WO2016138364A1

WO2016138364A1 - Seats with thermal devices

Info

Publication number: WO2016138364A1
Application number: PCT/US2016/019743
Authority: WO
Inventors: Kevin L. WRIGHT; Todd SIETING; John M. Perraut; John L. FRANKLIN; Tarek Makansi; Raghvendra T. JOSHI; Anne-Isabelle DACOSTA-MALLET
Original assignee: Faurecia Automotive Seating, Llc
Priority date: 2015-02-27
Filing date: 2016-02-26
Publication date: 2016-09-01

Abstract

A vehicle seat includes seat pads included in seat bottoms and/or seat backs. The seat pads may be configured to provide either or both a cold sensation and a warming sensation to an occupant sitting adjacent to the seat pads. A seat pad may include a cushion cover defining a cushion-receiving space and a cushion positioned to lie in the cushion-receiving space.

Description

SEATS WITH THERMAL DEVICES

CROSS-REFERENCE

[0001] This application claims priority to U.S. Provisional Patent Application No.

62/126, 159, filed February 27, 2015, and U.S. Provisional Patent Application No. 62/126,304, filed February 27, 2015, each of which is entirely incorporated herein by reference.

BACKGROUND

[0002] The thermoelectric effect is the conversion of temperature differences to electric voltage and vice versa. A thermoelectric device may create voltage when there is a

temperature gradient across the thermoelectric device, such as when there is a different temperature on each side of the thermoelectric device. Conversely, when a voltage is applied to the thermoelectric device, it may create a temperature difference. An applied temperature gradient may cause charge carriers in the thermoelectric device to diffuse from a hot side to a cold side of the thermoelectric device.

[0003] The term "thermoelectric effect" encompasses the Seebeck effect, Peltier effect and Thomson effect. Solid-state cooling and power generation based on thermoelectric effects typically employ the Seebeck effect or Peltier effect for power generation and heat pumping. The utility of such conventional thermoelectric devices is, however, typically limited by their low coefficient-of-performance (COP) (for refrigeration applications) or low efficiency (for power generation applications).

[0004] Thermoelectric modules may contain densely packed elements spaced apart by 1-3 mm. Up to 256 such elements may be connected in an array that is 2x2 inches (5.08x5.08 cm) in area. When these modules are deployed, large and heavy heat sinks and powerful fans may be required to dissipate or absorb heat on each side. Small elements with low resistance may allow larger current (I) to flow before the resistive heat (I²R) generated destroys the thermoelectric cooling. The use of short elements for maximum cooling capacity results in the hot and cold side circuit boards being close together. This proximity may result in the high density.

SUMMARY

[0005] The present disclosure provides seats with thermal devices. The seats may be vehicle seats. In an example, a vehicle seat has seat pads included in seat bottoms and seat backs. A seat pad of the present disclosure may be configured to provide both a cold sensation and a warming sensation to an occupant sitting on the seat pad. [0006] According to the present disclosure, a vehicle seat includes an occupant-support base. The occupant-support base includes a cushion cover defining a cushion-receiving space and a cushion positioned to lie in the cushion-receiving space.

[0007] In illustrative embodiments, the occupant-support base includes a seat bottom and a seat back extending upwardly from the seat bottom. Each of the seat bottom and seat back includes a cushion cover and a cushion in the cushion-receiving space defined by that cushion cover.

[0008] In illustrative embodiments, the occupant-support base further includes a thermal device coupled to a cushion included in either the seat bottom or the seat back to lie in the cushion-receiving space associated with that cushion. The thermal device may be configured to enable movement of heat between a heat-transfer station located in the cushion and an occupant seated on the occupant-support base without convective heat transfer. In an occupant cooling mode, the thermal device moves heat from the occupant seated on the occupant-support base through the cushion cover to a heat sink provided in the heat-transfer station. In an occupant warming mode, the thermal device moves heat from a heat source included in the heat-transfer station through the cushion cover to the seat occupant.

[0009] In an aspect, the present disclosure provides an occupant-support system for a vehicle seat, comprising a seat pad including a cushion cover defining a cushion-receiving space and a cushion positioned to lie in the cushion-receiving space; a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the seat pad without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the seat pad through the cushion cover to a heat sink included in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to seat occupant seated adjacent to the seat pad; and a heat mover cover arranged to lie in and fill a heat mover space formed in the cushion and configured to separate portions of neighboring heat-transfer stations and provide a smooth continuous outer surface to the cushion. The heat mover cover may be arranged to extend from an outer surface of the cushion toward a heat mover included in the heat-transfer station. An apex of the heat mover cover may be located between the heat mover and the outer surface of the cushion.

[0010] In some embodiments, the heat mover cover has a triangular shape when viewed from above the heat mover cover. In some embodiments, the heat mover cover has a triangular shape when viewed in cross section. In some embodiments, the apex of the heat mover cover is located between the heat mover and the outer surface of the cushion. In some embodiments, the heat mover includes one or more thermoelectric devices.

[0011] In another aspect, the present disclosure provides an occupant-support system for a vehicle seat, comprising a cushion cover having a cushion-receiving space; a cushion in the cushion-receiving space; and a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the cushion cover without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the cushion cover through the cushion cover to a heat sink in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to the occupant seated adjacent to the cushion cover. The heat-transfer station may include a heat mover and an outer heat- transfer node located between the cushion and the cushion cover.

[0012] In some embodiments, the outer heat-transfer node comprises a metal-wire mesh and individual wires included in the metal-wire mesh are collapsed toward one another to engage one another to form a high-density outer heat-transfer node to enhance thermal intensity felt by the occupant. In some embodiments, the heat mover includes one or more thermoelectric devices.

[0013] In another aspect, the present disclosure provides an occupant-support system for a vehicle seat, comprising a cushion cover having a cushion-receiving space; a cushion positioned in the cushion-receiving space; and a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat- transfer station located in the cushion and an occupant seated adjacent to the cushion cover without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the cushion cover through the cushion cover to a heat sink in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to the occupant seated adjacent to the cushion cover. The thermal device may include a plurality of heat-transfer stations coupled together in a serial connection to form a heat-transfer braid, which plurality of heat-transfer stations includes the heat-transfer station. The heat-transfer braid may be arranged in a pattern such that the heat-transfer stations are less dense in a high-pressure zone of the cushion, which high-pressure zone engages with an ischial spine or hip bone(s) of the occupant when the occupant is sitting adjacent to the cushion cover. [0014] In some embodiments, the heat-transfer braid includes a first portion having a generally quadrilateral shape and a second portion having a serpentine shape and the first portion is located to cause the high-pressure zone to be located inside a region defined by the first portion. In some embodiments, the heat-transfer braid includes a first portion having a generally C-shape and a second portion having a serpentine shape. In some embodiments, the first portion is positioned such that the high-pressure zone is located inside a region defined by the first portion.

[0015] In some embodiments, the heat-transfer braid includes a first portion having a serpentine shape and a second portion having a serpentine shape. In some embodiments, the first portion is positioned such that the high-pressure zone is located inside a region defined by a section included in the first portion. In some embodiments, the first portion is positioned such that a number of heat-transfer stations included in the first portion and the high-pressure zone is minimized.

[0016] In some embodiments, the pattern is arranged such that a first density of heat-transfer stations is positioned in the high-pressure zone and a second density of heat-transfer stations is positioned so as to align with a spine of the occupant. The first density may be less than the second density. In some embodiments, the pattern is arranged such that a first number of heat- transfer stations are located in the high-pressure zone and a second number of heat-transfer stations are spaced-apart in relation to the high-pressure zone. The first number may be less than the second number.

[0017] In some embodiments, the heat-transfer braid includes a first serpentine portion associated with a lower back of the occupant and a second serpentine portion associated with an upper back of the occupant. In some embodiments, the cushion and cushion cover are part of a seat back. In some embodiments, the heat-transfer braid is arranged to extend from a bottom of the seat back towards a top of the seat back and terminate between a bottom and top of the cushion.

[0018] In another aspect, the present disclosure provides an occupant-support system for a vehicle seat, comprising a cushion cover having a cushion-receiving space; a cushion in the cushion-receiving space; and a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the cushion cover without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the cushion cover through the cushion cover to a heat sink included in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to the occupant seated adjacent to the cushion cover. The cushion cover may include (i) an outer trim layer arranged in spaced apart relation to the cushion, and (ii) an inner foam layer located between the outer trim layer and the cushion. The inner foam layer may be configured to provide enhanced heat-transfer through the cushion cover between the occupant and the thermal device. The inner foam layer may include a viscoelastic foam and a carbon- containing material.

