Abstract:
A method of installing a modular comfort assembly within an occupant support includes the step of providing a modular comfort assembly including a heating element and at least one of a ventilation diffuser bag and a lumbar support system, the heating element, the diffuser bag, and the lumbar support system being modularly attachable to each other on sides thereof. The occupant support includes an outer cover, an internal foam bun, and a frame. The method further includes the step of mounting the modular comfort assembly onto a surface of the foam bun beneath the outer cover.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a division of U.S. application Ser. No. 10/816,701, filed Apr. 2, 2004, which claims the benefit of U.S. Provisional Application No. 60/476,207, filed Jun. 5, 2003. 
     
    
     TECHNICAL FIELD  
       [0002]     This invention relates generally to the field of comfort systems for occupant supports and more particularly to heating, venting and lumbar support systems for vehicle seating.  
       BACKGROUND OF THE INVENTION  
       [0003]     It is known in the art relating to automotive seating comfort systems to install stand-alone heating, venting and/or lumbar systems within the seat as separate units. Such individual application of more than one comfort system into a seat can be difficult and time consuming.  
         [0004]     Further, it is known in the art relating to automotive seating comfort systems to heat the seat by moving air over a heating element to warm the moving air and to subsequently heat the seat surface. This is inefficient as there may be heat loss in the moving air.  
         [0005]     Furthermore, it is known in the art relating to automotive seating comfort systems to condition the air moving that passes through the ventilation system to cool the vehicle seat. This is also inefficient because it requires the use of a separate air conditioner in the comfort system. The air conditioning unit itself makes the comfort system costlier to manufacture and the use of the unit, once installed, requires a high energy input.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention provides a modular assembly of comfort systems or subassemblies of heating, venting and/or lumbar support devices adaptable for use with occupant supports such as vehicle seats wherein a heating element, a ventilation “diffuser” and a lumbar support element are integrated into a single assembly. Such a modular comfort assembly has the advantage of allowing for the insertion into an occupant support such as a seat or other of a heating element, a ventilation element and a lumbar support element in one convenient operation. Moreover, the modular assembly has the advantage of being operable by a single control module or separate controllers for each component.  
         [0007]     More specifically, a modular comfort assembly in accordance with one embodiment of the invention includes a pneumatic, mechanical, and/or electrical lumbar support system with internal baffles to achieve the desired shape. An air pump is connected to the lumbar support system to allow for inflation and deflation of the system. Pressure sensitive adhesive, Velcro, or other similar material on the back side of the lumber support allows for mounting of the assembly to the surface of the interior foam of the seat. The modular comfort assembly further includes a ventilation “diffuser bag” having air permeable fabric encapsulated within the bag. The bag has an air inlet on one end thereof. A surface of the bag closest to the seat occupant includes perforations for air flow therethrough.  
         [0008]     An air mover such as a fan or blower may be connected to the diffuser bag inlet and mounted to the backside surface of the seat cushion foam with pressure sensitive adhesive, Velcro, or other similar material. Alternatively, the air mover may be mounted underneath the seat cushion or any other area in close proximity to the seat. The air mover causes circulation of air through the “diffuser bag” but does not condition or otherwise treat the air. Instead, the movement of air by the air mover through the “diffuser bag” gives the seat occupant the perception of being cool because of the convective effect of air moving over the occupant&#39;s body.  
         [0009]     The backside surface of the ventilation bag is lined with pressure sensitive adhesive, Velcro, or other similar material for attachment to the front surface of the lumbar support. The modular comfort assembly further includes a heating element that attaches to the front surface of the ventilation “diffuser bag” via pressure sensitive adhesive, Velcro, or other similar material. The surface of the heating element is permeable to communicate ventilating air to the seat occupant, but the heating of the seat via the heating element is independent of the movement of air through the “diffuser bag” and the permeable surface of the heating element.  
         [0010]     In another embodiment of the invention, the comfort assembly includes a heating element and a ventilation “diffuser bag.” In this embodiment, the back side of the heating element is attached to the front side of the “diffuser bag” via pressure sensitive adhesive, Velcro, or other similar material. The back side of the “diffuser bag” is also lined with pressure sensitive adhesive, Velcro, or other similar material for attachment of the assembly to the foam cushion of the seat. An air mover is connected to the “diffuser bag” to deliver unconditioned air to the ventilation system. The surface of the heating element is permeable to allow for communication of ventilating air to the seat occupant, but the heating of the seat is independent of the ventilation system.  
