U.S. patent application number 14/307211 was filed with the patent office on 2014-10-16 for thermal module.
The applicant listed for this patent is Gentherm Incorporated. Invention is credited to Dusko Petrovski.
Application Number | 20140305625 14/307211 |
Document ID | / |
Family ID | 36117684 |
Filed Date | 2014-10-16 |
United States Patent
Application |
20140305625 |
Kind Code |
A1 |
Petrovski; Dusko |
October 16, 2014 |
THERMAL MODULE
Abstract
A climate control device includes a first and a second thermal
module. The first module is configured to provide climate
conditioned air to a first portion of a seat. The second module is
configured to provide climate conditioned air to a second portion
of the seat. A control system is provided for controlling the
climate control device. The control system includes an input device
for providing a set point for the system. A first control unit of
the control system is provided for the first thermal module and a
second control unit is provided for the second thermal module.
Inventors: |
Petrovski; Dusko;
(Washington, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Gentherm Incorporated |
Northville |
MI |
US |
|
|
Family ID: |
36117684 |
Appl. No.: |
14/307211 |
Filed: |
June 17, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13973290 |
Aug 22, 2013 |
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14307211 |
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13169948 |
Jun 27, 2011 |
8516842 |
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13973290 |
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12559087 |
Sep 14, 2009 |
7966835 |
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13169948 |
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11047077 |
Jan 31, 2005 |
7587901 |
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12559087 |
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60637725 |
Dec 20, 2004 |
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Current U.S.
Class: |
165/203 ; 62/3.3;
62/3.61 |
Current CPC
Class: |
B60H 1/00478 20130101;
B60N 2/5642 20130101; B60N 2/5692 20130101; B60H 1/2218 20130101;
B60H 1/00285 20130101; A47C 7/74 20130101; B60N 2/5635 20130101;
B60H 2001/003 20130101; B60N 2/5614 20130101; B60N 2/5657
20130101 |
Class at
Publication: |
165/203 ; 62/3.3;
62/3.61 |
International
Class: |
B60H 1/00 20060101
B60H001/00; B60N 2/56 20060101 B60N002/56 |
Claims
1-10. (canceled)
11. A climate control assembly for a vehicle, comprising: a
protective casing having at least one fluid inlet and at least one
fluid outlet, said protective casing defining an enclosed interior
space; a thermal conditioning device; a first heat exchanger in
thermal communication with the thermal conditioning device; a fluid
pump configured to transfer a fluid from the at least one fluid
inlet to the at least one fluid outlet at least partially through
the first heat exchanger to selectively heat or cool the fluid
exiting the at least one fluid outlet; and a controller for
selectively controlling at least one of the thermal conditioning
device and the fluid pump; and wherein the thermal conditioning
device, the first heat exchanger, the fluid pump and the controller
are situated within the enclosed interior space of the protective
casing; and wherein the climate control assembly does not require
another physically separate independent controller in order to
control the at least one of the thermoelectric device and the fluid
pump.
12. The climate control assembly of claim 11, further comprising a
temperature sensor operatively connected to the controller.
13. The climate control assembly of claim 11, further comprising a
temperature sensor indicative of the temperature of the fluid
conditioned by the thermal conditioning device.
14. (The climate control assembly of claim 11, wherein the
controller adjusts the operation of the thermal conditioning device
and the fluid pump based upon predetermined logic.
15. The climate control assembly of claim 14, wherein the
controller comprises a single controller configured to adjust
operation of the thermal conditioning device and the fluid pump
based upon the predetermined logic.
16. The climate control assembly of claim 14, wherein the
predetermined logic uses a temperature signal and an occupant input
to adjust the operation of the thermal conditioning device and the
fluid pump.
17. The climate control assembly of claim 16, wherein the occupant
input includes a temperature setting.
18. The climate control assembly of claim 11, further comprising a
power control unit to provide electrical capacity to the thermal
conditioning device and the fluid pump.
19. The climate control assembly of claim 11 wherein the thermal
conditioning device comprises a thermoelectric device.
