U.S. patent application number 15/978802 was filed with the patent office on 2019-11-14 for vehicle seat with thermal comfort module.
The applicant listed for this patent is Faurecia Automotive Seating, LLC. Invention is credited to Shaun Dorian Tait.
Application Number | 20190344687 15/978802 |
Document ID | / |
Family ID | 68465101 |
Filed Date | 2019-11-14 |
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United States Patent
Application |
20190344687 |
Kind Code |
A1 |
Tait; Shaun Dorian |
November 14, 2019 |
VEHICLE SEAT WITH THERMAL COMFORT MODULE
Abstract
A vehicle seat includes a thermal comfort module installed in a
recess of a foam cushion beneath a trim cover. The thermal comfort
module includes an air duct, a thermoelectric device, a heat sink
extending inside the air duct from the thermoelectric device, and
an air mover that causes air to flow from the passenger cabin,
through the seating surface, along the air duct and heat sink, and
back out of the seat. In a seat cooling mode, the air flowing along
air duct absorbs heat from one side of the thermoelectric device
via the heat sink while the opposite side of the thermoelectric
device absorbs heat from the trim cover via thermal conduction. The
thickness of a foam cushion can be made greatest where most needed,
such as at the rear portion of the seat bottom.
Inventors: |
Tait; Shaun Dorian; (Troy,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Faurecia Automotive Seating, LLC |
Auburn Hills |
MI |
US |
|
|
Family ID: |
68465101 |
Appl. No.: |
15/978802 |
Filed: |
May 14, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60N 2/5685 20130101;
B60N 2/565 20130101 |
International
Class: |
B60N 2/56 20060101
B60N002/56 |
Claims
1. A vehicle seat comprising a seat bottom and a seat back, at
least one of the seat bottom or the seat back comprising: an air
permeable trim cover including a seating surface; an air duct
underlying the trim cover and defining an air flow channel in the
seat; a thermoelectric device underlying the trim cover and having
opposite first and second sides; a heat sink attached to the first
side of the thermoelectric device and extending into the air flow
channel; and an air mover operable to cause air to flow into the
seat through the trim cover, along the air flow channel and heat
sink, and out of the seat at a location away from the seating
surface, wherein the second side of the thermoelectric device is
outside the air flow channel and arranged to modulate the
temperature of the trim cover by thermal conduction.
2. A vehicle seat as defined in claim 1, further comprising a foam
cushion and a conductive layer, wherein a portion of the foam
cushion lies between the trim cover and the air duct, and wherein
the conductive layer is attached to the second side of the
thermoelectric device and extends between the trim cover and the
foam cushion.
3. A vehicle seat as defined in claim 1, wherein the air duct
comprises an intake port and an exhaust port spaced apart from the
intake port in a vertical direction and in a horizontal
direction.
4. A vehicle seat as defined in claim 1, wherein the air duct
comprises a plurality of intake ports and an exhaust port spaced
apart from each one of the intake ports in a vertical direction and
in a horizontal direction.
5. A vehicle seat as defined in claim 1, wherein the air duct
comprises an intake port and an exhaust port located below and
rearward of the intake port.
6. A vehicle seat as defined in claim 1, wherein the air mover is
operable to cause air to flow through the air flow channel in
downward and rearward directions.
7. A vehicle seat as defined in claim 6, wherein the air mover is
coupled with the air duct at a rear end of the air duct and along a
bottom side of the air duct to cause the air to flow is said
directions.
8. A vehicle seat as defined in claim 1, further comprising a foam
cushion disposed between the trim cover and the air flow channel,
wherein a thickness of the foam cushion is greater between the trim
cover and a rear end of the air flow channel than between the trim
cover and a front end of the air flow channel.
9. A vehicle seat as defined in claim 1, further comprising a foam
cushion having a recess formed along a bottom side of the foam
cushion, wherein the air duct is formed separately from the foam
cushion and fits in the recess.
10. A vehicle seat as defined in claim 9, further comprising a duct
support piece that fits in the recess with the air duct interposed
between the foam cushion and the duct support piece.
11. A vehicle seat as defined in claim 9, wherein the air duct is
formed from a plastic material having a stiffness greater than a
stiffness of the material of the foam cushion.
