Modular comfort assembly for occupant support

• US 20060138810A1
• Filed: 12/03/2004
• Published: 06/29/2006
• Est. Priority Date: 12/03/2004
• Status: Active Grant

• Current Assignee: IGB Automotive Limited (Lear Corporation)
• Original Assignee: IGB Automotive Limited (Lear Corporation)
• Inventors: Brady, Benson J., Knoll, Peter R., Bevan, Michael J.
• Granted Patent: US 7,452,028 B2
• Time in Patent Office: Days
• US Class Current: 297/180.100
• CPC Class Codes: A47C 7/74 for ventilation, heating or cooling actuated by rocking the chair A47C3/02
• CPC Class Codes: B60N 2/5635 coming from the passenger compartment
• CPC Class Codes: B60N 2/5657 blown towards the seat surface
• CPC Class Codes: B60N 2/5685 Resistance
• CPC Class Codes: B60N 2/665 using inflatable bladders
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for

Abstract

A modular comfort assembly is disclosed. The modular comfort assembly is adapted for installation within an occupant support. The occupant support includes a surface, which has a recess therein. The modular comfort assembly includes a ventilation diffuser allowing for flow of air through the diffuser. The diffuser has an outer edge sized to extend over and cover a perimeter of the recess. The modular comfort assembly also has a heating element adapted for placement on a surface of the diffuser.

Claims

1. A modular comfort assembly adapted for installation within an occupant support having a surface including a recess therein, the comfort assembly comprising:

a ventilation diffuser allowing for flow of air through said diffuser, and having an outer edge sized to extend over and cover a perimeter of the recess; and

a heating element adapted for placement on a surface of the diffuser.

2. The modular comfort assembly of claim 1 wherein said ventilation diffuser comprises a sheet including a plurality of spaced apertures surrounded by a non-perforated peripheral portion.

3. The modular comfort assembly of claim 2 comprising:

an air permeable spacer material allowing for an even flow of air therethrough disposed in said recess between said occupant support and diffuser sheet.

4. The modular comfort assembly of claim 1 wherein the ventilation diffuser comprises:

a three-dimensional diffuser bag including a top perforated surface including a non-perforated peripheral portion adapted to extend over said perimeter of said recess;

a bottom surface adapted to lay in said recess;

a sidewall extending between said top and bottom surfaces; and

an air permeable spacer material disposed in said diffuser bag.

5. The modular comfort assembly of claim 4 wherein the diffuser bag bottom surface includes perforations allowing for air flow through the bottom of the diffuser.

6. The modular comfort assembly of claim 1 wherein the heating element comprises:

a layer of permeable material adapted for placement on a surface of the diffuser; and

a heating wire formed in a predetermined pattern disposed about the layer of permeable material.

7. The modular comfort assembly of claim 1 comprising:

a lumbar support system adapted for placement on a surface of the diffuser opposing the diffuser surface upon which the heating element is placed.

8. The modular comfort assembly of claim 7 wherein said lumbar support system comprises internal baffles.

9. The modular comfort assembly of claim 7 comprising:

an air pump connected to an air inlet of said lumbar support system to allow for inflation and deflation of said lumbar support system.

10. The modular comfort assembly of claim 1 comprising:

an air moving device in communication with said diffuser for circulating air through said diffuser to provide a convection cooling effect.

11. The modular comfort assembly of claim 10 comprising:

a control system including;

a heat sensor for sensing temperature indicative of heat output from said heating element;

a cooling sensor for sensing temperature indicative of convection cooling output from said air moving device; and

a processor for receiving heat sensor and cooling sensor signals, the processor simultaneously controlling the heating element and air moving device to provide a predetermined occupant support temperature within the occupant support.

12. The modular comfort assembly of claim 11 wherein the control system comprises:

an occupant support temperature sensor for sensing the occupant support temperature.

13. A method of installing a modular comfort assembly within an occupant support having a surface including a recess therein, the method comprising the steps of:

providing a ventilation diffuser having an outer edge sized to extend over and cover a perimeter of said recess;

mounting said diffuser onto the surface of said occupant support such that said diffuser seals the perimeter of said recess; and

mounting a heating element on a surface of said diffuser.

14. The method of claim 13 comprising the steps of:

providing an air permeable spacer material allowing for an even flow of air therethrough; and

disposing the spacer material in said recess between the occupant support and the diffuser.

15. The method of claim 13 comprising the steps of:

forming through holes in the occupant support such that said through holes extend from said recess to a surface of the occupant support opposite said recess; and

providing an air moving device in communication with said diffuser via said through holes for circulating air through said diffuser to provide a convection cooling effect.

16. A method of installing a modular comfort assembly within an occupant support having a surface including a recess therein, the method comprising the steps of:

providing a three-dimensional diffuser bag including;

a top perforated surface having a non-perforated portion adapted to extend over the perimeter of said recess;

a bottom surface adapted to lay in said recess; and

a sidewall extending between the top and bottom surfaces;

disposing an air permeable spacer material within said diffuser bag; and

mounting said three-dimensional diffuser bag in said recess.

17. The method of claim 16 comprising the step of:

placing a lumbar support system on a surface of the diffuser opposing the diffuser surface upon which the heating element is placed.

18. A method for controlling the temperature in a vehicle occupant support including heating means operatively providing heat and air moving means operatively providing cooling air flow, the method comprising the steps of:

simultaneously operating said heating means and said air moving means to provide a desired occupant support temperature without temperature shock to an occupant.

19. A method of installing a modular comfort assembly within an occupant support having a surface including a recess therein, the method comprising the steps of:

forming a sub-assembly comprising a ventilation diffuser having an outer edge sized to extend over and cover a perimeter of said recess, and a heating element adjacent a surface of said diffuser; and

mounting said sub-assembly in said recess such that said diffuser outer edge seals the perimeter of said recess.

20. A method of installing a modular comfort assembly within an occupant support having a surface including a recess therein, the method comprising the steps of:

forming a sub-assembly comprising a three-dimensional diffuser bag including a top perforated surface having a non-perforated portion adapted to extend over the perimeter of said recess, a bottom surface adapted to lay in said recess, and a sidewall extending between the top and bottom surfaces; and

a heating element adjacent a surface of said diffuser bag;

disposing an air permeable spacer material within said diffuser bag; and

mounting said sub-assembly in said recess.

21. A method of forming an occupant support comprising the steps of:

providing a mold having a cavity therein;

disposing a modular comfort sub-assembly therein said cavity; and

injecting foam into said cavity to form a foam bun with an integral modular comfort sub-assembly.