20. A climate control assembly for a vehicle, comprising: a
protective casing having at least one fluid inlet and at least one
fluid outlet, said protective casing defining an enclosed interior
space; a thermal conditioning device; a first heat exchanger in
thermal communication with the thermal conditioning device; a
temperature sensor; a fluid pump configured to transfer a fluid
from the at least one fluid inlet to the at least one fluid outlet
at least partially through the first heat exchangers to selectively
heat or cool the fluid exiting the at least one fluid outlet; and a
controller configured to selectively control at least one of the
thermal conditioning device and the fluid pump according to
predetermined logic based upon temperature information from the
temperature sensor and an input from a user input device; and
wherein the thermal conditioning device, the first heat exchanger,
the fluid pump and the controller are situated within the enclosed
interior space of the protective casing.
21. The climate control assembly of claim 20, wherein the
temperature sensor is indicative of the temperature of the fluid
conditioned by the thermal conditioning device.
22. The climate control assembly of claim 20, wherein the
controller adjusts the operation of the thermal conditioning device
and the fluid pump based upon the predetermined logic.
23. The climate control assembly of claim 22, wherein the
controller comprises a single controller configured to adjust the
operation of the thermal conditioning device and the fluid pump
based upon the predetermined logic.
24. The climate control assembly of claim 20, wherein the input
from the user input device includes a temperature setting.
25. The climate control assembly of claim 20, comprising a power
control unit to provide electrical capacity to the thermal
conditioning device and the fluid pump.
26. The climate control assembly of claim 20 wherein the thermal
conditioning device comprises a thermoelectric device.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/973,290, filed Aug. 22, 2013, which is a
continuation of U.S. patent application Ser. No. 13/169,948, filed
Jun. 27, 2011, which is a continuation of U.S. patent application
Ser. No. 12/559,087, filed Sep. 14, 2009 and issued on Jun. 28,
2011 as U.S. Pat. No. 7,966,835, which is a continuation of U.S.
patent application Ser. No. 11/047,077, filed Jan. 31, 2005 and
issued on Sep. 15, 2009 as U.S. Pat. No. 7,587,901, which claims
the priority benefit under priority benefit under 35 U.S.C.
.sctn.119(e) of U.S. Provisional Application No. 60/637,725, filed
Dec. 20, 2004, the entireties of U.S. patent application Ser. No.
11/047,077, filed Jan. 31, 2005 and U.S. Provisional Application
No. 60/637,725, filed Dec. 20, 2004 are hereby incorporated by
reference herein.
BACKGROUND
[0002] 1. Field of the Inventions
[0003] This invention relates to climate control. More
specifically, this invention relates to climate 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 climate control systems for vehicle seats. Such
climate 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 conditions
the climate of the air and delivers the conditioned air to the
channels and passages. The climate 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 climate control
systems for seats. For example, some climate control systems are
not easily integrated into existing seat construction methods. Such
systems require a significantly greater number of parts as compared
to existing automotive seats, and often require complex mechanical
parts and/or electrical connections. In the past, this has resulted
in increased costs for individualized occupant cooling in
automobiles.
[0008] In particular, many advanced climate control systems allow
the user to control individually the climate for each seat in the
vehicle. In some systems, the user may also vary the climate
between different portions of the seat. For example, the user may
vary the climate settings between the seat cushion and the back
cushion. In one arrangement, the user inputs the desired climate
setting through an input or control switch. An intermediate control
module interprets the signal from the control switch and generates
control signals for a pair thermal modules, which are individually
associated with the seat and back cushions. A set of power, control
and signal wires extend between the thermal modules and the
intermediate control module. These wires are used to control and
drive the thermal modules to achieve the desired climate setting.
In certain arrangements, seven or more wires may extend between the
intermediate control modules and each thermal module. For one seat,
therefore, there may be over fourteen wires extending between the
intermediate control module and the climate control devices. These
wires require a significant amount of space and complicate the
design and layout of the climate control system.
[0009] Thus, there is a need for an improved climate control
apparatus for a climate control system for seats.