12. A vehicle seat as defined in claim 1, wherein the seat bottom
includes a structural frame comprising a transverse frame member, a
front end of the air duct being located above the transverse frame
member and a rear end of the air duct being located below the front
end of the air duct.
13. A vehicle seat as defined in claim 1, wherein the air duct
comprises a front end including an intake port, a rear end
including an exhaust port, and a central portion between the front
and rear ends, the thermoelectric device being coupled with the air
duct so that the heat sink extends into the air flow channel at the
central portion of the air duct.
14. A vehicle seat as defined in claim 1, wherein the air flow
channel is one of a pair of air flow channels defined by the air
duct, the air flow channels being laterally spaced apart at a front
end of the air duct and converging at a rear end of the air
duct.
15. A vehicle seat as defined in claim 14, further comprising an
additional thermoelectric device having opposite first and second
sides and an additional heat sink attached to the first side of the
additional thermoelectric device, wherein each heat sink extends
into a different one of the pair of air flow channels, and wherein
the second side of each thermoelectric device is outside the air
flow channels and arranged to modulate the temperature of the trim
cover by thermal conduction.
Description
TECHNICAL FIELD
[0001] The present disclosure relates to a vehicle seat and, in
particular, to a vehicle seat with a thermal comfort module.
BACKGROUND
[0002] Vehicle seats can be configured to provide a flow of air
through the seating surface to enhance environmental comfort of the
seat occupant by virtue of the movement of air in the vicinity of
the seat occupant's physical contact with the seating surface,
which is typically hotter or colder than the seat occupant desires,
particularly when the seat occupant is initially seated on
especially hot or cold days. Such ventilated vehicle seats may be
configured to flow air past a heat exchanger in the seat to heat or
cool the air before it is forced out of the seat through the
seating surface as conditioned air to provide desired thermal
comfort to the seat occupant.
[0003] For example, U.S. Pat. No. RE38,128 to Gallup et al.
discloses a vehicle seat with a climate control system including
individual heat pumps associated with the seat bottom and with the
seat back. Dedicated fans blow air through each of the heat pumps,
then along air channels inside the seat, and finally out of the
seat through the seating surface. The seat back and seat bottom are
separately controllable. The heat pumps may include thermoelectric
modules that selectively heat or cool the air before it passes
through the seating surface. Additional fans are provided to
separately blow air along opposite sides of the thermoelectric
modules. Heat energy is thus transferred to and from both opposite
sides of the thermoelectric modules by forced convection only.
SUMMARY
[0004] In accordance with one or more embodiments, a vehicle seat
includes a seat bottom and a seat back. At least one of the seat
bottom or the seat back includes an air permeable trim cover
including a seating surface, an air duct underlying the trim cover
and defining an air flow channel in the seat, a thermoelectric
device underlying the trim cover and having opposite first and
second sides, a heat sink attached to the first side of the
thermoelectric device and extending into the air flow channel, and
an air mover. The air mover is operable to cause air to flow into
the seat through the trim cover, along the air flow channel and
heat sink, and out of the seat at a location away from the seating
surface. The second side of the thermoelectric device is outside
the air flow channel and arranged to modulate the temperature of
the trim cover by thermal conduction.
[0005] In some embodiments, the vehicle seat includes a foam
cushion and a conductive layer. A portion of the foam cushion lies
between the trim cover and the air duct. The conductive layer is
attached to the second side of the thermoelectric device and
extends between the trim cover and the foam cushion.
[0006] In some embodiments, the air duct includes an intake port
and an exhaust port spaced apart from the intake port in a vertical
direction and in a horizontal direction.
[0007] In some embodiments, the air duct includes a plurality of
intake ports and an exhaust port spaced apart from each one of the
intake ports in a vertical direction and in a horizontal
direction.
[0008] In some embodiments, the air duct includes an intake port
and an exhaust port located below and rearward of the intake
port.
[0009] In some embodiments, the air mover is operable to cause air
to flow through the air flow channel in downward and rearward
directions. The air mover may be coupled with the air duct at a
rear end of the air duct and along a bottom side of the air duct to
cause the air to flow is those directions.