         [0011]     In yet another embodiment of the invention, the comfort assembly includes a heating element and pneumatic, mechanical, and/or electrical lumbar support system. In this embodiment, the back side of the heating element is attached to the front side of the lumbar support system via pressure sensitive adhesive, Velcro, or other similar material. The back side of the lumbar support system is also lined with pressure sensitive adhesive, Velcro, or other similar material for attachment of the assembly to the foam cushion of the seat. An air pump is connected to the lumbar support system to allow for inflation and deflation of the system.  
         [0012]     These and other features and advantages of the invention will be more fully understood from the following detailed description of the invention taken together with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     In the drawings:  
         [0014]      FIG. 1  is an exploded environmental perspective view of a vehicle seating assembly and modular comfort systems or subassemblies of heating, venting, and/or lumbar support devices constructed in accordance with the invention adapted for assembly in the seating assembly;  
         [0015]      FIG. 2  is a cutaway elevational view of one embodiment of a modular comfort system including a diffuser bag, a heating element and a lumbar support in accordance with the invention;  
         [0016]      FIG. 3  is a sectional view taken along lines  3 - 3  in  FIG. 2 ;  
         [0017]      FIG. 4  is a cutaway elevational view of a second embodiment of a modular comfort system including a diffuser bag and a heating element in accordance with the invention;  
         [0018]      FIG. 5  is a sectional view taken along lines  5 - 5  in  FIG. 4 ;  
         [0019]      FIG. 6  is a cutaway elevational view of a third embodiment of a modular comfort system including a heating element and a lumbar support in accordance with the invention; and  
         [0020]      FIG. 7  is a sectional view taken along lines  7 - 7  in  FIG. 6 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]     Referring now to the drawings in detail, numeral  10  generally indicates a modular comfort assembly in accordance with the present invention adapted for installation within an occupant support such as an automotive vehicle seat.  
         [0022]     With reference to  FIGS. 2 and 3 , in a preferred embodiment of the present invention a modular comfort assembly  10  includes a ventilation diffuser bag  12 , a heating element  14 , and a lumbar support system  16 . The ventilation diffuser bag  12  has two main surfaces, namely an A-side  18  and a B-side  20 . The heating element  14  also has two main surfaces, namely an A-side  22  and a B-side  24 . Likewise, the lumbar support system  16  has two main surfaces, namely an A-side  26  and a B-side  28 .  
         [0023]     The A-side  18  and B-side  20  of the diffuser bag  12  are lined with pressure sensitive adhesive, Velcro, or another similar, suitable material. The B-side  24  of the heating element  14  and the A-side  26  and B-side  28  of the lumbar support system  16  are also lined with pressure sensitive adhesive, Velcro, or another similar, suitable material. The heating element  14  is thereby attachable on one side (A-side)  18  of the diffuser bag  12  and the lumbar support system  16  is thereby mountable on another side (B-side)  20  of the diffuser bag  12 . In this way, the B-side  24  of the heating element  14  faces the A-side  18  of the diffuser bag  12  and the B-side  20  of the diffuser bag  12  faces the A-side  26  of the lumbar support system  16 .  
         [0024]     The ventilation diffuser bag  12  may include an air permeable fabric  30  encapsulated within the bag. The diffuser bag  12  may also include perforations  32  on the outer A-side surface  18  of the bag and an air inlet  34  on an end of the bag. The diffuser bag may also be constructed of a polyurethane material such as a polyether polyurethane or similar material. An air mover  36  may be connected to the diffuser bag air inlet  34 .  
         [0025]     The A-side  22  and B-side  24  surfaces of the heating element  14  may be permeable to allow for air to pass through the heating element  14 . The heating element  14  itself may be composed of an air permeable material. The heating element  14  may also include a wire harness  38  for connecting the heating element  14  to an electrical source. Further, the heating element  14  may be a two-dimensional heating element having a textile base material, such as, for example, a nonwoven or a textile filament material which acts as a carrier for electrically conductive contacts and heating conductors that touch one another and form an electric connection. Sending of an electric current through the conductive contacts thereby sends a current through the heating conductors, producing heat and warming the heating element. The heating element  14  is sufficiently flexible to fit the contours of the modular comfort assembly  10 . The modular comfort assembly  10  may also include a second heating element  15  (see  FIG. 1 ) that is electrically connected to the first heating element  14 .  