SUMMARY
[0010] Accordingly, one aspect of the present invention involves a
device for thermally conditioning and moving a fluid. The device
includes a thermoelectric device to convert electrical energy into
thermal energy producing a temperature change in response to an
electrical current being applied thereto. A fluid transfer device
produces a fluid flow that is in thermal communication with the
thermoelectric device so that the thermal energy generated by the
thermoelectric device is transferred to the fluid flow. A housing
has an outlet and an inlet through which the fluid flow is
directed. The thermoelectric device and the fluid transfer device
are positioned at least partially within the housing. A sensor is
configured to provide a temperature signal that is indicative of
the temperature of the fluid flow. A control unit is coupled to the
housing and is operatively connected to the sensor. The control
unit is configured to receive a set point signal that is indicative
of a desired temperature of the fluid flow based and configured to
control the thermoelectric device and the fluid transfer
device.
[0011] Another aspect of the present invention comprises a device
for thermally conditioning and moving a fluid. The device includes
a thermoelectric device to convert electrical energy into thermal
energy producing a temperature change in response to an electrical
current being applied thereto. A fluid transfer device produces a
fluid flow that is in thermal communication with the thermoelectric
device. A sensor is configured to provide a temperature signal that
is indicative of the temperature of the fluid flow. A control unit
is operatively connected to the sensor. The control unit is
configured to receive a set point signal that is indicative of a
desired temperature of the fluid flow and, based upon the set point
signal and the temperature signal, to control the thermoelectric
device and the fluid transfer device. The control unit is also
configured to receive a second temperature signal from a second
sensor. The second temperature signal is indicative of the
temperature of the fluid flow within a second device for thermally
conditioning and moving a fluid. The control unit is configured to
control the second device based upon the set point signal and the
second temperature signal so as to control the temperature and
fluid flow within the second device.
[0012] Another aspect of the present invention comprises a climate
controlled seat assembly that includes a seat cushion having a
ventilation system. A main control unit is configured to generate a
mode signal for the seat assembly. A first thermal module is
configured to thermally condition air at a first portion of the
ventilation system. A first sensor is configured to sense a
condition of the first thermal module and to provide a condition
signal corresponding to the sensed condition. A first control unit
is operatively connected to the main control unit, the first sensor
and the first thermal module. The first control unit is configured
to drive the first thermal unit based upon the mode signal and the
condition signal. A second thermal module is configured to
thermally condition air at a second portion of the ventilation
system. A second control unit is provided for the second thermal
module. The first control unit is configured to control the second
control unit based upon the mode signal and the condition
signal.
[0013] Another aspect of the present invention involves a method
for thermally conditioning a space adjacent a seat assembly. In the
method, an input signal from an input device is transmitted to a
control unit of a first thermal module. The first thermal module is
controlled based at least in part upon the input signal to deliver
thermally conditioned air to a first portion of a seat assembly. A
control signal is transmitted from the control unit of the first
thermal module to a control unit of a second thermal module so as
to control the second thermal module and deliver thermally
conditioned air to a second portion of the seat assembly based at
least in part upon the input signal from the input device.
[0014] Another aspect of the present invention involves a climate
controlled seat assembly that comprises a seat cushion, a main
control unit, a first thermal module and a second thermal module.
The seat cushion includes a ventilation system having a first
portion and a second portion. The main control unit is configured
to generate a mode signal for the seat assembly. The first thermal
module is configured to thermally condition air that is delivered
to the first portion of the ventilation system. The first thermal
module comprises a first sensor configured to sense a condition of
the first thermal module and to provide a condition signal
corresponding to the sensed condition and a first control unit that
is operatively connected to the main control unit, the first sensor
and the first thermal module. The first control unit is configured
to drive the first thermal unit based upon the mode signal and the
condition signal of the first thermal module. The second thermal
module hat is configured to thermally condition air that is
delivered to the second portion of the ventilation system. The
second thermal module comprises a second sensor configured to sense
a condition of the second thermal module and to provide a condition
signal corresponding to the sensed condition and a second control
unit that is operatively connected to the main control unit, the
second sensor and the second thermal module. The second control
unit is configured to drive the second thermal unit based upon the
mode signal and the condition signal of the second thermal
module.