[0010] In some embodiments, the vehicle seat includes a foam
cushion disposed between the trim cover and the air flow channel. A
thickness of the foam cushion is greater between the trim cover and
a rear end of the air flow channel than between the trim cover and
a front end of the air flow channel.
[0011] In some embodiments, the vehicle seat includes a foam
cushion having a recess formed along a bottom side of the foam
cushion, and the air duct is formed separately from the foam
cushion and fits in the recess. A duct support piece may be fitted
in the recess with the air duct interposed between the foam cushion
and the duct support piece. The air duct may be formed from a
plastic material having a stiffness greater than a stiffness of the
material of the foam cushion.
[0012] In some embodiments, the seat bottom includes a structural
frame having a transverse frame member. A front end of the air duct
is located above the transverse frame member, and a rear end of the
air duct is located below the front end of the air duct.
[0013] In some embodiments, the air duct includes a front end
including an intake port, a rear end including an exhaust port, and
a central portion between the front and rear ends. The
thermoelectric device is coupled with the air duct so that the heat
sink extends into the air flow channel at the central portion of
the air duct.
[0014] In some embodiments, a pair of air flow channels is defined
by the air duct and are laterally spaced apart at a front end of
the air duct while converging at a rear end of the air duct.
[0015] In some embodiments, the vehicle seat includes an additional
thermoelectric device having opposite first and second sides and an
additional heat sink attached to the first side of the additional
thermoelectric device. Each heat sink extends into a different one
of a pair of air flow channels, and the second side of each
thermoelectric device is outside the air flow channels and arranged
to modulate the temperature of the trim cover by thermal
conduction.
[0016] Various aspects, embodiments, examples, features and
alternatives set forth in the preceding paragraphs, in the claims,
and/or in the following description and drawings may be taken
independently or in any combination thereof. For example, features
disclosed in connection with one embodiment are applicable to all
embodiments in the absence of incompatibility of features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Exemplary embodiments will hereinafter be described in
conjunction with the appended drawings, wherein like designations
denote like elements, and wherein:
[0018] FIG. 1 is a perspective view of an embodiment of a vehicle
seat equipped with a thermal comfort module;
[0019] FIG. 2 is an exploded view of a seat bottom including a
thermal comfort module;
[0020] FIG. 3 is a perspective view of the thermal comfort module
of FIG. 2; and
[0021] FIG. 4 is a cross-sectional view of a seat bottom equipped
with an illustrative thermal comfort module illustrating air flow
through the module.
DETAILED DESCRIPTION
[0022] The vehicle seat described below uses a thermoelectric
device (TED) to help provide thermal comfort to a seat occupant by
heating or cooling the seating surface with the TED via thermal
conduction. In a cooling mode, air from the passenger cabin of the
vehicle can be drawn through the seating surface by an air mover to
provide a localized cooling sensation to the seat occupant and to
remove heat from the hot side of the thermoelectric device. This
air movement through the seating surface can also contribute to
modulating the temperature of the seating surface via convective
heat transfer. An air duct within the seat can be shaped to
position the TED near the seating surface for enhanced conductive
energy exchange and away from high occupant load areas of the seat
to maximize occupant comfort.
[0023] FIG. 1 illustrates an exemplary vehicle seat 10 adapted for
installation in the passenger cabin of a vehicle via rails along
the underside of the seat or other suitable attachment features.
The seat 10 includes a seat bottom 12 that supports the majority of
the weight of a seat occupant when in use and a seat back 14
extending from the seat bottom. The seat back 14 includes a head
rest 16 in this example. Forward (F) and rearward (R) directions
are designated in FIG. 1 and may be referred to as longitudinal
directions. Upward (U) and downward (D) directions may be referred
to as vertical directions, while left and right may be referred to
as transverse directions. These directions are with respect to the
seat 10 and not necessarily with the vehicle in which the seat is
installed. The seat 10 presents a seating surface 18 in the form of
an exterior surface of a trim cover 20. Each of the seat bottom 12
and the seat back 14 includes a portion of the seating surface 18,
which is in contact with the seat occupant in use. As used herein,
the terms "underlying" and "overlying" are in relation to a
reference frame in which the seating surface 18 is the topmost
surface. For example, an underlying layer in the seat back 14 is
generally located rearward of the portion of the seating surface 18
provided by the seat back, and an underlying layer in the seat
bottom 12 is generally located beneath the portion of the seating
surface provided by the seat bottom.