[0019] In some embodiments, the carbon-containing material is graphite.

[0020] In some embodiments, the inner foam layer includes a plurality of apertures. In some embodiments, the occupant-support system further comprises a plurality of heat-transfer stations. In some embodiments, the plurality of apertures is arranged to be unaligned with the plurality of heat-transfer stations. In some embodiments, each of the plurality of apertures has a generally circular shape. In some embodiments, each of the plurality of apertures has a generally quadrilateral shape. In some embodiments, each of the plurality of apertures has a generally square shape.

[0021] In another aspect, the present disclosure provides an occupant-support system for a vehicle seat, comprising a cushion cover having a cushion-receiving space; a cushion in the cushion-receiving space; a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the cushion cover without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the cushion cover through the cushion cover to a heat sink included in the heat- transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to the occupant seated adjacent to the cushion cover; and a massage device located between the cushion cover and the cushion and between the thermal device and the cushion cover. The massage device may include a plurality of bladders. The thermal device may include a plurality of heat-transfer stations coupled together in a serial connection to form a heat-transfer braid, which plurality of heat-transfer stations includes the heat-transfer station. The heat-transfer braid may be arranged in a pattern such that the heat-transfer stations are spaced apart from each of the plurality of bladders to minimize interference between the massage device and the thermal device.

[0022] In some embodiments, the heat-transfer braid includes at least one generally horizontal section and at least one generally vertical section. In some embodiments, the at least one generally horizontal section has a first length and the at least one generally vertical section has a second length. The first length may be the same as the second length.

[0023] In some embodiments, the at least one generally horizontal section has a first length and the at least one generally vertical section has a second length. The first length may be different than the second length. In some embodiments, the first length is less than the second length.

[0024] In some embodiments, the heat-transfer braid includes at least three generally horizontal sections and at least four generally vertical sections.

[0025] In another aspect, the present disclosure provides an occupant-support system for a vehicle seat, comprising a cushion cover having a cushion-receiving space; a cushion in the cushion-receiving space; and a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the cushion cover without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the cushion cover through the cushion cover to a heat sink in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to the occupant seated adjacent to the cushion cover. The heat-transfer station may include a heat mover located in a heat mover space in the cushion, an upper heat-transfer node coupled to the heat mover and arranged to extend away from the heat mover and the cushion, and a lower heat-transfer node arranged to extend away from the upper heat-transfer node and the heat mover.

[0026] In some embodiments, the lower heat-transfer node is a arranged in curled, J-shape, or plus sign configuration. In some embodiments, the upper heat-transfer node lies between the cushion and the cushion cover. In some embodiments, the lower heat-transfer node lies in a vent passageway in the cushion.

[0027] In another aspect, the present disclosure provides an occupant-support system for a vehicle seat, comprising a cushion cover having a cushion-receiving space; a cushion in the cushion-receiving space; and a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the cushion cover without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the cushion cover through the cushion cover to a heat sink in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to the occupant seated adjacent to the cushion cover. The heat-transfer station may include a heat mover, a first outer heat- transfer node coupled to the heat mover, a second outer heat-transfer node coupled to the heat mover, an inner heat-transfer node coupled to the heat mover, and an outer-node insulator coupled to the first outer heat-transfer node and configured to provide for separation of the first outer heat-transfer node from the second outer heat-transfer node.

[0028] In some embodiments, the outer-node insulator is a shrink-wrapped cover or conformal coating coupled to the first outer heat-transfer node.

[0029] In another aspect, the present disclosure provides an occupant-support system for a vehicle seat, comprising a seat pad including a cushion cover defining a cushion-receiving space and a cushion positioned to lie in the cushion-receiving space; and a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the seat pad without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the seat pad through the cushion cover to a heat sink included in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to the occupant seated adjacent to the seat pad. The thermal device may include an air mover coupled to the heat-transfer station to cause air to flow across at least a portion of the heat- transfer station. The air mover may include a blower and a manifold, which manifold is arranged to extend between and interconnect the cushion and the blower. The manifold may include first and second seat-bottom air inlets arranged to open into an air passageway formed in the manifold and a blower aperture formed in the manifold and aligned with a blower inlet formed in the blower.

[0030] In some embodiments, the manifold includes a seat-back inlet arranged to open into the air passageway. In some embodiments, the blower is configured to apply a negative pressure and suck air across the portion of the heat-transfer station.

[0031] Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive. INCORPORATION BY REFERENCE

[0032] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings (also "FIG." and "FIGs." herein), of which:

[0034] FIG. 1 is a perspective view and diagrammatic view of a vehicle seat in accordance with the present disclosure, showing that the vehicle seat includes a first occupant-support base configured as a seat bottom and a second occupant-support base configured as a seat back and suggesting that each occupant-support base includes a cushion, a cushion cover, and a thermal device configured to provide an occupant (not shown) seated on the occupant- support base with a cold sensation when the thermal device is in a cooling mode and a warming sensation when the thermal device is in a heating mode;

[0035] FIG. 2 is a diagrammatic view of an occupant-support base in accordance with the present disclosure, showing that the occupant-support base includes a seat pad including a cushion cover configured to engage an occupant sitting on the occupant-support base and a cushion arranged to lie in a cushion-receiving space defined by the cushion cover and support the occupant and a thermal device including an array of heat movers positioned to lie in spaced-apart relation below an outer surface of the cushion, an array of outer heat-transfer nodes positioned to lie between the outer surface of the cushion and the cushion cover to transfer heat between the occupant and the heat movers without the use of convection, and an array of inner heat-transfer nodes;

[0036] FIG. 3 is an elevation view of a another embodiment of an occupant-support base in accordance with the present disclosure, showing that the occupant-support base includes a seat pad, a thermal device including a series of outer heat-transfer nodes, heat movers, and inner heat-transfer nodes as suggested in FIG. 4, and a set of heat-mover covers arranged to lie in and fill a heat-mover space formed in the cushion and configured to separate neighboring outer heat-transfer nodes and provide a smooth continuous outer surface of the cushion;

[0037] FIG. 4 is a diagrammatic view of a portion of the thermal device of FIG. 3, showing that each heat-mover cover has a generally triangular shape used to extend into and fill the seat-mover space formed in the cushion to cause comfort to be maximized, visual

imperfections in the cushion cover to be minimized, and maintain separation of neighboring outer heat-transfer nodes;

[0038] FIG. 5 is an enlarged view taken from the circled region of FIG. 3, showing that a first outer heat-transfer node extends into the heat-mover space, a second outer heat-transfer node extends into the same heat-mover space, and that a triangular-shaped heat-mover cover is located between the neighboring outer heat-transfer nodes and extends into and fills the heat- mover space;

[0039] FIG. 6 is a plan view of one embodiment of an outer heat-transfer node comprising the metal-wire mesh that has been spread apart to form a low-density outer heat-transfer node so that an area where heat is transferred to the low-density outer heat-transfer node is maximized;

[0040] FIG. 7 is an enlarged plan view of one of the outer heat-transfer nodes of FIG. 6, showing the metal-wire mesh spread apart so as to maximize an area of contact with the cushion cover;

[0041] FIG. 8 is an enlarged plan view of another embodiment of an outer heat-transfer node comprising a metal-wire mesh that has been collapsed to form a high-density outer heat- transfer node to cause thermal intensity felt by an occupant of a single outer heat-transfer node to be maximized;

[0042] FIG. 9 is an enlarged plan view of one of the outer heat-transfer nodes of FIG. 8, showing the metal-wire mesh collapsed so as to minimize surface area of contact with the cushion cover and maximize felt thermal intensity of the outer heat-transfer node;

[0043] FIG. 10 is a diagrammatic view of another embodiment of an occupant support base in accordance with the present disclosure, showing the occupant-support base configured as a seat bottom and showing that the thermal device is arranged in a patter which is around high- pressure zones associated with the occupant's ischials or ischial spine;

[0044] FIG. 11 is a diagrammatic view of another embodiment of a seat bottom including a different pattern of the thermal device that is configured to minimize interaction with the high-pressure zones associated with the occupant's ischials or ischial spine while maximizing interaction between the thermal device and high-contact areas of the occupant surrounding the high-pressure zones;

[0045] FIG. 12 is a diagrammatic view of another embodiment of a seat bottom including a different pattern of the thermal device that is configured to minimize interaction with the high-pressure zones associated with the occupant's ischials or ischial spine;

[0046] FIG. 13 is a diagrammatic view of another embodiment of a seat bottom including a different pattern of the thermal device that is configured to minimize interaction with the high-pressure zones associated with the occupant's ischials or ischial spine;

