the air flow
structure that percolates up through the bedding top, however most
of the air in the tubular spacer material 30 flows through the
tubular spacer material 30 and vents out of the outlet vents shown
as air outlet vent 196 and air outlet vent 198 in FIG. 18 opposite
the air inlets. This means that preventing lateral mixing within
the tubular spacer material 30 is an effective way to provide an
essentially independent air temperature within, and hence,
essentially independent cooling and heating effects on the sections
of the convective cushion 10. In one or more embodiments, an extra
layer 24 is provided as shown in FIG. 18 and in FIG. 19 which can
be placed over a portion of the top surface 14 to provide
temperature control for the space adjacent to one or more of the
inlet nozzles 192 and 194 by limiting air flow through the top
surface 14 in the area of the extra layer 24.
[0094] FIG. 20 illustrates a further embodiment of the invention in
a perspective view of a solution to unraveling of filaments on the
ends of cut pieces of the tubular spacer material 30. Such a
solution is applicable to the convective cushion 10 such as
described and shown in FIG. 1 and in FIG. 18. Prior to cutting the
tubular spacer material 30 to a desired length, with length being
along the longitudinal direction or length of the tubes, film 200,
such as a flexible plastic film including SARAN Wrap or tape, is
affixed to the cut line or end being cut either with adhesive that
has already been applied to the film 200 or with spray or brushed
adhesive.
[0095] After the adhesive has cured, the tubular spacer material 30
is cut down the middle of the tape or film leaving a margin of film
200 on each side of the cut line 202 as shown in FIG. 20. This
allows the film 200 to be adhered to the fibers of the tubular
spacer material 30 before cutting and remains adhered after cutting
which keeps the fibers or filaments from unraveling.
[0096] FIG. 21 shows in a schematic illustration an embodiment of
an improved Peltier thermoelectric heat pump 210 for use with the
present invention. In this embodiment, an auxiliary blower 212
draws air through an auxiliary heat exchanger 214 that has fins in
both an outer air stream and an inner air stream. In the cooling
mode for this embodiment, the main blower 216 draws, or blows,
ambient air through the main heat exchanger 218, cooling the air
below ambient temperature. The main blower 216 then blows that
cooled air through a heat exchanger that can include inner fins and
outer fins. Meanwhile, the auxiliary blower 212 draws air in an
opposite direction, pulling ambient air that has been cooled below
ambient in the re-heater heat exchanger 220 across the auxiliary
heat exchanger 214. The thermoelectric device 215 is shown in FIG.
21. FIG. 21a is an end view of the improved Peltier thermoelectric
heat pump 210 shown in FIG. 21 and illustrates an end view of the
reheater heat exchanger 220.
[0097] The cooled air results in a lower auxiliary heat exchanger
temperature, which lowers the overall temperature difference
between the cold side and the hot side of the Peltier device,
increasing its coefficient of performance and energy efficiency.
The relative humidity of the cooled air delivered to the convective
cushion (as shown in arrow 222) is thereby reduced.
[0098] A condensate wick 224 is shown communicating between the
main heat exchanger 218 and the auxiliary heat exchanger 214.
Condensation produced in the main heat exchanger 218 in cooling
mode is drawn to the auxiliary heat exchanger 214 by the wick 224,
without allowing the two air streams to co-mingle, providing
whatever condensate is available to the auxiliary heat exchanger
214. The condensation evaporates on the relatively warm auxiliary
heat exchanger producing an additional cooling effect which
increases the COP of the thermoelectric device 210 and improves its
energy efficiency further beyond what is provided by the
counter-regenerative auxiliary air cooling system.
[0099] In further embodiments, if a thermoelectric device has
sufficient capability, such as, for example, that described in the
inventor's U.S. Pat. No. 6,855,880 entitled Modular Thermoelectric
Couple and Stack, it is useful to control main blower air relative
humidity by using the active reheater to raise cooling air
temperature and thereby reduce its relative humidity if
desired.
[0100] FIG. 22 is a schematic illustration of another embodiment of
an improved Peltier thermoelectric heat pump 210 for use with the
present invention in a heating mode. In this embodiment, the
re-heat heat exchanger 220 becomes regenerative in this mode
because it is a form of bottom cycling, in which heat energy is
taken from a low point in the cycle to a higher point in the cycle
to improve efficiency. By pre-heating auxiliary air, the cold side
runs at a higher temperature in heating mode.
[0101] Since the main exchanger 218 is hot in heating mode, the
warmer the auxiliary heat exchanger 220 is, the lower the overall
temperature change, hence the higher the COP, or energy efficiency
of the Peltier thermoelectric heat pump. In one embodiment, the
device 210 is designed with enough capacity to produce the desired
net heating mode air temperature even with a bit of cooling
provided by the regenerator.
[0102] While the present invention has been described with regards
to particular embodiments, it is recognized that additional
variations of the present invention may be devised without
departing from the inventive concepts in the claims and the
invention includes the full breadth and scope of the claims
including all equivalents.
* * * * *