[0024] The seat 10 is a ventilated seat configured to provide an
air flow (A) through the seating surface 18 when an underlying seat
component is pressurized or depressurized, such as via an internal
or external fan or blower. The air flow may include air discharged
into the passenger cabin through the seating surface in a
positive-ventilation or "push" configuration, or it may include
ambient air from the vehicle passenger cabin pulled through the
seating surface 18 in the illustrated negative-ventilation or
"pull" configuration. Positive and negative ventilation may also be
combined, with positive ventilation of the seat bottom 12 and
negative ventilation of the seat back 14, or vice versa. Or the
seat bottom and/or the seat back can each have positive and
negative ventilated portions. As noted above, air exiting the seat
through the seating surface may be heated or cooled by a heat
exchanger prior to exit. The embodiments of the thermal comfort
module illustrated in the figures are configured particularly for a
pull system, but many of the disclosed advantages may be realized
if reconfigured as a push system.
[0025] Air flow through the seating surface 18 is enabled in part
by at least a portion of the trim cover 20 being air permeable.
Perforated leather is one example of an air permeable trim cover
20. Certain woven or knit fabrics are also air permeable. Polymeric
materials such as polyvinyl chloride (PVC) or polyurethane can also
be used in the trim cover 20 and can be made air permeable via
perforations or other suitable means. Different types of materials
may also be combined to form the trim cover, so long as it is air
permeable at the desired locations. The trim cover 20 may also be a
multi-layer material including a plurality of different air
permeable materials laminated or otherwise attached together. In
the illustrated example, the air flow includes air drawn into the
seat 10 along a central portion 22 of both the seat bottom 12 and
the seat back 14, which is located between bolster portions 24, 26
located along opposite left and right sides of the seat 10. The
following description and illustrations are with respect to the
seat bottom 12 but are applicable to the seat back 14 as well.
[0026] FIG. 2 is an exploded view of a portion of the seat bottom
12 with the trim cover omitted. The illustrated seat bottom 12
includes a foam cushion 28, a thermal comfort module 30, a seat pan
32 that supports the overlying components, duct support pieces 34
that support a portion of the thermal comfort module that is spaced
away from the seat pan 32, and cushion inserts 35 that fill space
between the module 30 and the trim cover as described in further
detail below. The thermal comfort module 30 includes an air duct
36, a pair of thermoelectric devices 38, corresponding pairs of
heat sinks 40 and retainers 42, an air mover 44, and a conductive
layer 45. As illustrated in FIG. 3, the air duct 36 and thermal
comfort module 30 may have a U-shape or have an otherwise branched
shape for placement in the central portion of the seat bottom 12
with the branches generally corresponding to the location of the
legs of the seat occupant, as shown in FIG. 1. The thermal comfort
module 30 fits in a recess 46 formed in the foam cushion 28 with
contours matching those of the portion of the module it contacts.
In this example, the recess 46 is formed along a bottom side 48 of
the cushion. The duct support pieces 34 fill the remainder of the
recess 46 between the thermal comfort module 30 and the seat pan
32. The module 30 could also be insert-molded into the foam cushion
28. In some embodiments, the seat pan 32 is considered part of the
thermal comfort module 30.
[0027] The primary function of the foam cushion 28 is to support
the seat occupant in a comfortable manner by isolating the occupant
from the underlying structural members of the seat and vehicle. The
cushion 28 may be a single continuous piece of molded foam or may
be constructed from multiple pieces of foam of various densities,
for example. The duct support pieces 34 may be constructed from the
same foam material as the cushion 28 or from any other suitable
material and/or may be considered as part of the foam cushion. The
seat pan 32 may generally bridge the distance between structural
frame members. For instance, the seat bottom 12 may include a pair
of structural frame members spaced transversely from each other and
extending in the longitudinal direction, along with another pair of
structural frame members spaced longitudinally from each other and
extending in the transverse direction. In the illustrated example,
the seat pan 32 is a wire-frame configuration of a suitably rigid
material (e.g. steel) with front and rear ends having hook shapes
to engage front and rear transverse frame members. This
configuration is non-limiting, as any sufficiently rigid
component(s) can serve as the seat pan or as structural components
such as frame members.