[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 assembly removed;
[0021] FIG. 4 is a schematic illustration of the vehicle seat
assembly and climate control system of FIG. 1;
[0022] FIG. 5 is a perspective view of a thermal module of the
climate control system of FIG. 1;
[0023] FIG. 6 is a schematic illustration of another embodiment of
a climate control system; and
[0024] FIG. 7 is a schematic illustration the vehicle seat assembly
of FIG. 1 with a modified embodiment of a climate control
system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] FIGS. 1 and 2 illustrate an exemplary embodiment of a seat
assembly 30 that comprises a seat 32 and a backrest 34. The seat
assembly 30 includes a climate control system 36, which will be
described in more detail below with reference to FIG. 4.
[0026] 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.
[0027] 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.
[0028] With continued reference to FIGS. 1 and 2, the backrest 34
has a front side 54, a rear side 56, a top side 58 and a bottom
side 60. The backrest 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 34 is generally positioned between the sides 57, 59
of the backrest 34 near the seat portion 32.
[0029] 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.
[0030] FIG. 2A is a cross-sectional view of a portion of the
backrest 34. As shown, the backrest 34 is generally formed by a
cushion 72, which is covered with an appropriate covering material
74 (e.g., upholstery). The cushion 72 is typically supported on a
metallic 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 may be constructed in a similar
manner as the backrest 34.
[0031] FIG. 3 illustrates the seat assembly 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.
[0032] As shown in FIG. 3, the backrest 34 of the seat assembly 30
is provided with a backrest fluid distribution system 76A. The
distribution system 76A comprises an inlet passage 78A 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.
[0033] 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.
[0034] With reference back to FIG. 2A, the channels 80A are covered
by a scrim 81A to define distribution passages 82A for transporting
air through the seat assembly 30. The scrim 81A includes one or
more openings 84A for delivering air to and/or from the
distribution passages 82A. The scrim 81A may be formed of a
material similar to the cushion 72. In the illustrated embodiment,
the scrim 81A is attached to the cushion 72 in a manner that limits
leakage between the scrim 81A and cushion 72 thereby directing the
flow of air through the openings 84A. In one embodiment, an
adhesive is used to attach the scrim 81A to the cushion 72. In
other embodiments, a heat stake or fasteners may be used.
[0035] With continued reference to FIG. 2A, a 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 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 is
formed from a leather, or leather-like material that is provided
with small openings or apertures.
[0036] With reference to FIGS. 2B and 3, the seat 32 of the seat
assembly 30 is provided with a seat cushion fluid distribution
system 76B. The seat distribution system 76B also comprises an
inlet passage 78B through 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.
[0037] In the seat distribution system 76B, the channels 80B are
also covered by a scrim 81B to define distribution passages 82B for
transporting air through the seat assembly 30. The scrim 81B
includes one or more openings 84B for delivering air to and/or from
the distribution passages 82B. As described above, the scrim 81B
may be formed of a material similar to the cushion 72 and 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 disposed between the scrim 81B and the seat covering 74.
[0038] As will be explained in more detail below, in one
embodiment, conditioned air 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 layer
86A, 86B. The air is then directed through the covering 74 to a
space adjacent to the front surface 48 of the backrest 34 or the
top surface 50 of the seat 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 34 and/or the top surface 50 of
the seat 32. In such an embodiment, the air is withdrawn through
the covering 74 and into the distribution layers 86A, 84B. The air
is then withdrawn through the openings 84A, 84B, into the
distribution passages 82A, 82B and through the inlet passage 78A,
78B.
[0039] 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 34 and the
seat 32 may be modified in several different manners. For example,
the shape and/or number of channels 80A, 80B 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 yet another embodiment, a
separate insert may be positioned within the channels 80A, 80B for
distributing the air. See e.g., 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. In other
embodiments, the distribution systems 76A, 76B or portions thereof
may be combined with each other.
[0040] FIG. 4 is a schematic illustration of the climate control
system 36. In the illustrated embodiment, the climate control
system includes a back thermal module 92A and seat thermal module
92B. As will be explained below, both thermal modules 92A, 92B are
configured to provide conditioned air (and/or to remove air in some
embodiments) to the distribution systems 76A, 76B described above.