[0047] FIG. 14 is a perspective view of another embodiment of a seat back in accordance with the present disclosure, showing that the seat back includes a thermal device arranged in a pattern configured to maximize density of heat movers along an occupant's spine;

[0048] FIG. 15 is a perspective view of another embodiment of a seat back in accordance with the present disclosure, showing that the seat back includes a thermal device arranged in a pattern configured to minimize engagement with high pressure zones associated with an occupant's thigh bones and provide thermal sensation to both a lower back and upper back of an occupant so that long-term comfort is maximized;

[0049] FIG. 16 is a diagrammatic view of another embodiment of a seat back in accordance with the present disclosure, showing that the seat back includes a thermal device arranged in a pattern configured to minimize engagement with high pressure zones associated with an occupant's ischials or ischial spine, and provide thermal sensation to both a lower back and upper back of an occupant a third pattern of TED braids which are arranged to maximize long-term thermal comfort;

[0050] FIG. 17 is a diagrammatic view of another embodiment of a seat back in accordance with the present disclosure, showing that the seat back includes a thermal device arranged in a pattern configured to maximize engagement with an occupant's lower back;

[0051] FIG. 18 is a diagrammatic view of another embodiment of a seat back in accordance with the present disclosure, showing that the seat back includes a thermal device arranged in a pattern configured to minimize time to thermal sensation while maximizing long-term comfort of the occupant;

[0052] FIG. 19 is a diagrammatic view of another embodiment of a vehicle seat, showing that a cushion cover included in the seat bottom includes an outer trim layer and an inner thermal- foam layer including graphite and a viscoelastic foam that is configured to maximize heat transfer of the thermal-foam layer between the thermal device and the occupant; [0053] FIG. 20 is a photograph of the cushion cover of FIG. 19, showing that the cushion cover includes the outer trim layer made of leather and the inner thermal -foam layer including graphite and viscoelastic foam;

[0054] FIG. 21 is a photograph of the cushion of FIG. 20, showing the thermal -foam layer separated from the outer trim layer;

[0055] FIG. 22 is a diagrammatic view of another embodiment of a vehicle seat, showing that a cushion cover included in the seat bottom includes an outer trim layer and an inner foam layer formed to include a plurality of circular apertures arranged to overlie each outer heat- transfer node included in the thermal device to maximize heat transfer through the cushion cover;

[0056] FIG. 23 is a diagrammatic view of another embodiment of a vehicle seat, showing that a cushion cover included in the seat bottom includes an outer trim layer and an inner foam layer formed to include a plurality of square apertures arranged to overlie each outer heat- transfer node included in the thermal device to maximize heat transfer through the cushion cover;

[0057] FIG. 24 is a diagrammatic view of another embodiment of a vehicle seat in accordance with the present disclosure, showing that the vehicle seat includes a seat pad, a massage system located between a cushion cover and a cushion included in the seat pad, and a thermal device arranged to lie in a pattern configured to work in occupant-support bases including the massage system and occupant-support bases excluding the massage system and suggesting that the pattern is configured to minimize interference by the thermal system with the massage system;

[0058] FIG. 25 is a diagrammatic view of another embodiment of a vehicle seat in accordance with the present disclosure, showing that the vehicle seat includes a seat pad, a massage system, and a thermal device arranged to lie in a different pattern around the massage system;

[0059] FIG. 26 is a diagrammatic view of another embodiment of a vehicle seat in accordance with the present disclosure, showing that the vehicle seat includes a seat pad, a massage system, and a thermal device arranged to lie in a different pattern around the massage system;

[0060] FIG. 27 is a diagrammatic view of another embodiment of a vehicle seat in accordance with the present disclosure, showing that the vehicle seat includes a seat pad, a massage system, and a thermal device arranged to lie in a different pattern around the massage system;

[0061] FIG. 28 is a diagrammatic view of an occupant-support base in accordance with the present disclosure; [0062] FIG. 29 is a sectional view taken along line A-A of FIG. 28, showing that inner heat- transfer nodes included in the thermal device of FIG. 28 are arranged to have a curled shape;

[0063] FIG. 30 is a bottom perspective of an occupant-support base in accordance with the present disclosure, showing curled inner heat-transfer nodes;

[0064] FIG. 31 is a diagrammatic view of a portion of a thermal device in accordance with the present disclosure, showing that a shrink-wrap covering is coupled to a first outer heat- transfer node to cause the first outer heat-transfer node to be separated from a neighboring second outer heat-transfer node;

[0065] FIG. 32 is a view similar to FIG. 31 showing a thermal device in accordance with the present disclosure in which a conforming coating has been applied to both ends of neighboring outer heat-transfer nodes as they couple to a heat mover to cause the first outer heat-transfer node to be separated from the neighboring second outer heat-transfer node;

[0066] FIG. 33 is a diagrammatic view of a portion of a thermal device in accordance with the present disclosure, showing that a lower heat-transfer node is arranged in a straight configuration that extends downwardly away from an upper heat-transfer node;

[0067] FIG. 34 is a view similar to FIG. 33, showing a lower heat-transfer node arranged in a j -shape configuration;

[0068] FIG. 35 is a view similar to FIG. 34, showing a lower heat-transfer node arranged in a spiral configuration;

[0069] FIG. 36 is a view similar to FIG. 34, showing a lower heat-transfer node arranged in a plus-sign configuration;

[0070] FIG. 37 shows a lower heat-transfer node arranged in a plus-sign configuration and coupled to a first layer of a 3-D spacer material included in a cushion;

[0071] FIG. 38 is a diagrammatic view of a blower system in accordance with the present disclosure, showing that the blower system includes, from bottom to top, a fan configured to pull air and a manifold configured to pull air across lower heat-transfer nodes included in thermal devices by way of two seat-bottom inlets and one seat-back inlet; and

[0072] FIG. 39 shows a computer control system that is programmed or otherwise configured to implement devices, systems and methods of the present disclosure.

DETAILED DESCRIPTION

[0073] While various embodiments of the invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed.

[0074] The term "adjacent" or "adjacent to," as used herein, includes 'next to', 'adjoining', 'in contact with', and 'in proximity to' . In some instances, adjacent components are separated from one another by one or more intervening components.

[0075] The present disclosure provides occupant-support systems including occupant-support bases. Occupant-support systems of the present disclosure can include a heat-mover comprising one or more thermoelectric devices, each of which can include one or more thermoelectric elements. The thermoelectric elements can be alternating n-type and p-type thermoelectric elements electrically connected in series. The thermoelectric elements can have braids that are expanded in cross-section along a portion of a thermoelectric device and compacted in cross-section along another portion of the thermoelectric device.

[0076] The thermoelectric device can generate heat upon the flow of electrical current through the thermoelectric device. This can be used to heat an object, such as an occupant. As an alternative, the thermoelectric device can generate power upon the flow of heat across the thermoelectric device. This can be used to provide cooling to the object, such as the occupant.

[0077] FIG. 1 shows an occupant-support base 10, in accordance with the present disclosure, which may be used as a seat bottom 12 or a seat back 14 in a vehicle seat 16. Occupant- support base 10 includes a seat pad 20 and a thermal device 22 as suggested in FIGs. 1 and 2. Seat pad 20 may be coupled to a support pan (not shown) that may be arranged to underlie and support seat pad 20. Thermal device 22 may be coupled to seat pad 20 and configured to enable movement of heat 17 between a heat-transfer station 11 and an occupant 24 seated on occupant-support base 10 without convective heat transfer as suggested in FIGs. 1 and 2.

[0078] Seat pad 20 includes, for example, a cushion cover 26 defining a cushion-receiving space 28 therein and a cushion 30 as suggested in FIG. 1. Cushion 30 is positioned to lie in cushion-receiving space 28. Thermal device 22 is coupled to cushion 30 and is positioned to lie in cushion-receiving space 28 with cushion 30. In one illustrative example, cushion cover 26 is generally airtight and blocks communication of air from cushion-receiving space 28 to occupant 24 resting on occupant-support base 10. In another illustrative example, cushion cover 26 is air and/or moisture permeable and allows communication of air between cushion- receiving space 28 and occupant 24 resting on occupant-support base 10.

[0079] Thermal device 22 includes heat-transfer station 11 and a heat conductor 36 as shown in FIGs. 1 and 2. Heat-transfer station 11 is coupled to cushion 30 and positioned to lie in spaced-apart relation below an outer surface 38 of cushion 30. Heat conductor 36 is coupled to heat-transfer station 1 1 to extend between heat-transfer station 11 and an inner surface 40 of cushion cover 26.