[0028] As illustrated in FIG. 3, the thermal comfort module 30
includes a plurality of air flow ports, including at least one air
intake port 50 and at least one exhaust port 52 (FIG. 2). Each port
facilitates air flow between an internal air channel of the air
duct 36 and locations outside the air duct. In this example, a
plurality of air intake ports 50 are arranged along a top side 54
of each of two branches 56, 58 of the duct 36, and the air mover 44
is mounted at the exhaust port along a bottom side 60 of the air
duct 36 where the two branches of the duct meet. The air intake
ports 50 may be arranged along inner and outer edges of the
branches 56, 58 of the duct 36 as shown, thereby locating a
plurality of air intake ports generally along each of the inside
and the outside of each of the right and left legs of the seat
occupant. The illustrated air duct 36 thus defines a pair of
internal air flow channels--one in each branch 56, 58--that are
laterally spaced apart at a front end 62 of the duct and converging
at a rear end 64 of the duct. Separate TEDs 38 located along each
branch 56, 58 of the duct 36 have attached heat sinks extending
into each one of the pair of air flow channels.
[0029] In this example, some of the intake ports 50 are located at
the front end 62 of the air duct 36, the exhaust port 52 is located
at the rear end 64 of the air duct, and the thermoelectric devices
38 are located at a central portion 66 of the air duct between the
front and rear ends. Additional air intake ports 50 are located
along the duct 36 between the TEDs and the exhaust port 52 in this
example. It should be understood that the air duct 36 may include
any number of intake ports and exhaust ports in any of multitudes
of possible arrangements, the air mover 44 could be located
anywhere along and/or inside the duct, and the thermal comfort
module 30 could be operated in reverse with the air mover 44
operating to pull air into the rear bottom port 52 and discharge
air from the ports 50 along the top of the duct 36, whether or not
the TEDs 38 are operating. Also in this example, the air mover 44
discharges air in a frontward direction below and at a rear portion
of the seat bottom 12. However, the air mover 44 could be located
elsewhere, and the air could be discharged at a different location
and/or in a different direction than illustrated.
[0030] The air duct 36 may be considered the main body of the
thermal comfort module 30 to which the other components are
attached and supported for assembly into the vehicle seat. The air
duct 36 may be formed from an injection moldable thermoplastic
material and, being hollow, may be formed in more than one piece
(e.g., top and bottom halves) that are assembled together to form
the duct, or the air duct may be formed in a blow molding process.
The material of the air duct 36 should be sufficiently rigid to
hold its shape under the load of the seat occupant without
collapsing the internal air channel. Also, the material of the air
duct 36 may be selected to be sufficiently flexible to conform to
seat occupant applied loads without cracking or being overtly
noticeable to the seat occupant. One example of a suitable material
is an olefin-based polymeric material such as TPO with a high
elastomeric content. Certain thermoplastic elastomers (TPEs) are
suitable as well, including olefin-based TPEs. The air duct
material may have a stiffness that is greater than that of the foam
cushion material. Plastic materials are favored for their ease of
molding into complex shapes and their low thermal conductivity,
which can reduce or minimize the amount of conductive thermal
energy transfer between the air duct 36 and the TED 38.
[0031] The air duct 36 may be formed with an opening along the top
side 54 to receive the TED 38 and attached heat sink with a first
side 68 (FIG. 4) of the TED facing the inside of the air duct and
an opposite second side 70 exposed along the top side 54 of the air
duct through an opening in the retainer 42, which is configured to
secure the TED and heat sink to the air duct 36. The TEDs 38 are
solid-state electrically powered heat pumps including particular
dissimilar semi-conducting materials arranged between electrodes
and/or thermally conductive plates and that produce a temperature
differential across the conductive plates when a voltage is applied
thereacross. Reversing the polarity of the applied voltage reverses
the direction of the temperature differential and, thereby, the
heat flux through the TED 38.
