# Patent

## Title
Vehicle headliner assembly for zonal comfort

## Abstract

According to some embodiments, a zonal conditioning system for a vehicle comprises a headliner assembly configured to be secured to the top surface of a vehicle interior, wherein the headliner assembly comprises a first side positioned away from the vehicle interior and hidden from the vehicle interior, and a second side positioned toward the vehicle interior, the headliner assembly comprising at least two vents through which air selectively passes. The zonal conditioning system further includes at least two fluid modules positioned along the first side of the headliner assembly, wherein each of the fluid modules comprises a fluid transfer device and an outlet. In some embodiments, at least one property of the air discharged through the first and second vents can be selectively regulated to create separate conditioning zones within the interior of the vehicle.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/900,334, filed Nov. 5, 2013, the entirety of which is hereby incorporated by reference herein and made a part of the present application.


BACKGROUND
Field
This application relates to climate control, and more specifically, to zonal conditioning systems for vehicles and/or other spaces or areas.
Description of the Related Art
Temperature-conditioned and/or ambient air for environmental control of vehicles (e.g., automobiles) and/or living or working spaces is typically provided to relatively extensive areas. In the case of enclosed or semi-enclosed areas, such as vehicle interiors, homes, offices and the like, the interior space 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 zones for certain subareas or regions of such a space so that desired heating, cooling and/or ventilation can be achieved.
SUMMARY
According to some embodiments, a zonal conditioning system for a vehicle comprises a headliner assembly configured to be secured to the top surface of a vehicle interior, wherein the headliner assembly comprises a first side positioned away from the vehicle interior and hidden from the vehicle interior, and a second side positioned toward the vehicle interior, the headliner assembly comprising at least two vents through which air selectively passes. The zonal conditioning system further includes at least two fluid modules positioned along the first side of the headliner assembly, wherein each of the fluid modules comprises a fluid transfer device and an outlet. The system further includes a first fluid conduit placing the outlet of a first fluid module in fluid communication with a first vent of the headliner assembly, and a second fluid conduit placing the outlet of a second fluid module in fluid communication with a second vent of the headliner assembly, wherein at least one property of the air discharged through the first and second vents can be selectively regulated to create separate conditioning zones within the interior of the vehicle.
According to some embodiments, a method of creating at least two separate climate control zones within an interior of a vehicle comprises positioning at least two fluid modules along a first side of a headliner assembly of the vehicle, each of the fluid modules comprising a fluid transfer device and an outlet, wherein the first side of the headliner is positioned away from the vehicle interior; placing a first fluid module in fluid communication with at least one first vent of the headliner, and placing at least a second fluid module in fluid communication with at least one second vent of the headliner, wherein air is delivered from the fluid modules to and through the vents toward the interior of the vehicle, wherein at least one property of the air discharged through the first and second vents can be selectively regulated to create separate conditioning zones within the interior of the vehicle.
According to some embodiments, at least one of the fluid modules comprises a thermal conditioning device (e.g., thermoelectric device, convective heater, another heating or cooling device, etc.). In some embodiments, the method further comprises positioning at least one waste conduit in fluid communication with at least one of the fluid modules for transferring waste fluid from the at least one of the fluid modules to a location exterior of the vehicle. In some embodiments, the waste conduit comprises a conduit routed at least partially through a pillar of the vehicle. In some embodiments, the waste conduit comprises a conduit routed at least partially through a package tray of the vehicle.
According to some embodiments, the at least one property of the air discharged through the first and second vents comprises at least one of the following: airflow rate, whether thermal conditioning occurs, a level of thermal conditioning and/or the like. In some embodiments, at least one of the fluid modules is automatically regulated using an automated control scheme. In some embodiments, at least one of the fluid modules is manually regulated by a user. In some embodiments, the method further comprises positioning at least one controller within the vehicle to enable a user to selectively regulate at least one operational aspect of at least of the fluid modules.



BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present inventions are described with reference to drawings of certain preferred embodiments, which are intended to illustrate, but not to limit, the present inventions. It is to be understood that the attached drawings are provided for the purpose of illustrating concepts of the present inventions and may not be to scale.
FIG. 1 illustrates a side view of an automobile configured to receive a zonal conditioning system according to one embodiment;
FIG. 2 illustrates a view of the lower, exposed surface of a climate conditioned headliner assembly for use in a vehicle;
FIG. 3 illustrates a view of the upper, hidden surface of the headliner assembly of FIG. 2;
FIG. 4 illustrates a detailed view of the upper surface of the headliner assembly of FIG. 2;
FIGS. 5 and 6 illustrate side perspective views of one embodiment of a thermal module positioned along the upper surface of the headliner assembly; and
FIG. 7 illustrates a perspective view of one embodiment of an outlet coupling configured to be placed in fluid communication with a fluid module.



DETAILED DESCRIPTION
According to some embodiments, a zonal conditioning system can be used to selectively direct thermally-conditioned and/or ambient air to one or more locations within the interior of an automobile, other vehicle or other at least partially-enclosed space. As discussed in greater detail herein, in some embodiments, the zonal conditioning system can be configured to provide a different type of air (e.g., heated air, cooled air, ambient air, etc.) to or near one or more areas within the vehicle interior. For example, separate fluid streams can be used to condition (e.g., thermally condition) one or more of the following areas within a vehicle interior: the area at or near the driver, the area at or near the front passenger, the area at or near a rear passenger (e.g., second row, third row, etc.), the trunk and/or the like.
Although various concepts are described herein with specific reference to an automobile or other vehicle, the disclosed embodiments can be adapted for inclusion in any other enclosed or partially-enclosed space, such as, for example, an office, a room and/or the like.
FIG. 2 illustrates one embodiment of a headliner assembly 100 of a zonal conditioning system configured to be used within a vehicle interior. As shown, the headliner assembly 100, which is configured to be positioned along the ceiling of the vehicle, can include one or more openings to accommodate the various design features of the vehicle into which it is placed, depending on the vehicle. For example, the headliner assembly 100 can include an opening 102 for the sunroof, moon-roof or the like. In addition, one or more other openings 104 can be included in the assembly 100 to accommodate lights, buttons, modules and/or other features. The shape, size and/or other characteristics of the headliner assembly 100 can be customized according to the vehicle into which it will be installed, as desired or required. The headliner assembly 100 and/or other components of the zonal conditioning system can be incorporated into the original manufacturing process of the vehicle (e.g., at the time the vehicle is initially assembled). Alternatively, the headliner assembly and/or other components of the zonal conditioning system can be after-market items that are installed into an already-manufactured vehicle.
With continued reference to FIG. 2, the headliner assembly 100 can include a plurality of vents or other fluid openings 110a-110d through which air (e.g., heated air, cooled air, ambient air, etc.) discharged by one or more fluid modules is routed (e.g., into the main cabin of the vehicle interior). In the illustrated embodiment, the headliner assembly 100 comprises a total of four vents 110a-110d that are generally circular in shape. However, in other embodiments, the quantity, shape, size, spacing, orientation and/or other details of the vents 110a-110d can be different than illustrated herein, as desired or required for a particular use or application. In addition, the vents 110a-110d can include one or more louvers or other adjustable features that enable users to vary the flowrate and/or direction of air being discharged therethrough.
FIG. 3 illustrates the opposite (upper) surface of headliner assembly 100 shown in FIG. 2. As shown, the upper surface of the headliner assembly 100 can include one or more fluid modules 200, controllers 300, wires, cables or other electrical/communication lines, fasteners and/or the like. In the depicted arrangement, there are a total of four fluid modules 200 mounted or otherwise secured to the top or hidden surface of the assembly 100. As shown, each fluid module 200 can be positioned so that an output of the module 200 can be placed in fluid communication with a vent 110a-110d (FIG. 2). In some embodiments, a fluid module is aligned or generally aligned with a vent 110a-110d. However, alternatively, a module 200 can be placed in a different location than a vent; in such embodiments, one or more fluid conduits can be used to direct fluid from a module to a desired vent 110a-110d. Accordingly, thermally conditioned air (e.g., heated or cooled air) and/or ambient air (e.g., thermally unconditioned air) can be selectively delivered to and through the vents 110a-110d and to or near one or more regions, areas or zones of the vehicle interior. As a result, one or more properties of the fluid modules 200, such as, for example, the amount of air being discharged, if and how that air is thermally conditioned, etc., can be modified to advantageously create separate and customized conditioning zones within the vehicle.