[0080] Heat-transfer station 11 includes a heat mover 34, a heat source 13, and a heat sink 15. Heat mover 34 is coupled to cushion 30 and positioned to lie in spaced-apart relation below an outer surface 38 of cushion 30. Heat conductor 36 is coupled to heat mover 34 to extend between heat mover 34 and an inner surface 40 of cushion cover 26. Heat mover 34 is a mover of thermal energy as a result of creating a temperature gradient. In one illustrative example, heat mover 34 establishes a temperature gradient of about 10 degrees Fahrenheit.

[0081] Thermal device 22 may be arranged in one of a heating mode and a cooling mode. Thermal device 22, when in the heating mode, causes heat mover 34 to move (or transfer) heat 17 from heat source 13, through heat conductor 36 to cushion cover 26. There, heat 17 is transferred through cushion cover 26 to occupant 24 through a combination of conductive heat transfer and radiative heat transfer to provide a warming sensation 44 to occupant 24. Thermal device 22, when in the cooling mode, causes heat mover 34 to move heat 17 collected from occupant 24 through heat conductor 36 and into heat sink 15 to provide a cold sensation 46 to occupant 24.

[0082] In one illustrative example, a heat source 13 is one or more cavities 58 formed in cushion 30 that contain air as suggested FIG. 2. In another example, the heat source 13 is one or more cavities formed in the cushion and filled with air heated by a resistive heater. In still yet another example, the heat source may be a heat exchanger that is filled with a hot fluid such as air, water, or any other suitable medium that is coupled to heat mover 34.

[0083] In another illustrative example, heat sink 15 is one or more cavities 58 formed in cushion 30 that contain air. In another example, the cavities may be filled with water, gel, or any other suitable medium.

[0084] The heat-transfer station may include a heat sink separate from a heat source. Both the heat sink and the heat source may be combined into cavity 58 formed in cushion 30. As a result, heat 17 is drawn from the air in cavity 58 when thermal device 22 is in the occupant heating mode. Heat is rejected to the air in cavity 58 when thermal device 22 is in the occupant cooling mode.

[0085] Heat mover 34 is configured in either the occupant heating mode or the occupant cooling mode by a controller 42 coupled to heat mover 34 as shown in FIGs. 1 and 2. A user input 48 is coupled to controller 42 and configured to transmit commands received from occupant 24 to controller 42 to cause controller 42 to command heat mover 34 to assume either the heating mode or the cooling mode. User input 48 may be coupled to controller 42 to control an upper thermal device 22U associated with seat back 14 independently of a lower thermal device 22L associated with seat bottom 12. As a result, one user input 48 and one controller may be used to control both upper and lower thermal device 22U, 22L.

[0086] In an illustrative example, heat mover 34 is a thermal electric device microchip.

Thermal electric device microchips may be as described in U.S. Application Nos. 12/367,965, filed on February 9, 2009 and titled ENERGY CONVERSION DEVICE, 13/101,015, filed May 4, 2011 and titled DISTRIBUTED THERMOELECTRIC STRING AND INSULATING PANEL, 13/131,535, filed on May 26, 2011 and titled DEVICE FOR ENERGY

CONVERSION, ELECTRICAL SWITCHING, AND THERMAL SWITCHING, and 13/541,530, filed on July 3, 2012 and titled INTEGRATION OF DISTRIBUTED

THERMOELECTRIC HEATING AND COOLING and International (PCT) Application Nos. PCT/US11/51227, filed on September 12, 2011 and titled DISTRIBUTED

THERMOELECTRIC STRING AND INSULATING PANEL AND APPLICATIONS FOR LOCAL HEATING, COOLING, AND POWER GENERATION FROM HEAT and

PCT/US 12/45443, filed on July 3, 2012 and titled INTEGRATION OF DISTRIBUTED THERMOELECTRIC HEATING AND COOLING, each of which applications is entirely incorporated herein by reference.

[0087] Heat conductor 36 includes an outer heat-transfer node 50, a heat pipe 52, and an inner heat-transfer node 54 as shown in FIGs. 13-15. Outer heat-transfer node 50 is positioned to lie between outer surface 38 of cushion 30 and inner surface 40 of cushion cover 26 as suggested in FIGs. 1 and 2. Inner heat-transfer node 54 is positioned to lie in spaced-apart relation to outer heat-transfer node 50 and lie below outer surface 38 of cushion 30. Heat pipe 52 is arranged to extend between and interconnect outer heat-transfer node 50 and heat mover 34 as shown in FIG. 2. Inner heat-transfer node 54 is coupled to heat mover 34 and positioned to locate heat mover 34 between inner heat-transfer node 54 and heat pipe 52.

[0088] In an example, inner heat-transfer node 54 is located in or coupled to heat source 13 and heat sink 15 of heat-transfer station 11. As suggested in FIG. 2, inner heat-transfer node 54 is located in cavity 58 which functions as both heat source 13 and heat sink 15. In this example, heat-transfer station 11 transfers heat to cavity 58 through convective heat transfer.

[0089] Thermal device 22 is coupled to cushion 30 to move heat 17 between occupant 24 and cushion 30 through cushion cover 26 to cause an amount of time to effect thermal sensation to be minimized. As shown in FIG. 2, cushion 30 includes an inner layer 31, a middle layer 32, and an outer layer 33 as shown in FIGs. 6, 7, and 13. Inner layer 31 may be arranged to lie on and be supported by support pan 18. Middle layer 32 is positioned to lie between inner layer 31 and outer layer 33. As suggested in FIG. 2, cavities 58 are formed in middle layer 32. Outer layer 33 is positioned to lie between cushion cover 26 and middle layer 32 as shown, for example, in FIGs. 6, 7, and 13. In some embodiments, inner layer 31 may be omitted.

[0090] As shown in FIG. 2, outer heat-transfer node 50 is positioned to lie in confronting relation with cushion cover 26. Heat mover 34 is spaced apart from outer heat-transfer node 50 and positioned to lie in middle layer 32 as shown in FIG. 2. Heat pipe 52 is arranged to extend through a hole 56 formed in outer layer 33 of cushion 30 to interconnect outer heat- transfer node 50 and heat mover 34. Inner heat-transfer node 54 is coupled to heat mover 34 and positioned to lie in middle layer 32 as shown in FIG. 2.

[0091] In an example of use, occupant 24 provides a command via user input 48 to controller 42 to cause heat mover 34 to be in the heating mode. When heat mover 34 is in the heating mode, heat is moved from heat mover 34 through heat pipe 52 to outer heat-transfer node 50 without the use of convection. Heat continues to move from outer heat-transfer node 50 through cushion cover 26 and into occupant 24 through conductive heat transfer and radiative heat transfer.

[0092] In another example of use, occupant 24 provides a different command via user input 48 to controller 42 to cause heat mover 34 to be in the cooling mode. When heat mover 34 is in the cooling mode, heat is collected by outer heat-transfer node 50 and communicated through outer layer 33 of cushion 30 by heat pipe 52 to inner heat-transfer node 54. There, inner heat-transfer node 54 rejects waste heat to middle layer 32 of cushion 30. In an example, middle layer 32 includes cavity 58 through which air may be moved by a fan 60 as suggested in FIG. 2.

[0093] An occupant-support base 110 for a vehicle seat comprises a seat pad 120, a thermal device 122, and a heat-mover cover 102 as shown in FIGs. 3-5. Seat pad 120 includes a cushion cover defining a cushion-receiving space therein and a cushion 130 positioned to lie in the cushion-receiving space. Thermal device 122 is coupled to cushion 130 and arranged to lie in the cushion-receiving space and configured to move heat between a heat-transfer station 111 located in cushion 130 and an occupant seated on occupant-support base 110 without convective heat transfer in one of a cooling mode in which heat moves (or is transferred) from the occupant seated on occupant-support base 110 through the cushion cover to a heat sink provided in heat-transfer station 111 and a warming mode in which heat moves from a heat source included in heat-transfer station 111 through the cushion cover to the seat occupant. Heat-mover cover 102 is arranged to lie in and fill a heat-mover space 104 formed in cushion 130. Heat-mover cover 102 is configured to separate portions of neighboring heat-transfer stations 111 A, 11 IB and provide a smooth continuous outer surface 106 to cushion 130.

[0094] In an example, heat-mover cover 102 has a triangular shape when viewed from above heat-mover cover 102 as shown in FIGs. 3-5. In another example, heat-mover cover 102 is arranged to extend from outer surface 106 of cushion 130 toward a heat mover 134 included in heat-transfer station 1 11. As shown in FIG. 4, heat-mover cover 102 has a triangular shape when viewed in cross section and an apex of the triangular shape is located between heat mover 134 and outer surface 106 of cushion 103.

[0095] Heat-mover cover 102 may have various shapes, such as circular, triangular, square, rectangular, or pentagonal, or a partial shape or a combination of shapes thereof. In an example, the heat-mover cover 102 is triangular.

[0096] A heat-transfer station 211 includes a heat mover 234 and an outer heat-transfer node 250 located between cushion 230 and the cushion cover 228. In an example, outer heat- transfer node 250 comprises a metal-wire mesh 202 and individual wires 204 included in metal-wire mesh 202 have been spread apart from one another to form a low-density outer heat-transfer node 250 as shown in FIGs. 6 and 7. As a result, heat transfer to low-density outer heat-transfer node 250A is improved, enhanced or maximized. In another example, outer heat-transfer node comprises metal-wire mesh 202 and individual wires 204 included in metal-wire mesh 202 have been collapsed toward one another to engage one another to form a high-density outer heat-transfer node 250B as shown in FIGs. 8 and 9. As a result, thermal intensity felt by an occupant is improved, enhanced or maximized.

[0097] A thermal device 322 in accordance with the present disclosure includes a plurality of heat-transfer stations 311 coupled together in a serial connection to form a heat-transfer braid 302 as shown in FIG. 10. Heat-transfer braid 302 is arranged in a pattern to cause heat- transfer stations 311 to be spaced apart from a high-pressure zone 304 of a cushion 330 associated with engagement of an occupant's ischials or ischial spine when the occupant is sitting on cushion 330. Heat-transfer braid 302 includes a first portion 302A having a generally quadrilateral shape and a second portion 302B having a serpentine shape as shown in FIG. 10. First portion 302A is located to cause high-pressure zone 304 to be located inside a region 306 defined by first portion 302 A.

[0098] A thermal device 422 in accordance with the present disclosure includes a plurality of heat-transfer stations 411 coupled together in a serial connection to form a heat-transfer braid 402 as shown in FIG. 11. Heat-transfer braid 402 is arranged in a pattern to cause heat- transfer stations 411 to be spaced apart from a high-pressure zone 404 of a cushion 430 associated with engagement of an occupant's ischials or ischial spine when the occupant is sitting on cushion 430. Heat-transfer braid 402 includes a first portion 402A a generally C- shape and a second portion 402B having a serpentine shape as shown in FIG. 11. First portion 402A is located to cause high-pressure zone 404 to be located inside a region 406 defined by first portion 402A.

[0099] A thermal device 522 in accordance with the present disclosure includes a plurality of heat-transfer stations 511 coupled together in a serial connection to form a heat-transfer braid 502 as shown in FIG. 12. Heat-transfer braid 502 is arranged in a pattern to cause heat- transfer stations 511 to be spaced apart from a high-pressure zone 504 of a cushion 530 associated with engagement of an occupant's ischials or ischial spine when the occupant is sitting on cushion 530. Heat-transfer braid 502 includes a first portion 502A having a serpentine shape and a second portion 502B having a serpentine shape as shown in FIG. 12. First portion 502A is located to cause high-pressure zone 504 to be located inside a region 506 defined by a section 508 included in first portion 502A.

[0100] A thermal device 622 in accordance with the present disclosure includes a plurality of heat-transfer stations 611 coupled together in a serial connection to form a heat-transfer braid 602 as shown in FIG. 13. Heat-transfer braid 602 includes a first portion 602 A having a serpentine shape and a second portion 602B having a serpentine shape. First portion 602A is located to minimize a number of heat-transfer stations 611 included in first portion 602 A that are also located in high-pressure zone 604 determined by a portion of first portion 602A

[0101] A thermal device 722 in accordance with the present disclosure includes a plurality of heat-transfer stations 711 coupled together in a serial connection to form a heat-transfer braid 702 as shown in FIG. 14. Heat-transfer braid 702 is arranged in a pattern to cause a small density of heat-transfer stations 711 to be located in a high-pressure zone 704 and a relatively large density of heat-transfer stations 711 to be located so as to align with an occupant's spine as shown in FIG. 14.

[0102] A thermal device 822 in accordance with the present disclosure includes a plurality of heat-transfer stations 811 coupled together in a serial connection to form a heat-transfer braid 802 as shown in FIG. 14. Heat-transfer braid 802 is arranged in a pattern to cause heat- transfer stations 811 to be spaced apart from a high-pressure zone 804 of a cushion 830 associated with engagement of an occupant's hip bones when the occupant is sitting on cushion 830 as suggested in FIG. 14. The pattern is further arranged to cause a small number of heat-transfer stations 811 to be located in high-pressure zone 804 and a relatively large number of heat-transfer stations 811 to be located in spaced-apart relation to high-pressure zone 804.

[0103] A thermal device 922 in accordance with the present disclosure includes a plurality of heat-transfer stations coupled together in a serial connection to form a heat-transfer braid 902 as shown in FIG. 15. Heat-transfer braid 902 includes a first serpentine portion 902 A associated with an occupant's lower back and a second serpentine portion 902B associated with an occupant's upper back as shown in FIG. 15.

[0104] A thermal device 1022 in accordance with the present disclosure includes a plurality of heat-transfer stations 1011 coupled together in a serial connection to form a heat-transfer braid 1002 as shown in FIG. 16. Heat-transfer braid 1002 includes a first serpentine portion 1002A associated with an occupant's lower back and a second serpentine portion 1002B associated with an occupant's upper back as shown in FIG. 16.

[0105] A thermal device 1122 in accordance with the present disclosure includes a plurality of heat-transfer stations 1111 coupled together in a serial connection to form a heat-transfer braid 1102 as shown in FIG. 17. Heat-transfer braid 1102 is arranged to extend from a bottom 1104 of a seat back 1106 towards a top 1108 of seat back 1106 and terminate between bottom 1104 and top 1108 of a cushion 1130 included in seat back 1106 as shown in FIG. 17. Heat-transfer braid 1102 includes a series of generally horizontal sections 1102 A and each generally horizontal section 1102A is spaced apart equally from each neighboring generally horizontal section 1102A as shown in FIG. 17.

[0106] A thermal device 1222 in accordance with the present disclosure includes a plurality of heat-transfer stations coupled together in a serial connection to form a heat-transfer braid 1202 as shown in FIG. 18. Heat-transfer braid 1202 includes a first serpentine portion 1202A associated with an occupant's lower back and a second serpentine portion 1202B associated with an occupant's upper back as shown in FIG. 18. First serpentine portion 1202A includes a series of generally horizontal sections 1202A1 and each generally horizontal section 1202A1 is spaced apart equally from each neighboring generally horizontal section 1202A1. Second serpentine portion 1202B includes a series of generally horizontal sections 1202B1 and each generally horizontal section 1202B1 is spaced apart equally from each neighboring generally horizontal section 1202B1. Each generally horizontal section 1202A1 of the first serpentine portion 1202A has a first length and each generally horizontal section 1202B1 of the second serpentine portion 1202B has a second length and the first length is greater than the second length as shown in FIG. 18. [0107] A cushion cover 1326 in accordance with the present disclosure includes an outer trim layer 1302 and an inner foam layer 1304 as shown in FIGs. 19-21. Outer trim layer 1302 is arranged in spaced apart relation to a cushion 1330. Inner foam layer 1304 is located between outer trim layer 1302 and cushion 1330. Inner foam layer 1304 may be configured to maximize heat-transfer through cushion cover 1326 between the occupant and a thermal device as suggested in FIGs. 19-21. In an example, inner foam layer 1304 includes a viscoelastic foam 1306 and graphite 1308 as shown in FIGs. 20 and 21.

[0108] A cushion cover 1426 in accordance with the present disclosure includes an outer trim layer 1402 and an inner foam layer 1404 as shown in FIG. 22. Outer trim layer 1402 is arranged in spaced apart relation to a cushion 1430. Inner foam layer 1404 is located between outer trim layer 1402 and cushion 1430. Inner foam layer 1404 may be configured to improve or maximize heat-transfer through cushion cover 1426 between the occupant and a thermal device as suggested in FIG. 22. In an example, heat-transfer is improved, enhanced or maximized using a plurality of apertures 1406 formed in inner foam layer 1404. Each aperture 1406 is arranged to align with each heat-transfer station 1411 located therebelow. In an example, the plurality of apertures 1406 has a generally circular shape which is any suitable size.

[0109] A cushion cover 1526 in accordance with the present disclosure includes an outer trim layer 1502 and an inner foam layer 1504 as shown in FIG. 23. Outer trim layer 1502 is arranged in spaced apart relation to a cushion 1530. Inner foam layer 1504 is located between outer trim layer 1502 and cushion 1530. Inner foam layer 1504 may be configured to improve or maximize heat-transfer through cushion cover 1526 between the occupant and a thermal device as suggested in FIG. 23. In an example, a plurality of apertures 1506 formed in inner foam layer 1504 improves of maximizes heat transfer. Each aperture 1506 is arranged to align with each heat-transfer station 1511 located therebelow. In an example, the plurality of apertures 1506 has a generally quadrilateral shape which is any suitable size. In another example, the plurality of apertures 1506 has a generally square shape which is any suitable size.

[0110] An occupant-support base 1610 in accordance with the present disclosure includes a seat pad 1620, a thermal device 1622, and a massage system 1602 as shown in FIG. 24.

Massage system 1602 is located between a cushion cover 1626 and a cushion 1630 included in seat pad 1620. Massage system 1602 is located between thermal device 1622 and cushion cover 1626 as shown in FIG. 24. Thermal device 1622 includes a plurality of heat-transfer stations 1611 coupled together in a serial connection to form a heat-transfer braid 1604. Heat- transfer braid 1604 is arranged in a pattern to cause heat-transfer stations 1611 to be spaced apart from each bladder 1606 included in massage system 1602 to minimize interference between massage system 1602 and thermal device 1622 as shown in FIG. 24. Each bladder 1606 may be an air-filled bag inflates and deflates sequentially in time to provide a massage function.

[0111] In an example, heat-transfer braid 1604 includes at least one generally horizontal section 1604A and at least one generally vertical section 1604B as shown in FIG. 24. The at least one generally horizontal section 1604 A has a length. The at least one generally vertical section 1604B has a length. The length of the at least one generally horizontal section 1604A is about equal to the length of the at least one generally vertical section 1604B as shown in FIG. 24.

[0112] An occupant-support base 1710 in accordance with the present disclosure includes a seat pad 1720, a thermal device 1722, and a massage system 1702 as shown in FIG. 25.

Massage system 1702 is located between a cushion cover 1726 and a cushion 1730 included in seat pad 1720. Massage system 1702 is also located between thermal device 1722 and cushion cover 1726 as shown in FIG. 25. Thermal device 1722 includes a plurality of heat- transfer stations 1711 coupled together in a serial connection to form a heat-transfer braid 1704. Heat-transfer braid 1704 is arranged in a pattern to cause heat-transfer stations 1711 to be spaced apart from each bladder 1706 included in massage system 1702 to minimize interference between massage system 1702 and thermal device 1722 as shown in FIG. 25. Each bladder 1706 may be an air-filled bag that inflates and deflates sequentially to provide a massage function.

[0113] In an example, heat-transfer braid 1704 includes at least one generally horizontal section 1704 A and at least one generally vertical section 1704B as shown in FIG. 25. The at least one generally horizontal section 1704 A has a length. The at least one generally vertical section 1704B has a length. The length of the at least one generally horizontal section 1704A is about equal to the length of the at least one generally vertical section 1704B as shown in FIG. 25.

[0114] An occupant-support base 1810 in accordance with the present disclosure includes a seat pad 1820, a thermal device 1822, and a massage system 1802 as shown in FIG. 26.

Massage system 1802 is located between a cushion cover 1826 and a cushion 1830 included in seat pad 1820. Massage system 1802 is located between thermal device 1822 and cushion cover 1826 as shown in FIG. 26. Thermal device 1822 includes a plurality of heat-transfer stations 1811 coupled together in a serial connection to form a heat-transfer braid 1804. Heat- transfer braid 1804 is arranged in a pattern to cause heat-transfer stations 1811 to be spaced apart from each bladder 1806 included in massage system 1802 to minimize interference between massage system 1802 and thermal device 1822 as shown in FIG. 26. Each bladder 1806 may be an air-filled bag that inflates and deflates sequentially to provide a massage function.

[0115] In an example, heat-transfer braid 1804 includes at least one generally horizontal section 1804A and at least one generally vertical section 1804B as shown in FIG. 26. The at least one generally horizontal section 1804A has a length. The at least one generally vertical section 1804B has a length. The length of the at least one generally horizontal section 1804A is less than the length of the at least one generally vertical section 1804B as shown in FIG. 26. As shown in FIG. 26, heat-transfer braid 1804 includes three generally horizontal sections 1804A1, 1804A2, 1804A3 and four generally vertical sections 1804B1, 1804B2, 1804B3, 1804B4.

[0116] An occupant-support base 1910 in accordance with the present disclosure includes a seat pad 1920, a thermal device 1922, and a massage system 1902 as shown in FIG. 27.

Massage system 1902 is located between a cushion cover 1926 and a cushion 1930 included in seat pad 1920. Massage system 1902 is located between thermal device 1922 and cushion cover 1926 as shown in FIG. 27. Thermal device 1922 includes a plurality of heat-transfer stations 1911 coupled together in a serial connection to form a heat-transfer braid 1904. Heat- transfer braid 1904 is arranged in a pattern to cause heat-transfer stations 1911 to be spaced apart from each bladder 1906 included in massage system 1902 to minimize interference between massage system 1902 and thermal device 1922 as shown in FIG. 27. Each bladder 1906 may be an air-filled bag that inflates and deflates sequentially to provide a massage function.

[0117] In an example, heat-transfer braid 1904 includes at least one generally horizontal section 1904A and at least one generally vertical section 1904B as shown in FIG. 27. The at least one generally horizontal section 1904 A has a length. The at least one generally vertical section 1904B has a length. The length of the at least one generally horizontal section 1904A is less than the length of the at least one generally vertical section 1904B as shown in FIG. 27. As shown in FIG. 27, heat-transfer braid 1904 includes three generally horizontal sections 1904A1, 1904A2, 1904A3 and four generally vertical sections 1904B1, 1904B2, 1904B3, 1904B4.

[0118] A thermal device 2022 in accordance with the present disclosure includes an outer heat-transfer node 2050, an inner heat-transfer node 2054, and a heat mover 2034 as shown in FIGs. 28 and 29. In an example, inner heat-transfer node 2054 is arranged in curled configuration as shown in FIGs. 29 and 30. The heat mover 2034 may be disposed in a heat mover space in the cushion.

[0119] A thermal device 2122 in accordance with the present disclosure includes an outer heat-transfer node 2150, an inner heat-transfer node 2154, and a heat mover 2234 as shown in FIG. 33. In an example, inner heat-transfer node 2154 is arranged in a straight configuration as shown in FIG. 33.

[0120] A thermal device 2222 in accordance with the present disclosure includes an outer heat-transfer node 2250, an inner heat-transfer node 2254, and a heat mover 2234 as shown in FIG. 34. In an example, inner heat-transfer node 2254 is arranged in a j -shape configuration as shown in FIG. 34.

[0121] A thermal device 2322 in accordance with the present disclosure includes an outer heat-transfer node 2350, an inner heat-transfer node 2354, and a heat mover 2334 as shown in FIG. 35. In an example, inner heat-transfer node 2354 is arranged in a spiral configuration as shown in FIG. 35.

[0122] A thermal device 2422 in accordance with the present disclosure includes an outer heat-transfer node 2450, an inner heat-transfer node 2454, and a heat mover 2434 as shown in FIG. 36. In an example, inner heat-transfer node 2454 is arranged in a plus-sign configuration as shown in FIGs. 36 and 37.

[0123] A thermal device 2522 in accordance with the present disclosure includes a first outer heat-transfer node 2550A, a second outer heat-transfer node 2550B, an inner heat-transfer node 2554, a heat mover 2534, and an outer-node insulator 2502 as shown in FIG. 31. Outer- node insulator 2502 may be configured to enable separation of first outer heat-transfer node 2550A from second outer heat-transfer node 2550B, as shown in FIG. 31. In an example, outer-node insulator 2502 is a shrink-wrap cover 2502 coupled to first outer heat-transfer node 2550A as shown in FIG. 31.

[0124] A thermal device 2622 in accordance with the present disclosure includes a first outer heat-transfer node 2650A, a second outer heat-transfer node 2650B, an inner heat-transfer node 2654, a heat mover 2634, and an outer-node insulator 2602 as shown in FIG. 32. Outer- node insulator 2602 may be configured to enable separation of first outer heat-transfer node 2650A from second outer heat-transfer node 2650B, as shown in FIG. 32. In an example, outer-node insulator 2602 is a conforming coating 2602 coupled to first outer heat-transfer node 2650A and second outer heat-transfer node 2650B as shown in FIG. 32. One example of a conforming coating is silicone caulking, however, any other suitable alternative may be used.

[0125] A thermal device in accordance with the present disclosure further includes an air mover 2702 as shown for example in FIG. 38. Air mover 2702 is coupled to a heat-transfer station included in the thermal device to cause air to be moved across a portion of the heat- transfer station. Air mover 2702 includes a blower 2704 and a manifold 2706 as shown in FIG. 38. Manifold 2706 is arranged to extend between and interconnect a cushion supporting the thermal device and blower 2704 as suggested in FIG. 38. Blower 2704 is configured to apply a negative pressure and suck air across the portion of the heat-transfer station.

[0126] Manifold 2706 includes first and second seat-bottom air inlets 2706A, 2706B arranged to open into an air passageway 2706D formed in manifold 2706 as shown in FIG. 38. A blower aperture 2706E is formed in manifold 2706 and aligned with a blower inlet 2704A formed in blower 2704 as shown in FIG. 38. Manifold 2706 is further formed to include a seat-back inlet 2706C arranged to open into air passageway 2706D. Seat-back inlet 2706C allows one blower to move air across a second thermal device when the second thermal device is located in a seat back, for example.

Computer control systems

[0127] The present disclosure provides computer control systems that are programmed to implement methods of the disclosure. FIG. 39 shows a computer system 3901 that is programmed or otherwise configured to control thermoelectric devices and systems of the present disclosure. The computer system 3901 includes a central processing unit (CPU, also "processor" and "computer processor" herein) 3905, which can be a single core or multi core processor, or a plurality of processors for parallel processing. The computer system 3901 also includes memory or memory location 3910 (e.g., random-access memory, read-only memory, flash memory), electronic storage unit 3915 (e.g., hard disk), communication interface 3920 (e.g., network adapter) for communicating with one or more other systems, and peripheral devices 3925, such as cache, other memory, data storage and/or electronic display adapters. The memory 3910, storage unit 3915, interface 3920 and peripheral devices 3925 are in communication with the CPU 3905 through a communication bus (solid lines), such as a motherboard. The storage unit 3915 can be a data storage unit (or data repository) for storing data. The computer system 3901 can be operatively coupled to a computer network

("network") 3930 with the aid of the communication interface 3920. The network 3930 can be the Internet, an internet and/or extranet, or an intranet and/or extranet that is in

communication with the Internet. The network 3930 in some cases is a telecommunication and/or data network. The network 3930 can include one or more computer servers, which can enable distributed computing, such as cloud computing. The network 3930, in some cases with the aid of the computer system 3901, can implement a peer-to-peer network, which may enable devices coupled to the computer system 3901 to behave as a client or a server.

[0128] The CPU 3905 can execute a sequence of machine-readable instructions, which can be embodied in a program or software. The instructions may be stored in a memory location, such as the memory 3910. The instructions can be directed to the CPU 3905, which can subsequently program or otherwise configure the CPU 3905 to implement methods of the present disclosure. Examples of operations performed by the CPU 3905 can include fetch, decode, execute, and writeback.

[0129] The CPU 3905 can be part of a circuit, such as an integrated circuit. One or more other components of the system 3901 can be included in the circuit. In some cases, the circuit is an application specific integrated circuit (ASIC).

[0130] The storage unit 3915 can store files, such as drivers, libraries and saved programs. The storage unit 3915 can store user data, e.g., user preferences and user programs. The computer system 3901 in some cases can include one or more additional data storage units that are external to the computer system 3901, such as located on a remote server that is in communication with the computer system 3901 through an intranet or the Internet. The computer system 3901 can communicate with one or more remote computer systems through the network 3930.

[0131] Methods as described herein can be implemented by way of machine (e.g., computer processor) executable code stored on an electronic storage location of the computer system 3901, such as, for example, on the memory 3910 or electronic storage unit 3915. The machine executable or machine readable code can be provided in the form of software.

During use, the code can be executed by the processor 3905. In some cases, the code can be retrieved from the storage unit 3915 and stored on the memory 3910 for ready access by the processor 3905. In some situations, the electronic storage unit 3915 can be precluded, and machine-executable instructions are stored on memory 3910.

[0132] The code can be pre-compiled and configured for use with a machine having a processer adapted to execute the code, or can be compiled during runtime. The code can be supplied in a programming language that can be selected to enable the code to execute in a pre-compiled or as-compiled fashion.

[0133] Aspects of the systems and methods provided herein, such as the computer system 3901, can be embodied in programming. Various aspects of the technology may be thought of as "products" or "articles of manufacture" typically in the form of machine (or processor) executable code and/or associated data that is carried on or embodied in a type of machine readable medium. Machine-executable code can be stored on an electronic storage unit, such as memory (e.g., read-only memory, random-access memory, flash memory) or a hard disk. "Storage" type media can include any or all of the tangible memory of the computers, processors or the like, or associated modules thereof, such as various semiconductor memories, tape drives, disk drives and the like, which may provide non-transitory storage at any time for the software programming. All or portions of the software may at times be communicated through the Internet or various other telecommunication networks. Such communications, for example, may enable loading of the software from one computer or processor into another, for example, from a management server or host computer into the computer platform of an application server. Thus, another type of media that may bear the software elements includes optical, electrical and electromagnetic waves, such as used across physical interfaces between local devices, through wired and optical landline networks and over various air-links. The physical elements that carry such waves, such as wired or wireless links, optical links or the like, also may be considered as media bearing the software. As used herein, unless restricted to non-transitory, tangible "storage" media, terms such as computer or machine "readable medium" refer to any medium that participates in providing instructions to a processor for execution.

[0134] Hence, a machine readable medium, such as computer-executable code, may take many forms, including but not limited to, a tangible storage medium, a carrier wave medium or physical transmission medium. Non-volatile storage media include, for example, optical or magnetic disks, such as any of the storage devices in any computer(s) or the like, such as may be used to implement the databases, etc. shown in the drawings. Volatile storage media include dynamic memory, such as main memory of such a computer platform. Tangible transmission media include coaxial cables; copper wire and fiber optics, including the wires that comprise a bus within a computer system. Carrier-wave transmission media may take the form of electric or electromagnetic signals, or acoustic or light waves such as those generated during radio frequency (RF) and infrared (IR) data communications. Common forms of computer-readable media therefore include for example: a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD or DVD-ROM, any other optical medium, punch cards paper tape, any other physical storage medium with patterns of holes, a RAM, a ROM, a PROM and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave transporting data or instructions, cables or links transporting such a carrier wave, or any other medium from which a computer may read programming code and/or data. Many of these forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to a processor for execution.

[0135] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. It is not intended that the invention be limited by the specific examples provided within the specification. While the invention has been described with reference to the aforementioned specification, the descriptions and illustrations of the embodiments herein are not meant to be construed in a limiting sense. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Furthermore, it shall be understood that all aspects of the invention are not limited to the specific depictions, configurations or relative proportions set forth herein which depend upon a variety of conditions and variables. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is therefore contemplated that the invention shall also cover any such alternatives, modifications, variations or equivalents. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.

Claims

CLAIMS WHAT IS CLAIMED IS:

1. An occupant-support system for a vehicle seat, comprising:

a seat pad including a cushion cover defining a cushion-receiving space and a cushion positioned to lie in the cushion-receiving space;

a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the seat pad without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the seat pad through the cushion cover to a heat sink included in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to seat occupant seated adjacent to the seat pad; and

a heat mover cover arranged to lie in and fill a heat mover space formed in the cushion and configured to separate portions of neighboring heat-transfer stations and provide a smooth continuous outer surface to the cushion,

wherein the heat mover cover is arranged to extend from an outer surface of the cushion toward a heat mover included in the heat-transfer station, and wherein an apex of the heat mover cover is located between the heat mover and the outer surface of the cushion.

2. The occupant-support system of Claim 1, wherein the heat mover cover has a triangular shape when viewed from above the heat mover cover.

3. The occupant-support system of Claim 1, wherein the heat mover cover has a triangular shape when viewed in cross section.

4. The occupant-support system of Claim 3, wherein the apex of the heat mover cover is located between the heat mover and the outer surface of the cushion.