[0032] In this example, one thermally conductive plate of each TED
38 provides the exposed side second side 70 of the TED. The heat
sink 40 is affixed to another thermally conductive plate that
provides the first side 68 of the TED and is located inside the air
duct 36, as illustrated in FIG. 4. The thermally conductive layer
45 is in the form of two thin and flexible strips comprising a
thermally conductive material. Each strip includes a central
portion 55 attached to the second side 70 of one of the TEDs 38,
and each strip extends in opposite frontward and rearward
directions from the central portion 55 to opposite ends that
correspond to the opposite front and rear ends 62, 64 of the duct
36. With the illustrated U-shaped air duct 36 and thermal comfort
module, the conductive layer 45 is thereby located generally
beneath the legs of the seat occupant. The illustrated conductive
layer is non-limiting and may take on a variety of different shapes
and be placed in conductive contact with the TED anywhere along the
conductive layer and/or may be in some other non-strip form.
[0033] FIG. 4 is a cross-sectional view of the seat bottom 12
equipped with an illustrative thermal comfort module 30 similar to
that of FIG. 3. The seat bottom 12 is illustrated with the air
permeable trim cover 20 which includes the occupant seating surface
18. The thermal comfort module 30 underlies the trim cover 20, and
the air duct 36 defines an air flow channel 72 in the seat. The air
flow channel 72 is defined by the inner surface of the air duct 36.
The thermoelectric device 38 also underlies the trim cover 20, with
the heat sink 40 attached to the first or bottom side 68 of the TED
and extending into the air flow channel 72. The air mover 44 is a
fan, blower, pump, or other suitable device operable to cause air
to flow into the seat through the air permeable trim cover 20,
along the air flow channel 72 and heat sink 40, and then back out
of the seat at a location away from the seating surface 18, such as
beneath the seat. The second or top side 70 of the thermoelectric
device 38 is outside the air flow channel 72 and is arranged to
modulate the temperature of the trim cover 20 by thermal
conduction.
[0034] This means that there is a continuous path of solid material
between the second side 70 of the TED 38 and an inner surface of
the trim cover 20. The solid materials along this path preferably
have a high thermal conductivity on the order of metallic
materials, which is generally greater than 10 W/m-K and preferably
greater than 100 W/m-K. Copper, aluminum, or graphite foils or
layers are some examples of materials that may be included in the
path of solid material between the second side of the TED and the
trim cover. In another manner of describing this thermal conduction
type of temperature control and thermal energy exchange, there is
an absence of air or other fluid flow between the second side of
the TED and the trim cover--i.e., there is substantially no forced
convection or other convective heat transfer between the second
side of the TED and the trim cover.
[0035] In the illustrated embodiments, the conductive heat exchange
between the TED 38 and the trim cover is facilitated by the
thermally conductive layer 45, a portion of which is attached to
the second or top side 70 of the TED 38, and other portions of
which extend away from the TED to locations between the foam
cushion 28 and the trim cover 20. In one embodiment, the conductive
layer 45 includes one or more flexible strips of graphite or
multi-layer graphene. In a more particular example, each flexible
strip includes graphite pressed and laminated between protective
carrier films, such as metal foils or polymer films that are
sufficiently thin to minimize thermal losses. Such strips may be
about 0.5 mm to 2.0 mm thick, with the majority of the thickness
provided by the graphite. The conductive layer 45 serves to
selectively locate areas of high thermal energy exchange wherever
desired along the seating surface--i.e., without the conductive
layer, heating and cooling by the TED via thermal conduction is
limited to the relatively small area at the second side of the
TED.
[0036] The thermally conductive layer 45 also allows the TED to be
spaced away from the trim cover 20 as illustrated to make it less
noticeable or unnoticeable to the seat occupant. In the illustrated
embodiment, the cushion insert 35 separates the second side 70 of
the TED 38 from the trim cover. The cushion insert 35 may be formed
from a similar type of foam material as the foam cushion 28 and
fills a space between the TED 38 and the trim cover ranging from
about 5 mm to about 25 mm. Depending on the particular materials
and TED location, a spacing between about 10 mm and about 20 mm, or
about 15 mm may be sufficient to make the TED virtually
undetectable to the seat occupant with use of the cushion insert
35. It is however contemplated that TEDs could be configured with
relatively flexible thermally conductive plates along their
opposite sides to place the TED closer to the trim cover.