In this manner, the thermal modules 92A, 92B provide a fluid flow
to either warm or cool the front surface 48 of the backrest 34 and
the top surface 50 of the seat portion 32 respectively.
Specifically, the climate control apparatus 36 preferably provides
conditioned air that is either heated or cooled relative to the
temperature of the front surface 48 of the back rest 32 and the top
surface 50 of the seat 32.
[0041] In the illustrated embodiment, the thermal modules 92A, 92B
preferably each include a thermoelectric device 94A, 94B for
temperature conditioning (i.e. selectively heating 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 thermal 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). The modules 92A, 92B also preferably include a
waste heat exchanger 100A, 100B 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 thermal 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 exchangers 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.
[0042] It should be appreciated that the thermal modules 92A, 92B
described above represents only one exemplary embodiment of a
device that may be used to condition the air supplied to the
distribution systems 76A, 76B. Any of a variety of differently
configured thermal modules may be used to provide conditioned air.
Other examples of thermal 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 thermal module is currently sold under the
trademark Micro-Thermal Module.TM. by Amerigon, Inc. In another
example, the thermal module may comprise a pump device without a
thermoelectric device 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 thermal modules 92A, 92B, may share one or more components
(e.g., pumping devices, thermoelectric devices, etc.) with the
vehicles general climate control system.
[0043] In operation, fluid in the form of air can be delivered from
the thermal modules 92A, 92B, through the conduits 98A, 98B to the
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 layer 86A, 86B and through the covering 74.
In this manner, conditioned air can be provided to the front
surface 48 of the backrest 34 and the top surface 50 of the seat
32.
[0044] In a modified embodiment, air from within the passenger
compartment of the automobile can be drawn through the covering 74,
into the distribution layer 86A, 86B and through the openings 84A,
84B. The air then can flow through the distribution passages 82A,
82B, into the inlet passage 78A, 78B and then into the conduit 98A,
98B. In this manner, the climate control system 36 can provide
suction so that air near the surface of the seat assembly 30 is
removed.
[0045] A control system 104 for the climate 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).
[0046] With continued reference to FIG. 4, the input device 106 is
operatively connected to a seat control module 110, which in the
illustrated embodiment is associated with the seat thermal module
92B. The seat control module 110 is, in turn, operatively connected
to the pumping device 102B and the thermoelectric device 94B. In
addition, a temperature sensor 112 is provided to measure the
temperature of the fluid conditioned by the thermoelectric device
94B. The temperature sensor 112 is operatively connected to the
seat control module 110. The seat control module 110 is preferably
also 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 all of the
aforementioned devices (92B, 94B, 112) of the seat thermal module
92B. The seat control module 110 preferably also has a controller
that is configured to receive the occupant inputs from the input
device 106 and the temperature information from the temperature
sensor 112. From this information, the seat control module 110 is
configured to make adjustments to the operation of the
thermoelectric device 94B and the fluid pump 102B according to a
predetermined logic designed to ensure occupant comfort and to
protect against system damage. Those of skill in the art will
appreciate that the seat control module 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 additions, the controller within the
seat control module 110 may be combined or divided as deemed
appropriate.
[0047] 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) 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 an additional intermediate device).
[0048] The seat 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 thermal module 92B only if the vehicle's
engine is running.
[0049] With continued reference to FIG. 4, the backrest thermal
module 92A includes a backrest control module 120. As shown, the
backrest control module 120 is operatively connected to the
thermoelectric device 94A and the fluid pump 102A for the backrest
34. The backrest control module 120 is connected to the power
source 114 and the ground source 116 and includes a controller
configured to provide sufficient electrical capacity to operate the
thermoelectric device 94A and the fluid pump 102A. As will be
explained below, the backrest control module 120 is configured to
receive a control signal from the seat control module 110. From
this information, the backrest control module 120 operates the
thermoelectric device 94B and the fluid pump 102B to ensure
occupant comfort and safety, and protect against system damage.
Those of skill in the art will appreciate that the backrest control
module 120 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.
[0050] In the illustrated embodiment, a communication line 122
operatively connects the backrest control module 120 to the seat
control module 110. In one embodiment, the seat control module 110
is configured to receive the inputs from the input device 106 to
make adjustments to the operation of the thermoelectric device 94A
and the fluid pump 96A in the backrest thermal module 92A according
to a predetermined logic designed to ensure occupant comfort and
safety, and protect against system damage. The control signals
generated by the seat control module 110 are transmitted to the
backrest control module 120 through the communication line 122.
[0051] The illustrated embodiment optionally includes a backrest
temperature sensor 124 for measuring the temperature of the fluid
that has been thermally conditioned by the backrest thermal module
92A. The information from this temperature sensor 124 may
optionally be transmitted through the communication line 122 to the
seat control unit 110. In such a configuration, the seat control
unit 110 may be configured to use this temperature signal to
generate the control signals transmitted to the backrest control
unit 120. In yet another modified embodiment, the control unit 120
for the backrest 34 may be operatively connected directly to the
input device 106 in a manner similar to that described above for
the control unit 110 for the seat 32. An example of such an
embodiment will be described in more detail below with reference to
FIG. 7. It should also be appreciated that the control unit 120 for
the backrest 34 may be operatively connected to the power source
114 and the ground source 116 through the communication line
122.
[0052] In the above description, the control units 110, 120 are
described as being associated with the "back" or "seat" cushion. In
modified embodiments, it should be appreciated that the features of
the back and seat controllers may be reversed. That is, the
backrest control module 120 may be configured to interpret the
signals from the user input device 106 and to control the seat
control module. However, the above-described arrangement is
generally preferred because in most applications there is generally
more room in the seat cushion 32 for various electrical connections
that are described above. In still other embodiments, the features
of the back and seat controllers may be applied to different zones
of a seat, such as, for example, a top and bottom portion of a
backrest. In other embodiments, the features of the back and seat
controllers 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.
[0053] In a preferred embodiment, the backrest control unit 120
and/or the seat control unit 110 are generally coupled to the other
components of their respective thermal modules 92A, 92B and, more
preferably, disposed substantially within the same housing or
protective casing 130 which contains the thermoelectric device 94A,
94B and fluid pumps 102A, 102B. FIG. 5 is an illustration of an
exemplary cushion thermal unit 92B, which includes a casing 130
that generally surrounds the thermoelectric device 94B and fluid
pump 102B. The casing 130 preferably also surrounds the seat
control module 110. Electrical wires 132 are operatively connected
to the seat control module 110 and extend through an opening 134 in
the casing 130. In the illustrated embodiment, the electrical wires
132 provide the operational connection to the input device 106,
power source 114, ground source 116 and/or engine control unit 118.
An electrical connector (not shown) may be provided at one end of
the electrical wires 132 for providing a convenient connection
point. The electrical wires may be positioned within a protective
tube 138 to form what is often referred to in the art as a "pig
tail."
[0054] With continued reference to FIG. 5, another set of
electrical wires 140 may be used to form the communication line 122
between the seat control unit 110 and the backrest control unit
120. These electrical wires 140 preferably also extend from an
opening in the casing 130. These wires 140 may be positioned within
a protective tube 141 to form a "pig tail." The electrical wires
140 may also provide the connection between the backrest control
module 120 and the power source 114 and ground source 116.
[0055] The above described embodiments have several advantages. For
example, there are no physically separate independent controllers
for controlling the back and seat thermal modules 92A, 92B as is
typically found in the prior art. This reduces the amount of space
required by the climate control system 36 and reduces the
complexity of the overall system design. Advantageously, the system
36 also requires fewer connections between various components. As
described above, the prior art often required seven or more
electrical connections that extend between the intermediate
controller and the thermal modules 92A, 92B. The illustrated
embodiment significantly reduces the number of these connections,
thereby decreasing the complexity of the system, which reduces
installation time and saves space.
[0056] FIG. 6 illustrates a climate control system 150 which is
configured to control the climates of two seat assemblies 152, 154.
As shown, the system 150 includes a back and seat thermal modules
92A, 92B as described below for each seat. The seat thermal modules
92B of each seat are operatively connected to an input device 106',
which may include appropriate user interface such that the user may
select the desired climate control for each seat. Those of skill in
the art will recognize that the above-described system may be
expanded to three, four or more seats and/or seats of different
configurations and/or having more than two thermal units associated
with each seat.
[0057] FIG. 7 illustrates a modified embodiment of a climate
control system 36'. In FIG. 7, like elements to those shown in FIG.
4 are designated with the same reference numbers used in FIG. 4. In
addition, only certain elements of the climate control system 36'
will be described in detail below. For those elements not described
in detail, reference may be made to the previous detailed
description of those elements.
[0058] As with the embodiment shown in FIG. 4, the climate control
system 36' 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'. As will be explained
below, in this embodiment, the user input device 106 is operatively
connected to both the seat control module 110 and the back control
module 120'.
[0059] The seat control module 110 is operatively connected to the
pumping device 102B and the thermoelectric device 94B. In addition,
a temperature sensor 112 is provided to measure the temperature of
the fluid conditioned by the thermoelectric device 94B. The
temperature sensor 112 is operatively connected to the seat control
module 110. The seat control module 110 is preferably also
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 all of the aforementioned
devices (92B, 94B, 112) of the seat thermal module 92B. The seat
control module 110 may also be operatively connected to a vehicle
control device 118 that indicates whether the vehicle's ignition
has been turned on. As described above with reference to FIG. 4,
the seat control module 110 preferably also has a controller that
is configured to receive the occupant inputs from the input device
106 and the temperature information from the temperature sensor
112. From this information, the seat control module 110 can make
adjustments to the operation of the thermoelectric device 94B and
the fluid pump 102B according to a predetermined logic designed to
ensure occupant comfort and to protect against system damage.
[0060] As mentioned above, in this embodiment, the back control
unit 120' is also operatively connected to the user input device
106. The back control module 120', in turn, is operatively
connected to a pumping device 102A and a thermoelectric device 94A.
In addition, a temperature sensor 124 may be provided to measure
the temperature of the fluid conditioned by the thermoelectric
device 94A. The temperature sensor 124 is operatively connected to
the back control module 120'. The back control module 120' is
preferably also operatively connected to the power source 114 and
the ground source 116 and includes an appropriate power control
unit to provide sufficient electrical capacity to operate all of
the aforementioned devices (92A, 94A, 124) of the back thermal
module 92A. As with the seat control module 110, the back control
module 120' preferably has a controller that is configured to
receive the occupant inputs from the input device 106 and the
temperature information from the temperature sensor 124. From this
information, the back control module 120' makes adjustments to the
operation of the thermoelectric device 94A and the fluid pump 102A
according to a predetermined logic designed to ensure occupant
comfort and to protect against system damage.
[0061] In a preferred embodiment, the backrest control unit 120
and/or the seat control unit 110 are generally coupled to the other
components of their respective thermal modules 92A, 92B and, more
preferably, disposed substantially within the same housing or
protective casing which contains the respective thermoelectric
device 94A, 94B and fluid pumps 102A, 102B.
[0062] In one embodiment, the back control module 120' and the seat
control module 110 are substantially similar such that the thermal
modules 92A, 92B are also substantially similar. Such an
arrangement allows for the same type of thermal module to be used
for both the seat and back cushions 32, 34, while consequentially
reducing costs associated with inventory and production as compared
to a system that utilizes two different types of thermal modules.
In addition, as with the embodiment of FIG. 3, there are no
physically separate independent controllers for controlling the
back and seat thermal modules 92A, 92B as is typically found in the
prior art. This reduces the amount of space required by the climate
control system 36' and reduces the complexity of the overall system
design. Advantageously, the system 36' also requires fewer
connections between various components. As described above, the
prior art often required seven or more electrical connections that
extend between the intermediate controller and the thermal modules
92A, 92B. The illustrated embodiment significantly reduces the
number of these connections, thereby decreasing the complexity of
the system, which reduces installation time and saves space.
[0063] To assist in the description of the disclosed embodiments,
words such as upward, upper, downward, lower, vertical, horizontal,
upstream, and downstream have and 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.
[0064] 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.
* * * * *