5. The occupant-support system of Claim 1, wherein the heat mover includes one or more thermoelectric devices.

6. An occupant-support system for a vehicle seat, comprising:

a cushion cover having a cushion-receiving space;

a cushion in the cushion-receiving space; and

a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the cushion cover without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the cushion cover through the cushion cover to a heat sink in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to the occupant seated adjacent to the cushion cover,

wherein the heat-transfer station includes a heat mover and an outer heat-transfer node located between the cushion and the cushion cover.

7. The occupant-support system of Claim 6, wherein the outer heat-transfer node comprises a metal-wire mesh and individual wires included in the metal-wire mesh are collapsed toward one another to engage one another to form a high-density outer heat-transfer node to enhance thermal intensity felt by the occupant.

8. The occupant-support system of Claim 6, wherein the heat mover includes one or more thermoelectric devices.

9. An occupant-support system for a vehicle seat, comprising:

a cushion cover having a cushion-receiving space;

a cushion positioned in the cushion-receiving space; and

wherein the thermal device includes a plurality of heat-transfer stations coupled together in a serial connection to form a heat-transfer braid, which plurality of heat-transfer stations includes the heat-transfer station, wherein the heat-transfer braid is arranged in a pattern such that the heat-transfer stations are less dense in a high-pressure zone of the cushion, which high-pressure zone engages with an ischial spine or hip bone(s) of the occupant when the occupant is sitting adjacent to the cushion cover.

10. The occupant-support system of Claim 9, wherein the heat-transfer braid includes a first portion having a generally quadrilateral shape and a second portion having a serpentine shape and the first portion is located to cause the high-pressure zone to be located inside a region defined by the first portion.

11. The occupant-support system of Claim 9, wherein the heat-transfer braid includes a first portion having a generally C-shape and a second portion having a serpentine shape.

12. The occupant-support system of Claim 11, wherein the first portion is positioned such that the high-pressure zone is located inside a region defined by the first portion.

13. The occupant-support system of Claim 9, wherein the heat-transfer braid includes a first portion having a serpentine shape and a second portion having a serpentine shape.

14. The occupant-support system of Claim 13, wherein the first portion is positioned such that the high-pressure zone is located inside a region defined by a section included in the first portion.

15. The occupant-support system of Claim 13, wherein the first portion is positioned such that a number of heat-transfer stations included in the first portion and the high-pressure zone is minimized.

16. The occupant-support system of Claim 9, wherein the pattern is arranged such that a first density of heat-transfer stations is positioned in the high-pressure zone and a second density of heat-transfer stations is positioned so as to align with a spine of the occupant, wherein the first density is less than the second density.

17. The occupant-support system of Claim 9, wherein the pattern is arranged such that a first number of heat-transfer stations are located in the high-pressure zone and a second number of heat-transfer stations are spaced-apart in relation to the high-pressure zone, wherein the first number is less than the second number.

18. The occupant-support system of Claim 9, wherein the heat-transfer braid includes a first serpentine portion associated with a lower back of the occupant and a second serpentine portion associated with an upper back of the occupant.

19. The occupant-support system of Claim 9, wherein the cushion and cushion cover are part of a seat back, and wherein the heat-transfer braid is arranged to extend from a bottom of the seat back towards a top of the seat back and terminate between a bottom and top of the cushion.

20. An occupant-support system for a vehicle seat, comprising:

a cushion cover having a cushion-receiving space;

a cushion in the cushion-receiving space; and

a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the cushion cover without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the cushion cover through the cushion cover to a heat sink included in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat- transfer station through the cushion cover to the occupant seated adjacent to the cushion cover, wherein the cushion cover includes (i) an outer trim layer arranged in spaced apart relation to the cushion, and (ii) an inner foam layer located between the outer trim layer and the cushion, and wherein the inner foam layer is configured to provide enhanced heat-transfer through the cushion cover between the occupant and the thermal device.

wherein the inner foam layer includes a viscoelastic foam and a carbon-containing material.

21. The occupant-support system of Claim 20, wherein the carbon-containing material is graphite.

22. The occupant-support system of Claim 20, wherein the inner foam layer includes a plurality of apertures.

23. The occupant-support system of Claim 22, further comprising a plurality of heat- transfer stations.

24. The occupant-support system of Claim 23, wherein the plurality of apertures is arranged to be unaligned with the plurality of heat-transfer stations.

25. The occupant-support system of Claim 22, wherein each of the plurality of apertures has a generally circular shape.

26. The occupant-support system of Claim 22, wherein each of the plurality of apertures has a generally quadrilateral shape.

27. The occupant-support system of Claim 26, wherein each of the plurality of apertures has a generally square shape.

28. An occupant-support system for a vehicle seat, comprising:

a cushion cover having a cushion-receiving space;

a cushion in the cushion-receiving space;

a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the cushion cover without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the cushion cover through the cushion cover to a heat sink included in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat- transfer station through the cushion cover to the occupant seated adjacent to the cushion cover; and

a massage device located between the cushion cover and the cushion and between the thermal device and the cushion cover, wherein the massage device includes a plurality of bladders, wherein the thermal device includes a plurality of heat-transfer stations coupled together in a serial connection to form a heat-transfer braid, which plurality of heat-transfer stations includes the heat-transfer station, wherein the heat-transfer braid is arranged in a pattern such that the heat-transfer stations are spaced apart from each of the plurality of bladders to minimize interference between the massage device and the thermal device.

29. The occupant-support system of Claim 28, wherein the heat-transfer braid includes at least one generally horizontal section and at least one generally vertical section.

30. The occupant-support system of Claim 29, wherein the at least one generally horizontal section has a first length and the at least one generally vertical section has a second length, and wherein the first length is the same as the second length.

31. The occupant-support system of Claim 29, wherein the at least one generally horizontal section has a first length and the at least one generally vertical section has a second length, and wherein the first length is different than the second length.

32. The occupant-support system of Claim 31, wherein the first length is less than the second length.

33. The occupant-support system of Claim 29, wherein the heat-transfer braid includes at least three generally horizontal sections and at least four generally vertical sections.

34. An occupant-support system for a vehicle seat, comprising:

a cushion cover having a cushion-receiving space;

a cushion in the cushion-receiving space; and

wherein the heat-transfer station includes a heat mover located in a heat mover space in the cushion, an upper heat-transfer node coupled to the heat mover and arranged to extend away from the heat mover and the cushion, and a lower heat-transfer node arranged to extend away from the upper heat-transfer node and the heat mover.

35. The occupant-support system of Claim 34, wherein the lower heat-transfer node is a arranged in curled, J-shape, or plus sign configuration.

36. The occupant-support system of Claim 34, wherein the upper heat-transfer node lies between the cushion and the cushion cover.

37. The occupant-support system of Claim 34, wherein the lower heat-transfer node lies in a vent passageway in the cushion.

38. An occupant-support system for a vehicle seat, comprising:

a cushion cover having a cushion-receiving space;

a cushion in the cushion-receiving space; and

wherein the heat-transfer station includes a heat mover, a first outer heat-transfer node coupled to the heat mover, a second outer heat-transfer node coupled to the heat mover, an inner heat-transfer node coupled to the heat mover, and an outer-node insulator coupled to the first outer heat-transfer node and configured to provide for separation of the first outer heat- transfer node from the second outer heat-transfer node.

39. The occupant-support system of Claim 38, wherein the outer-node insulator is a shrink-wrapped cover or conformal coating coupled to the first outer heat-transfer node.

40. An occupant-support system for a vehicle seat, comprising:

a seat pad including a cushion cover defining a cushion-receiving space and a cushion positioned to lie in the cushion-receiving space; and

a thermal device coupled to the cushion and arranged to lie in the cushion-receiving space and configured to transfer heat between a heat-transfer station located in the cushion and an occupant seated adjacent to the seat pad without convective heat transfer in one of (i) a cooling mode in which heat is transferred from the occupant seated adjacent to the seat pad through the cushion cover to a heat sink included in the heat-transfer station, and (ii) a warming mode in which heat is transferred from a heat source included in the heat-transfer station through the cushion cover to the occupant seated adjacent to the seat pad,

wherein the thermal device further includes an air mover coupled to the heat-transfer station to cause air to flow across at least a portion of the heat-transfer station, wherein the air mover includes a blower and a manifold, which manifold is arranged to extend between and interconnect the cushion and the blower,

wherein the manifold includes first and second seat-bottom air inlets arranged to open into an air passageway formed in the manifold and a blower aperture formed in the manifold and aligned with a blower inlet formed in the blower.

41. The occupant-support system of Claim 40, wherein the manifold includes a seat-back inlet arranged to open into the air passageway.

42. The occupant-support system of Claim 40, wherein the blower is configured to apply a negative pressure and suck air across the portion of the heat-transfer station.