[0037] The conductive strips 45 may be pre-assembled to the TEDs as
part of the thermal comfort module 30, with the opposite ends of
the strips fed through openings along the top of the foam cushion
28 when the module is received in the recess along the bottom of
the foam cushion. This allows the ends of conductive strips to lie
along the top of the foam cushion 28 at the desired locations in
thermally conductive contact with the TEDs before the trim cover is
attached. The trim cover 20 can then be disposed over the foam
cushion 28 after the cushion insert 35 is placed over the central
portion 55 of each strip above each TED 38.
[0038] During operation in a cooling mode, the air mover 44
operates to cause air flow (A) in the illustrated direction through
the air duct 36. The TED 38 is powered with a voltage and current
flow that causes the first side 68 of the TED to be the hot side
and the second side 70 of the TED to be the cold side. The seat
occupant experiences a cooling sensation provided in part by the
TED 36 extracting thermal energy through the trim cover 20 via the
conductive layer 45 and in part by the air movement in the vicinity
of their legs and the associated evaporation of perspiration. Some
of the same air that moves past the seat occupant's legs at the
seating surface 18 also flows along the heat sink 40 toward the
exhaust port 52 and absorbs thermal energy from the first side 68
of the TED, thereby maintaining the capacity of the TED to absorb
thermal energy at the second side 70. In a heating mode, the
polarity of the voltage and the direction of current flow through
the TED 38 is reversed so that the first side 68 of the TED is the
cold side and the second side 70 of the TED is the hot side. The
seat occupant experiences a heating sensation provided at least in
part by the TED 38 transferring thermal energy through the trim
cover. The air mover 44 may be optionally operated in the heating
mode to allow the first side 68 of the TED to absorb available
thermal energy from the air flow via the heat sink 40 to help
maintain the capacity of the TED to provide thermal energy at the
second side 70.
[0039] As illustrated in the figures, one or more of the intake
ports 50 and may be spaced apart from the exhaust port 52 in
vertical and horizontal directions. In the case of the illustrated
seat bottom 12, the exhaust port 52 is located both below and
rearward of each one of the plurality of intake ports 50. This
results in a direction of air flow through the seat that is
generally down and away from an upper-front portion of the seat
bottom toward a lower-rear portion of the seat bottom. The shape of
the air duct 36 that results in this arrangement of intake and
exhaust ports 50, 52 has other beneficial features.
[0040] For example, the thickness of the portion of the foam
cushion 28 over the rear end 64 of the air duct 36 is greater than
the thickness of the portion of the foam cushion over the front end
62 of the air duct. This provides more cushioning where it is
needed most toward the rear of the seat bottom 12 where the
majority of the weight (W) of the seat occupant is
supported--making the presence of the thermal comfort module 30
less detectable by the seat occupant. This air duct shape also
places the TED 38 relatively close to the trim cover 20, which
reduces thermal losses along the thermally conductive layer 45 and
reduces the amount of bending required for the conductive layer to
reach from the trim cover 20 to the TED. For example, if the TED 38
is located along the bottom of the foam cushion 28, where it would
be least detectable by the seat occupant, the conductive layer must
extend vertically through the foam cushion to a greater extent, and
the required bending angle of the conductive layer would be much
greater than illustrated in FIG. 4--i.e., closer to 90 degrees.
[0041] Such sharp bends can have a negative effect on the thermal
conductivity of the conductive layer, especially when the conductor
is a relatively brittle material such as graphite. Bending a
graphite-containing layer to high angles can cause a thermally
"open" condition, analogous to breaking a wire in an electrical
connection. Also, there are thermal losses along the length of the
thermally conductive layer 45, analogous to electrical losses along
an electrical cable, such that the longer the conductive layer, the
less efficient is the thermal energy transfer between the TED and
the desired locations of the trim cover. Also, thermally conductive
materials can be relatively expensive compared to other materials
of the seat bottom, such as foam and other polymeric materials. The
ability to place the TED closer to the trim cover reduces the
amount of thermally conductive material necessary in the thermally
conductive layer, or it allows a thicker and more conductive layer
to be made with the same amount of material in a longer thinner
layer.
[0042] Additionally, placement of the second side 70 of the TED 38
outside the air flow channel 72 avoids inadvertent heating or
cooling of the second side of the TED and/or the conductive layer
45, which would reduce TED performance. The illustrated
construction with a path of solid material that limits the heat
transfer mode to conduction while avoiding convection optimizes TED
performance.
[0043] The illustrated air duct shape and thermal comfort module
configuration also facilitates routing the air flow through the
seat while avoiding structural members. For instance, as noted
above, the seat bottom 12 may include a structural frame that
supports or includes the seat pan 32. The cross-section of FIG. 4
is taken through a transverse frame member 74 located toward the
front of the seat bottom 12, and the front end 62 of the air duct
36 is located above the frame member 74. The rear end 64 of the air
duct 36 may be located below the frame member 74.
[0044] The illustrated embodiment has the air duct 36 formed as a
separate piece from the foam cushion 28 and fitting into a
same-shaped recess in the foam cushion with duct support pieces 34
supporting the duct where spaced away from the seat pan 32. The air
channel 72 defined by the inner surface of the duct 36 is fluidly
connected with additional air channels 76 that extend between the
air duct and the outer surface of the foam cushion 28. The
illustrated air channels 76 are formed through the foam cushion 28
along the recess into which the air duct 36 fits and are aligned
with the air intake ports 50 of the air duct 36. A tubular portion
78 of the air duct 36 extends into each one of the air channels 76
of the cushion 28, with at least the rearmost air intake ports 50
provided on tubular portions that extend only partly along the air
channel 76 so that the intake ports 50 are spaced from the trim
cover 20. This spacing also helps prevent the presence of the
thermal comfort module 30 from being noticeable to the seat
occupant. The forwardmost air intake ports may be closer to the
trim cover, as shown, as they are less detectable due to less
occupant weight being distributed there.
[0045] It is also possible to form the air flow channel 72 as one
with the air channels 76 of the foam cushion 28, omitting the
separately formed air duct so that the foam cushion itself acts as
the air duct with an air channel arrangement that provides air flow
in the downward and rearward directions. Such a construction
achieves similar benefits in that the rigid air mover 44 can be
located beneath a thick portion of the foam cushion with the air
channel 70 routed above forward structural members of the seat
bottom.
[0046] The vehicle seat may include other components and/or layers
that are not explicitly illustrated in the figures, such as a
reticulated foam or 3D-mesh layer between the foam cushion 28 and
trim cover 20, or additional air channels formed along the top side
of the foam cushion and/or in non-vertical orientations.
Resistance-type heating elements could be included to supplement or
to be the primary source of heating in a heating mode, and the
disclosed arrangements do not preclude the use of circulatory fluid
cooling systems. While described above primarily as part of the
seat bottom 12, at least certain features of the disclosed thermal
comfort module may also be employed for occupant comfort control
along the seat back. For instance, the air flow channel may be
defined in the seat back 14 (FIG. 1) such that the air flows down
and away from an upper portion of the seat back near the seat
occupant's shoulders while exiting the seat at along a rear lower
portion of the seat back. The TED could be located near the trim
cover at a location along the seat back where the seat occupant
load is relatively low with the air duct spaced further from the
trim cover with thicker foam cushion material at a location where
the seat occupant load is relatively high, such as the lumbar area.
This would also allow the air duct and internal air channel to be
routed around a lumbar support mechanism or other structural
members of the seat back.
[0047] It is to be understood that the foregoing is a description
of one or more preferred exemplary embodiments of the invention.
The invention is not limited to the particular embodiment(s)
disclosed herein, but rather is defined solely by the claims below.
Furthermore, the statements contained in the foregoing description
relate to particular embodiments and are not to be construed as
limitations on the scope of the invention or on the definition of
terms used in the claims, except where a term or phrase is
expressly defined above. Various other embodiments and various
changes and modifications to the disclosed embodiment(s) will
become apparent to those skilled in the art. All such other
embodiments, changes, and modifications are intended to come within
the scope of the appended claims.
[0048] As used in this specification and claims, the terms "for
example," "for instance," "such as," and "like," and the verbs
"comprising," "having," "including," and their other verb forms,
when used in conjunction with a listing of one or more components
or other items, are each to be construed as open-ended, meaning
that that the listing is not to be considered as excluding other,
additional components or items. Other terms are to be construed
using their broadest reasonable meaning unless they are used in a
context that requires a different interpretation.
* * * * *