         [0026]     The lumbar support system  16  may include internal baffles  40  and an air inlet  42 . An air pump  50  (see  FIG. 1 ) may be connected to the air inlet  42  to allow for inflation and deflation of the lumbar support system  16 .  
         [0027]      FIGS. 4 and 5  illustrate an alternative embodiment of a modular comfort assembly  10 . In this arrangement, the modular comfort assembly  10  includes a ventilation diffuser bag  12  and a heating element  14 . The ventilation diffuser bag  12  has two main surfaces, namely an A-side  18  and a B-side  20 . The heating element  14  also has two main surfaces, namely an A-side  22  and a B-side  24 . The A-side  18  and B-side  20  of the diffuser bag  12  are lined with pressure sensitive adhesive, Velcro, or another similar, suitable material. The B-side  24  of the heating element  14  is also lined with pressure sensitive adhesive, Velcro, or another similar, suitable material. The heating element  14  is thereby attachable on one side (A-side)  18  of the diffuser bag  12 . In this way, the B-side  24  of the heating element  14  faces the A-side  18  of the diffuser bag  12 . The ventilation diffuser bag  12  and the heating element  14  may also include all of the features detailed above.  
         [0028]      FIGS. 6 and 7  illustrate yet another alternative embodiment of a modular comfort assembly  10 . In this arrangement, the modular comfort assembly  10  includes a heating element  14  and a lumbar support system  16 . The heating element  14  has two main surfaces, namely an A-side  22  and a B-side  24 . The lumbar support system  16  also has two main surfaces, namely an A-side  26  and a B-side  28 . The B-side  24  of the heating element  14  and the A-side  26  and B-side  28  of the lumbar support system  16  are also lined with pressure sensitive adhesive, Velcro, or another similar, suitable material. The heating element  14  is thereby attachable on one side (A-side)  26  of the lumbar support system  16 . In this way, the B-side  24  of the heating element  14  faces the A-side  26  of the lumbar support system  16 . The heating element  14  and the lumbar support system  16  may also include all of the features detailed above.  
         [0029]     With reference now to  FIGS. 1 through 7 , installation of a modular comfort assembly  10  in an occupant support is a simple and efficient process. The outer cover (not shown) of the occupant support, in this case an automotive vehicle seat, is opened to unveil the internal foam bun  44  and the support frame  46 . The foam bun  44  may also be any other material used for cushioning an automotive vehicle seat. The modular comfort assembly  10  is then mounted to a surface  48  of the foam bun  44  by the pressure sensitive adhesive, Velcro, or other similar, suitable material lining the B-side  28  of the lumbar support system  16  and/or the B-side  20  of the ventilation diffuser bag  12  and/or the B-side  24  of the heating element  14 . In the case that the modular comfort assembly  10  includes a second heating element  15  and a second diffuser bag  13 , these parts are also mounted to a surface  48  of the foam bun  44  by pressure sensitive adhesive, Velcro, or other similar, suitable material lining the second diffuser bag  13  and/or the second heating element  15 .  
         [0030]     At this time, diffuser bag air movers  36 , which may be either a fan or blower, may be mounted to a backside of the foam bun  44  and the underside of the foam bun  44  by pressure sensitive adhesive, Velcro, or another similar, suitable material. Alternatively, the air movers  36  may also be mounted to the frame in any suitable location near the modular comfort assembly  10 , such as on a bottom area or a back area of the frame  46 . If the second diffuser bag  13  is not installed, then it is not necessary to mount an air mover to the bottom of the foam bun or bottom of the frame. An air pump  50  connected to the air inlet  42  of the lumbar support system  16  may be mounted onto the frame  46 , preferably around the back area of the frame.  
         [0031]     Harnesses from the control module  52  are then connected to the lumbar support system  16 , the diffuser bags  12 ,  13  and the heating elements  14 ,  15 . The modular comfort assembly  10  is then enclosed into the occupant support by closing the outer cover (not shown) of the occupant support. This is accomplished by pulling the outer cover back over foam bun  44  and the support frame  48  and re-stitching the outer cover shut.  
         [0032]     The modular comfort assembly  10  may be operated and controlled by a single control module  52 . Alternatively, the modular comfort assembly  10  may include separate controllers for each component (i.e., the diffuser bag  12 , the heating element  14 , and the lumbar support system  16 ) of the assembly.  
         [0033]     Although the invention has been described by reference to specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims.