Patent Publication Number: US-11377006-B2

Title: Seat conditioning module

Description:
CLAIM OF PRIORITY 
     The present application claims the benefit of the filing date of U.S. provisional Application Ser. No. 61/012,616; Filed: Dec. 10, 2007, Hereby Incorporated by Reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to an apparatus and method of conditioning a vehicle seat, more particularly to provide an apparatus and method of conditioning a vehicle seat via a seat conditioning module using at least one set of movable valves to communicate through an air distribution system to a surface of an automotive seat enabling any number of conditioning modes. 
     BACKGROUND OF THE INVENTION 
     It is well known that vehicles are being equipped with a variety of features to enhance the comfort of its occupants, particularly features such as ventilated, heated and/or cooled seats (e.g. seat conditioning modules). These seat conditioning modules can add cost and complexity to the seats and to the assembly of these seats. It is desirous to design a seat conditioning module so that any number of conditioning modes (e.g. pulling ambient air, pushing ambient air, pushing conditioned air, direct thermal heating via resistance heating, or any combination thereof) while minimizing the number of components of the seat conditioning module. To this end, the present invention seeks to improve on the current state of the art by the use of a unique fluid control system and conditioning module design to control and enhance the conditioning modes for the occupant. 
     SUMMARY OF THE INVENTION 
     The present invention is an improved seat conditioning module and method of using the unique seat conditioning module to enhance the conditioning environment and modes for the occupant. 
     Accordingly, pursuant to one aspect of the present invention, there is contemplated a seat conditioning module for a seat conditioning assembly that may comprise an air mover for moving a fluid and that may be fluidly connected to at least one intake port, at least one outtake port, or both wherein the intake port and the outtake port can be in fluid communication with a conditioned area via a distribution channel; a valve assembly with at least two apertures that may be movably disposed between the air mover and the at least one intake and at least one outtake ports for controlling the movement of the fluid between the at least one intake and at least one outtake ports and the conditioned area; at least one actuation device that may move the valve assembly to control the passage of the fluid through the at least two apertures or ports; an optional conditioning device in fluid communication with the air mover and the conditioned area; and a control device that may at least control the position of the at least two apertures of the valve assembly, activation of the optional conditioning device, the operation of the air mover, or any combination thereof. 
     The invention may be further characterized by one or any combination of the features described herein, such as the optional conditioning device may be a thermoelectric device for heating, cooling or both the fluid. The seat conditioning assembly may include a separate heater device disposed within 25 mm of a seat surface. The optional conditioning device may include at least one thermal collection device for storing thermal energy. The seat conditioning module may further include a venting system disposed adjacent to the seat surface for fluidly communicating air from the seat conditioning module to an area of a seat occupant, from the area of the seat occupant, or both. The venting system may include a thermal conditioning device disposed between the seat conditioning module and a vent aperture located adjacent to the seating surface. The air mover may be disposed in an air-impermeable housing that defines a hollow chamber which may include at least one opening which the valve assembly is disposed upon and may be fluidly connected to the at least one input and at least one output ports, wherein at least one of the ports may be defined by a air-impermeable hollow tubular structure. 
     Accordingly, pursuant to another aspect of the present invention, there is contemplated a method conditioning a vehicle seat, including the steps of (a) providing a seat conditioning assembly including a seat conditioning module and a distribution channel, wherein the seat conditioning module may include an air mover, a valve system that may include at least two movable apertures disposed between at least one input port and at least one output port and may be fluidly connected to the distribution channel, wherein the distribution channel may be fluidly connected to a conditioned area of the vehicle seat; (b) providing an optional conditioning device that may include a thermal collection device disposed within the seat conditioning module and in fluid communication with the air mover; (c) moving the at least two apertures of the valve system such that it may allow air flow between the seat conditioning module and the distribution channel; and activating the air mover such that it may fluidly communicate air to the conditioned area, from the conditioned area, or both through the valve system for conditioning the vehicle seat. 
     The invention may be further characterized by one or any combination of the features described herein, such as further including the conditioning device represented by a heat pump having main and waste side (of Peltier, Stirling, or traditional two phase compression heat pump principles). The valve system may be adapted to block a flow through a main side and thus create a condition for collecting thermal energy or cold in the heat pump main side for following release it towards the conditioned area when the main side flow is open. Including the step of releasing the collected thermal energy or cold in a burst to the conditioned area 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a schematic side view of an exemplary aspect according to the present invention. 
         FIG. 2  illustrates a series of schematic valve opening positions according to one aspect of the present invention. 
         FIG. 3  illustrates a series of schematic top views of an exemplary aspect according to the present invention. 
         FIG. 4  illustrates a schematic side view of an exemplary aspect according to the present invention. 
         FIG. 5  illustrates a schematic valve opening positions according to the present invention. 
         FIG. 6  illustrates a series of schematic top views according to another aspect of the present invention. 
         FIG. 7  illustrates a schematic side view of an exemplary aspect according to the present invention. 
         FIG. 8  illustrates a series of schematic valve opening positions according to another aspect of the present invention. 
         FIG. 9  illustrates a series of schematic top views according to the present invention. 
         FIG. 10  illustrates a schematic side view of an exemplary aspect according to another aspect of the present invention. 
         FIG. 11  illustrates a series of schematic valve opening positions according to the present invention. 
         FIG. 12  illustrates a series of schematic top views according to the present invention. 
         FIG. 13  illustrates a series of schematic top views according to the present invention. 
         FIG. 14  illustrates a schematic side view of an exemplary aspect according to the present invention. 
         FIG. 15  illustrates schematic side view of an exemplary aspect according to the present invention. 
         FIG. 16  illustrates a summary schematic top view according to the present invention. 
         FIG. 17  illustrates a schematic side view of an exemplary aspect according to the present invention. 
         FIG. 18  illustrates a schematic side view of an exemplary aspect according to the present invention. 
         FIG. 19  illustrates a schematic side view of an exemplary aspect according to the present invention. 
         FIG. 20  illustrates a schematic side view of an exemplary aspect according to the present invention. 
         FIG. 21  illustrates an exploded perspective view of an exemplary aspect according to the present invention. 
         FIG. 22  illustrates an exploded perspective view of an exemplary aspect according to the present invention. 
         FIG. 23  illustrates a side view of an exemplary aspect according to the present invention. 
         FIG. 24  illustrates a side view of an exemplary aspect according to the present invention. 
         FIG. 25  illustrates a top and perspective view of an exemplary aspect according to the present invention. 
         FIG. 26  illustrates a schematic side view of an exemplary aspect according to the present invention. 
         FIG. 27  illustrates a schematic side view of an exemplary aspect according to the present invention. 
         FIG. 28  illustrates a schematic side view of an exemplary aspect according to the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     As illustratively depicted in  FIGS. 1-28 , the present invention is directed at an improved seat conditioning module  20  and method for providing an improved conditioning effect for a conditioned area  52  of an automotive seat. For all figures, arrows depict an air flow and air flow direction. 
     In general, one aspect of the present invention contemplates an improved seat conditioning module  20  for use in a seat conditioning assembly  22  of a vehicle seat. The seat conditioning module  20  may include an air-impermeable housing  24  that defines a hollow chamber with an air mover  28  that essentially splits the chamber into two parts, a pull line  30  and a push line  32 . The pull line  30  being located on the intake side of the air mover  28  and the push line being located on the output side of the air mover  28 . It is also contemplated that the housing  24  may be partially or fully air permeable, but preferably is substantially air-impermeable. The housing  24  may also contain openings for other components (e.g. openings for wires, assembly tooling, motor cooling flow, spare holes for screws, condensed water drainage, etc.) It should be noted that for purposes of the present invention described below, it is assumed that the air mover  28  motivates the fluid in one direction (e.g. pull line to push line), although it is contemplated that the air mover function could be reversible. 
     The fluid preferably enters and exits the seat conditioning module  20 , into and out from the pull line  30  and the push line  32  respectively, through at least two or more ports  34  in a controllable valve system  36 . From these ports  34 , air can be fluidly connected to and travel to and/or from a distribution channel(s)  58  including distribution system(s)  38  within the seat, a ventilation duct(s)  40 , an exhaust port(s)  42 , an intake port(s)  44 , back into the module, or any combination thereof, which are further described below. All of these ports  34  could be a variety of shapes and/or sizes, so long as they are sufficiently large to allow enough fluid to pass therebetween to effectively provide the desired conditioning effect to the seat surface  46 . It is also contemplated that it may desirous to include fluid passageways that are not part of the controllable valve system  36  (e.g. open holes or mechanically independent valves in the module wall, not shown) to allow air or other fluids to flow in or out of the module. 
     The seat conditioning module  20  may also contain (within or spaced apart from) a control mechanism or device (not shown). This control device may control (e.g. switch on, off) and/or provide various power levels to part or all of the functions of the module (e.g. air mover, valve system, additional conditioning devices, conditioning modes, etc. . . . ). This control device may include a memory function that stores pre-programmed functional information that allows it to control the different “modes” described in further detail below. 
     In another aspect of the present invention it is contemplated the improved seat conditioning module  20  as described above also may include a thermal conditioning device  48  (e.g. a thermoelectric heating/cooling unit or “TED”, an interface to the vehicle environmental control unit-“HVAC”, a heat pump, or the like). When the thermal conditioning device  48  is integral to the module (e.g. located within the hollow chamber), it is preferably located within the push line  32  area of the module. If the thermal conditioning device  48  is remote (e.g. in the case of the HVAC) from the module, then it may be preferably fluidly connected to the module on the pull line  30  side. The inclusion of such a thermal conditioning device  48  may help with the goal of the present invention of improved occupant comfort by allowing the seat conditioning module  20  to provide heated or cooled air. 
     In yet another aspect of the present invention it is contemplated that the improved seat conditioning module  20  that includes the thermal conditioning device  48  may also include a thermal energy collection device  50 , and optionally a thermo-Insulation layer  55 . This collection device may serve to collect and store thermal energy for use in what may be described as a “burst” mode. This “burst” mode may serve to provide a relatively short (e.g. several seconds to several minutes) burst of additional thermal conditioning (e.g. thermal energy or cold) to the conditioning area  52  about the seat surface  46 . 
     General illustrative examples of packaging of the system are shown in  FIGS. 25-27 . 
     Valve System  36   
     For purposes of the present invention, the valve system  36  may be described as a substantially air-impermeable layer or layers  54  (e.g. a metal or plastic plate) with a number (e.g. two or more) of through-holes, apertures, or ports  34  that functions to control most, if not all, of the fluid flow to and from the seat conditioning module  20 . It is contemplated that the function of the valve system  36  may be accomplished in a number of structural configurations. For example, the valve system  36  could include a plate member or members (air-impermeable layer  54 ) with a series of apertures (ports  34 ) that either moves in a linear or rotational motion by use of an actuation means  56  (e.g. electric motor, pneumatically, hydraulically, or the like). It also may include cylindrical, conical or spherical shape or of any other axis-symmetrical shape with apertures in it. Or a slider of trapezoidal crossection moving for example in curved tunnel, for example in spiral channel. Or a belt and drag through curved slot-shaped tunnel. Also the spheroid segment may be moving in polar coordinates and not along the same route. The motion may be used as a means for positioning the apertures over the desired part of the pull line  30  and push line  32  and the corresponding distribution channel  58  (e.g. the distribution system(s)  38  within the seat, the ventilation duct(s)  40 , the exhaust port(s)  42 , the intake port(s)  44 , etc. . . . ). In another example, the valve system  36  may be structured as a moveable flap  60  or series of flaps, again allowing fluid to flow between the module and the desired distribution channel  58 . Examples of some of the various valve systems described above are shown in  FIGS. 21-24 . In particular,  FIG. 21  shows an exemplary rotary style vent.  FIG. 22  shows an exemplary linear valve system.  FIGS. 23-24  show an exemplary flap style valve system. It is further contemplated that the valves, particularly in the case of flap  60  type of valve, may be mechanically linked, independently actuated, or any combination thereof. 
     It is contemplated that the valve system  36  could utilize either of the above described structures or any combination thereof, or any fluid control structure that serves the same or similar function. The valve assembly movable element with apertures (or assembly itself) may be done of variety of shapes able to maintain sufficiently fluid-tight interface with structures (ducts) delivering fluid media to/from the conditioning device. 
     Control Device (not Shown) 
     For purposes of the present invention, the control device (not shown) may be described as a device or mechanism that functions to control and/or power the functionality and/or the components of the seat conditioning module  20 . For example, this may be accomplished by the use of a programmable electronic control module. The control module may be activated automatically or manually where it essentially instructs (e.g. via electrical signals) the components of the seat conditioning to activate. For example, the control module may instruct the air mover to motivate the air in a specific direction, instruct the thermal conditioning device  48  to activate, instruct the valve system  36  to open a desired port  34 , or any combination of these actions or more. 
     Thermal Conditioning Device  48   
     For purposes of the present invention, the thermal conditioning device  48  may be described as a device that changes the thermal energy of the fluid environment (e.g. heating or cooling). Illustrative examples include a TED unit  64 , a HVAC unit of a vehicle (not shown), heat pumps (not shown), resistance heaters (not shown), or the like. An example of a seat conditioning module  20  that may utilize the HVAC unit of a vehicle is shown in  FIGS. 19 and 20 . In this example the intake port  44  and one possible output port  70  are fluidly connected to the HVAC unit via a ducting system  66 . Additionally, a separate heater device  68  (e.g. an electrical resistance heater) may be located preferably within about 35 mm of the seat surface  46 , more preferably with about 25 mm or less of the seating surface  46 . This may aid the functionality of the total system by providing all or part of the heating of the seat surface  46  that may be desired. 
     Thermal Energy Collection Device  50   
     For purposes of the present invention, the thermal energy collection device  50  may be described as a device that takes the thermal energy from the thermal conditioning device and stores such energy for future use. For example, this may be accomplished by the use of a mass of thermally conductive materials (e.g. metal, plastic, liquids, gases, phase change materials may also be applied or the like) that is disposed either on, in the vicinity of, or both of the thermal conditioning device  48 . It may be massive body in thermal connection with the heat pump main side heat sink or the sink itself may be made heavier than normal. Any sink has this functionality but normally sinks are light and not designed to collect the energy. In one example, the thermal energy collection device  50  may be a steel plate brought to connection to the heat sink (attached via thermal conductive paste). Aluminum, copper, steel are examples of suitable materials, but other may be applied as well. 
     Distribution System  38   
     For purposes of the present invention, the distribution system  38  may be described as any system or method (e.g. manifold(s), spacer layer(s) or the like) for communicating fluid (e.g. air) to and/or from the seating surface (e.g. through an air-permeable trim layer). Such distribution systems  38 , at least as they exist internal to the seat and located above the seat conditioning module  20 , are taught and described in U.S. Pat. No. 6,786,541; 7,052,091; 7,083,227; and 7,114,771. These references all incorporated hereto by reference for the express purpose of describing an article or method of communicating a fluid from the improved seat conditioning module  20  to and/or from the seat surface  46 . 
     In one example of such a distribution system, as described in U.S. Pat. No. 6,786,541; the distribution system involves a pad assembly for a ventilated seat. The pad assembly includes a cushion member having an insert member of higher density foam providing an air distribution plenum. A channel whose open top is closed by a high density foam cover forms the plenum in the higher density insert member. The covering member is preferably molded as an integral part of the insert member. A trim layer would ordinarily cover the cushion, including the insert and insert channel cover. An open-celled foam layer could be used between the decorative trim layer and the cushion, including the insert and insert channel cover, to facilitate lateral air distribution to or from the cushion plenum while the seat is occupied. 
     In a second example of such a distribution system, as described in U.S. Pat. No. 7,083,227; the distribution system includes an insert located beneath the trim surface of each ventilated component. The insert includes a first layer having a heater integrated therein and a second layer formed of spacer material wherein the second layer defines an open space. A tubular structure is preferably provided in the system for providing the fluid communication between the insert and the fluid mover. 
     Ventilation Duct  40   
     For purposes of the present invention, the ventilation duct  40  may be described as a hollow channel member (e.g. a tube, conduit, air plenum, or the like) constructed of at least a semi-ridged material. The duct  40  may also be flexible or hinged and locationally adjustable (e.g. allowing a user to change the direction of the air flow). The duct  40  may be fluidly connected to the seat conditioning module  20  via an aperture  72  located at a lower duct end portion. 
     The duct may be fluidly connected to the seat occupant area via a nozzle aperture  74  or set of apertures in an upper duct end portion. The nozzle aperture  74  is preferably located within at least about 100 mm of the seat surface  46 , more preferably with about 75 mm, and most preferably within about 25 mm or less. It is contemplated that the nozzle apertures may be located such that any air output is directed at any number or combinations of occupant locations (e.g. occupant&#39;s head, shoulders, neck, feet, arms, etc.). It is also contemplated that the nozzle apertures  74  could be flush with or sit in a local depression on the seat surface. It is contemplated that nozzle apertures  74  can be any number of shapes and sizes ranging pin hole like structures of less than about 0.01 mm in diameter to round, square, triangular holes 10 mm across or more. The nozzle aperture  74  could also be covered in an air permeable fabric, screen, or filter material. 
     It is also contemplated that any ventilation duct  40  may also contain a thermal conditioning device  76  within, about the walls of the hollow channel member, or even located adjacent to the nozzle apertures  74 . It is contemplated that this thermal conditioning device  76  may be similar in type to that of the above described thermal conditioning device  48 . Also, it could be a heat exchanger, heated or cooled by a liquid carrier supplied from another centralized thermal management system. This thermal conditioning device  76  could help provide additional warming or cooling to the seat surface  46  or any area that the ventilation duct  40  air output could reach. 
     Exhaust Port  42   
     For purposes of the present invention, the exhaust port  42  may be described as a port or aperture that serves as an exit point for fluid from the seat conditioning module  20  that may not necessarily be directed to the seat surface  46  (e.g. directed remotely via a manifold system  80 ). For example, when a thermoelectric heating/cooling unit (TED unit  64 ) is utilized by the present invention, the exhaust port  42  may be utilized as an exit point for the heated or cooled air from what is commonly known as the waste side of the TED. 
     Intake Port  44   
     For purposes of the present invention, the intake port  44  may be described as a port or aperture that serves as one possible entry point for fluid from the environment external to the seat conditioning module  20 , via the valve system  36 . In other words, the intake port  44  may be located above the valve system, on the pull line  30  side of the seat conditioning module  20  and through which fluid is supplied to the air mover  28 . It is also contemplated that this port may be ducted via a manifold system  80  such that it may be possible to be at least partial fluid communication with the vehicle HVAC system or at least have the air taken in remotely from the module. 
     Operation of the Seat Conditioning Module 
     The present invention contemplates that the seat conditioning unit may operate in a number of “modes”. These modes, which are detailed in the illustrative examples below and shown in  FIGS. 1-20 , can be described as “Push Mode” (into the seat), “Push Mode” (with partial Nozzle flow), “Nozzle Flow Only”, “Push-Pull Mode”, and “Pull Mode”. A summary schematic view of the various functions described above is shown in  FIG. 16 . 
     Of note, each of these modes could be utilized with or without the optional thermal conditioning devices  48  and  76  and/or thermal energy collection device  50 . Additionally, unless the particular mode calls for the use of the nozzles  74  of the vent ducts  40 , inclusion of the ventilation ducts  40  may be entirely optional. 
     Additionally, several valve types (e.g. flap type, slide plates, or rotational plates) are shown in the exemplary figures and are not intended to limit the mode functionality, but are shown as examples of alternative valve styles. 
     “Push Mode” 
     Push mode is generally where the air mover pushes significantly all of air from the conditioning system to the seat surface  46  through the distribution system  38 . Illustrative examples are seen in  FIGS. 1-12  and described in more detail below. Arrows depict the direction of air flow. 
     Various illustrative schematic views of the push mode, with the optional vent system and without a conditioning device  48 , are shown in  FIGS. 1-2 . The air mover is activated in such a manner as to motivate substantially all of the air towards the seat surface  46  via the distribution system  38 .  FIGS. 1, 3  show schematic views of the push mode.  FIG. 3  shows a schematic view of the valve opening (e.g. port  34 ) positions. 
     In another illustrative example, as seen in  FIGS. 4-6 , an exemplary thermal conditioning device  48 , an exemplary thermal energy collection device  50 , and an exhaust port  42  are shown and utilized in the seat conditioning module  20 . This example is similar to the above one with some exceptions. The first is that some of the fluid exits the system via the exhaust port  42 . Second, any stored thermal energy in the thermal energy collection device  50  would be transferred to the fluid flow going to the conditioning area  52  as in the “burst” mode as described previously.  FIG. 5  shows a schematic view of the valve opening (e.g. port  34 ) positions. 
     In another illustrative example, as seen in  FIGS. 7-9 , the example shown is similar to that of  FIGS. 4-6 , except that the optional venting duct  40  is not present.  FIG. 8  shows a schematic view of the valve opening (e.g. port  34 ) positions. 
     In another illustrative example, as seen in  FIGS. 10-12 , the example shown is similar to that of  FIGS. 1-3 , except that an optional remote manifold system  80  is show and no vent duct  40  is present.  FIG. 9  shows a schematic view of the valve opening (e.g. port  34 ) positions. 
     “Push Mode” (with Partial Nozzle Flow) 
     Push mode with partial Nozzle flow is generally where the air mover pushes air from the conditioning system to the seat surface  46  through the distribution system  38  and to the nozzles  74  of the ventilation ducts  40 . Illustrative examples are seen in  FIGS. 2, 3, 5, 6, 13, and 18 , described in more detail below. Arrows depict the direction of air flow.  FIGS. 2, 5  show a schematic view of the valve opening (e.g. port  34 ) positions.  FIGS. 3, 6, 13, and 18  show examples with a conditioning device  48 , although this is not necessary for the functioning of this mode of operation. 
     “Nozzle Flow Only” 
     Nozzle flow only is an operational mode where substantially all the air is pushed from the module through the vent duct  40  and through the nozzle(s)  74 . Illustrative examples can be seen in  FIGS. 2, 3, 5, 6, and 14 .  FIGS. 2, 5  show a schematic view of the valve opening (e.g. port  34 ) positions.  FIGS. 3, 6, and 14  show examples with a conditioning device  48  within the module and with a conditioning device  76 , although this is not necessary for the functioning of this mode of operation. 
     “Push-Pull Mode” 
     In an illustrative example, as seen in  FIGS. 2-3 , of one possible push-pull mode configuration is described. In this example, the valve system is configured and positioned such that the input port  44  allows fluid flow from both the seat distribution system  38  and the intake port  44  into the seat conditioning module  20 . It is also configured to allow fluid to flow out of the exhaust port  42  and the ventilation ducts  40 . 
     “Pull Mode” 
     In an illustrative example, as seen in  FIGS. 2, 3, 5, 13, and 18 , show possible pull mode configurations. In the example shown in  FIG. 18 , the valve system is configured and positioned such that the input port  44  allows substantially only fluid to flow from the seat distribution system  38  into the seat conditioning module  20 . It is also may be configured to allow fluid to flow out of the exhaust port  42 . In the example shown in FIG.  13 , the valve system is configured such that air is pulled from the input port  44 , the seat surface and from the ventilation duct  40 . It is contemplated that in the case where an exemplary thermal conditioning device  48  with an exemplary thermal energy collection device  50  are present, then these devices may be activated in order to optionally build up a storage of thermal energy for use at a later time and “mode”. 
     Combination Mode 
     It is contemplated that any combination of the above operational modes may be combined in sequence (e.g. pull mode-push mode-nozzle flow-etc . . . ) over time to provide an occupant with a unique comfort experience. This may be described as a type of thermal conditioning massage. It is contemplated that a number of combination modes may be predetermined and programmed into the control device, discussed earlier. Therefore a user could selectively choose a pre-programmed combination or alternatively they could create their own. 
     Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. 
     The preferred embodiment of the present invention has been disclosed. A person of ordinary skill in the art would realize however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.