With continued reference to FIG. 3, one or more control units or other controllers 300 can be incorporated into the zonal conditioning system. As shown, for example, the controllers 300 can be mounted to or near one or more portions of the headliner assembly 100. Each controller 300 can be configured to control or otherwise regulate one, two or more of the fluid modules 200, as desired or required by a particular application or use. In some embodiments, each fluid module 200 is associated with a single controller 300. In other embodiments, a single main control unit can at least partially regulate the operations of all fluid modules included in a particular system.
In some embodiments, the fluid module comprises at least one fluid transfer device (e.g., blower, fan, pump, etc.). In some embodiments, the fluid module is configured to environmentally and/or thermally condition (e.g., heat, cool, dehumidify, etc.) air or fluid passing therethrough. In some embodiments, the fluid module comprises at least one thermoelectric device (e.g., Peltier circuit) to selectively heat or cool air that is passed through or near the fluid module. In some embodiments, the fluid module comprises at least one convective heater and/or any other heating and/or cooling device. In some embodiments, the fluid module 200 can include a control unit or controller positioned within the same housing of the module that also encompasses the fluid transfer device (e.g., fan), thermal conditioning device (e.g., thermoelectric device, convective heater, etc.) and/or other components of the module. Additional details regarding fluid modules are provided in U.S. Pat. No. 7,587,901, filed on Jan. 31, 2005 and issued on Sep. 15, 2009, and U.S. application Ser. No. 13/289,923, filed on Nov. 4, 2011 and published as U.S. Publ. No. 2012/0114512 on May 10, 2012, the entireties of both of which are incorporated by reference herein and made a part of the present application.
In some embodiments, the fluid modules 200 are selectively controlled using one or more switches, buttons, knobs and/or other control devices 130, 130a-130d that enable a user to regulate one or more aspects of the fluid modules. As shown, the switches or control devices 130, 130a-130d can extend through the body of the headliner assembly 100 to enable a user to manipulate them along or near the headliner assembly itself. In some embodiments, the control devices comprise one or more of the following: switches, knobs, rollerballs and/or the like. Such control devices can be positioned (e.g., mounted to or near) the headliner assembly 100. Alternatively, the control devices 130, 130a-130d can be incorporated into a separate or remote assembly, such as, for example, a handheld controller, a control device or feature positioned on a seat, a center console, a ceiling console and/or the like, a touchscreen or other display of the vehicle, a smartphone, tablet or other computing device that is separate from the vehicle and/or the like, as desired or required. Regardless of their position, configuration and/or other characteristics, the control devices 130, 130a-130d can be configured to allow a user to modify one or more aspects of the fluid modules, such as, for example, which fluid modules are activated (e.g., turned on or off), how long the modules are activated, if the fluid modules are being operated to heat or cool air (or delivering ambient air), the flowrate at which air is being delivered by a fluid module, etc. Accordingly, as noted above, the level of thermal or ambient conditioning delivered to one or more zones or regions of the vehicle can be customized. In some embodiments, a user can control, for one or more zones or regions, whether to provide heated air, cooled air or ambient air. Further, the user can control a setting (e.g., low, medium, high, numeric value, etc.) for such a zonal conditioning effect.
As illustrated in FIG. 3, the various components of the zonal conditioning system (e.g., the fluid modules, controllers, control devices, etc.) can be electrically coupled to each other using one or more wires or other electrical connections. In addition, power can be supplied to fluid modules 200 and/or other components of the zonal conditioning system using a main power line P. Such a power line can be supplied with electrical power via the vehicle's main power system (e.g., the automobile battery), another centralized power source and/or a separate source of power (e.g., a separate battery, panel, etc.).
FIGS. 4 through 6 illustrate detailed views of one of the fluid modules 200 mounted to the top (hidden) surface of the headliner assembly 100. As shown, the fluid module 200 can include a blower or other fluid transfer device 210 that is configured to receive air (e.g., from the region defined between the headliner assembly 100 and the ceiling of the vehicle frame) and deliver it through one or more thermal conditioning devices (e.g., thermoelectric devices, convective heaters, other heating or cooling devices, etc.) placed in fluid communication with the blower or other fluid transfer device 210. For example, in the depicted embodiment, a thermoelectric device or other heating or cooling device (not shown) can be positioned immediately adjacent to or near the outlet of the fluid transfer device, such that air or other fluid discharged by the fluid transfer device passes near thermoelectric device (e.g., through fins, pins and/or other heat transfer devices that are in thermal communication with the thermoelectric device) to selectively heat or cool the air being transferred. In other embodiments, the fluid module 200 does not include any thermal conditioning devices or the thermal conditioning devices of the fluid module are not activated so that ambient air is transferred by the fluid transfer device, as desired or required.
As shown in FIG. 6, the fluid module 200 can be mounted so that a gap exists between the blower or other fluid transfer device 210 and the adjacent surface of the headliner assembly 100. In such arrangements, such a gap can facilitate the passage of air into the inlet of the fluid transfer device.
In some embodiments, one or more conduits or other passages 216 are used to place the air discharged by the fluid transfer device 210 to an outlet structure 250 that is mounted or otherwise positioned on the upper surface of the headliner assembly 100. The outlet structure 250 can be aligned and positioned over a vent 110a-110d (FIG. 2) of the headliner assembly 100. As illustrated in FIG. 7, the outlet structure 250 can include a cup-shaped or other curved or rounded portion 254.
In some embodiments, when thermoelectric devices or similar thermal conditioning devices are used, a stream of waste fluid is created. For example, when cooled air is being delivered to and through the outlet structure and the corresponding vent 110, heated, waste air is generated. Such waste air can be delivered through one or more separate fluid conduits (or a separate passage or lumen of the conduit 216) and to waste outlet 218. In the depicted embodiment, the waste outlet 218 terminates near (e.g., shortly after) the outlet structure 250. However, in some embodiments, the waste outlet can extend, either directly or indirectly (e.g., using one or more separate conduits or channels), to one or more locations of the vehicle. In some embodiments, the waste air stream is discharged to the exterior of the vehicle. For example, in some embodiments, waste air is discharged through conduits or channels routed through one or more of the pillars of the vehicle (e.g., the A-pillar, B-pillar, C-pillar, other structural components of the vehicle, etc.). See, for example, FIG. 1. In some embodiments, air being delivered through the A-pillar can be directed to the hinge pillar before exiting the vehicle. In other embodiments, waste air can be routed through the package tray of the vehicle and into the truck or other rear portion of the vehicle. One or more flapper valves or other one-way valves can be incorporated into the waste fluid channel network to ensure that waste air does not inadvertently re-enter the interior of the vehicle.
According to some embodiments, one or more fluid modules are controlled automatically according to a pre-designated control scheme. For example, the fluid modules can be controlled (e.g., power level, on/off, flowrate, heating or cooling effect, etc.) so that a particular temperature or climate conditioning effect is maintained in one or more zones of the vehicle. For example, in some embodiments, the driver zone can be maintained relatively cool, the front passenger zone is maintained relatively warm, and a rear passenger zone is maintained in ventilation (ambient) mode. In other embodiments, the zonal conditioning system can go through a number of repeating or non-repeating cycles to alter the type of conditioning effect within the vehicle interior while accomplishing one or more other goals (e.g., power consumption), as desired or required. Accordingly, in order to assist in automated control schemes under which the zonal conditioning system can be operated, the system and/or vehicle can include one or more sensors (e.g., temperature, humidity, condensation, etc.) that can be placed in data communication with the fluid modules and/or the controllers of the system.
To assist in the description of the disclosed embodiments, words such as upward, upper, downward, lower, vertical, horizontal, upstream, downstream, top, bottom, soft, rigid, simple, complex and others have and used above to discuss various embodiments and to describe the accompanying figures. It will be appreciated, however, that the illustrated embodiments, or equivalents thereof, can be located and oriented in a variety of desired positions, and thus, should not be limited by the use of such relative terms.
Although these inventions have been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and obvious modifications and equivalents thereof. In addition, while the number of variations of the inventions have been shown and described in detail, other modifications, which are within the scope of these inventions, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the inventions. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another in order to perform varying modes of the disclosed inventions. Thus, it is intended that the scope of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims.

## Claims

1. A zonal conditioning system for a vehicle, comprising:
a headliner assembly configured to be secured to a top surface of a vehicle interior, wherein the headliner assembly comprises a first side positioned away from the vehicle interior and hidden from the vehicle interior, and wherein the headliner assembly comprises a second side positioned toward the vehicle interior, the headliner assembly comprising at least two vents through which air selectively passes;
at least two fluid modules positioned along the first side of the headliner assembly, each of the fluid modules comprising a fluid transfer device and an outlet, each of the at least two fluid modules comprising a thermoelectric device and a waste conduit for transferring waste fluid from the respective fluid module, the fluid transfer device including an inlet that is positioned such that a gap exists between the inlet of the fluid transfer device and the first side of the headliner assembly;
a first fluid conduit placing the outlet of a first fluid module in fluid communication with a first vent of the headliner assembly; and
a second fluid conduit placing the outlet of a second fluid module in fluid communication with a second vent of the headliner assembly;
wherein at least one property of the air discharged through the first and second vents can be selectively regulated to create separate conditioning zones within the vehicle interior of the vehicle.

2. The zonal conditioning system of claim 1, wherein the waste conduit transfers waste fluid to a location exterior of the vehicle.

3. The zonal condition system of claim 1, wherein the at least one property of the air discharged through the first and second vents comprises at least one of the following: airflow rate, whether thermal conditioning occurs and a level of thermal conditioning.

4. The zonal condition system of claim 1, wherein at least one of the fluid modules is automatically regulated using an automated control scheme.

5. The zonal condition system of claim 1, further comprising a controller for selectively controlling at least one aspect of at least one of the fluid modules.

6. A method of creating at least two separate climate control zones within an interior of a vehicle, the method comprising:
positioning at least two fluid modules along a first side of a headliner assembly of the vehicle, each of the fluid modules comprising a fluid transfer device and an outlet, wherein the first side of the headliner assembly is positioned away from the interior of the vehicle; and
placing a first fluid module in fluid communication with at least one first vent of the headliner assembly, and placing at least a second fluid module in fluid communication with at least one second vent of the headliner assembly, wherein air is delivered from the fluid modules to and through the vents toward the interior of the vehicle, wherein the first and second fluid modules each include a thermoelectric device and a waste conduit that transfers waste fluid from the respective fluid module to a location exterior to the headliner assembly;
wherein at least one property of the air discharged through the first and second vents can be selectively regulated to create separate conditioning zones within the interior of the vehicle.

7. The method of claim 6, wherein the waste conduit transfers waste fluid from the respective fluid module to a location exterior of the vehicle.

8. The method of claim 6, wherein the at least one property of the air discharged through the first and second vents comprises at least one of the following: airflow rate, whether thermal conditioning occurs and a level of thermal conditioning.

9. The method of claim 6, wherein at least one of the fluid modules is automatically regulated using an automated control scheme.

10. The method of claim 6, further comprising positioning at least one controller within the vehicle to enable a user to selectively regulate at least one operational aspect of at least of the fluid modules.