Controller intelligent cooling structure and cooling method

Abstract

The application provides a controller intelligent cooling structure and a cooling method, and relates to the technical field of automobiles.The controller intelligent cooling structure comprises an air source device, a main air path, a heat dissipation branch, an air flow switching device and a controller, the heat dissipation branch is used for cooling internal components of the controller, the air flow switching device is connected to the main air path, the air flow switching device is configured to divert excess gas in the main air path to the heat dissipation branch when the main function of the system is working, and the air flow switching device is configured to guide all gas in the main air path to the heat dissipation branch when the main function of the system is paused, the heat dissipation branch is a diffusion air duct arranged in the controller and connected, the controller is provided with a plurality of directional spray air holes connected to the diffusion air duct, and the air flow switching device is automatically switched according to the working state of the main function of the system.The controller intelligent cooling structure and the cooling method provided by the application solve the technical problems of high energy consumption, loud noise and conflict with the main function in the prior art.

Description

Technical Field

[0001] This invention relates to the automotive field, and more specifically, to a controller intelligent cooling structure and cooling method. Background Technology

[0002] With the rapid development of electronic technology, integrated controllers, as core components of various electronic devices and systems, are widely used in fields such as automation, new energy, and automotive electronics. As controller functionality and computing power continue to improve, their power consumption and heat generation have increased significantly. Especially in confined spaces such as car seats, traditional heat dissipation methods relying on natural convection or simple metal casing conduction are limited in effectiveness. Prolonged operation of controllers in high-temperature environments can easily lead to component performance degradation, malfunctions, or even failure, severely impacting the system's operational stability, reliability, and lifespan.

[0003] In existing technologies, although there are solutions that use airflow from an air source device to cool the controller, they are all continuous unidirectional flow modes. They cannot adaptively adjust the heat dissipation intensity according to the actual working state of the controller, resulting in problems such as high energy consumption, high noise, and conflict with the main function. They are difficult to meet the comprehensive requirements of automotive seat controllers for quietness, energy saving, and high reliability. Summary of the Invention

[0004] The purpose of this invention is to provide a smart cooling structure and cooling method for controllers, so as to alleviate the technical problems of high energy consumption, high noise, and conflict with main functions in the existing controller cooling schemes.

[0005] This invention provides an intelligent cooling structure for a controller, comprising an air source device, a main air path, a heat dissipation branch, an airflow switching device, and a controller. The air source device provides airflow; the main air path is fluidly connected to the air outlet of the air source device; the heat dissipation branch cools the internal components of the controller; the airflow switching device is connected to the main air path and is configured to divert excess gas in the main air path to the heat dissipation branch when the main system function is operating, and to guide all gas from the main air path into the heat dissipation branch when the main system function is paused; the heat dissipation branch is a diffused air channel located inside and connected to the controller, and the inner surface of the controller has several directional spray vents connected to the diffused air channel for directional spraying of cooling gas onto the internal components of the controller; wherein, the airflow switching device automatically switches according to the operating status of the main system function, switching between a passive diversion cooling mode and an active full-flow cooling mode.

[0006] In some embodiments, the airflow switching device includes an overflow valve and an active cooling control valve, which work together or independently as needed to achieve the switching between the passive diversion cooling mode and the active full-flow cooling mode.

[0007] In some embodiments, the valve body of the airflow switching device used to divert excess gas in the main air path to the heat dissipation branch when the main function of the system is working is a temperature control valve. The temperature control valve is connected to a temperature sensor signal and automatically opens and closes according to the comparison result between the real-time temperature inside the controller and a preset threshold, thereby realizing precise passive heat dissipation control based on the temperature threshold.

[0008] In some embodiments, the controller includes an upper housing and a lower housing, and the diffusion-type air passage is disposed on the inner side wall of the upper housing or the lower housing, and the diffusion-type air passage is arranged in a grid shape, a circumferential shape or a star shape.

[0009] In some embodiments, the aperture of the directional spray vents is configured differently according to the temperature zone distribution inside the controller.

[0010] In some embodiments, the airflow of the heat dissipation branch is ultimately discharged to the outside of the controller through an exhaust port or exhaust pipe provided on the controller.

[0011] In some embodiments, the gas source device is an air pump, an air tank, or an intermittent gas supply device.

[0012] In some embodiments, the airflow switching device may be integrated inside the controller, or disposed in the air path between the air source device and the controller, or integrated into the air outlet of the air source device.

[0013] This invention also provides a method for intelligent cooling of a controller, comprising the following steps: Detect the operating status of the controller's main system; When the main system is in operation, the overflow valve in the control airflow switching device opens and the active cooling control valve closes, so that the excess gas in the main air path is passively diverted to the control heat dissipation branch to passively cool the controller. When the main system is in standby mode, the overflow valve is closed and the active cooling control valve is opened, so that all the gas in the main gas path is actively introduced into the heat dissipation branch of the controller to actively cool the controller.

[0014] In some embodiments, during the passive cooling step and the active cooling step, the heat dissipation airflow is directly discharged to the outside of the controller through the housing exhaust port or exhaust pipe.

[0015] In some embodiments, the intelligent cooling method for the controller further includes a temperature monitoring step. When the controller temperature exceeds a preset threshold, an active cooling mode is activated, which is not limited by the working status of the main system.

[0016] The beneficial effects of this invention are: The intelligent cooling structure and method of the controller of this invention automatically switch according to the working status of the main function of the system through an airflow switching device, enabling the controller to switch between passive diversion cooling mode and active full-flow cooling mode, realizing intelligent adaptation between zero-energy passive heat dissipation and efficient active heat dissipation; by setting a diffused air channel and directional spray vent on the housing of the controller, precise airflow spraying is performed on the high-heat area of ​​the integrated circuit board, significantly improving heat dissipation efficiency; the overall structure is compact, requiring no additional fan or heat sink, effectively reducing noise, reducing space occupation, and improving the working stability of the controller and the reliability of the system. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments of this application will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the control logic of the automotive seat control system of the present invention; Figure 2 This is a schematic diagram of the structure of an automotive seat control system according to one embodiment of the present invention; Figure 3 This is a schematic cross-sectional view of the automotive seat control system of the present invention; Figure 4 This is a schematic diagram of the automotive seat control system of the present invention in an explosive state; Figure 5 This is a schematic diagram of the structure of an automotive seat control system according to one embodiment of the present invention; Figure 6 This is a schematic diagram of the structure of an automotive seat control system according to one embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of a diffusion-type airway according to one embodiment of the present invention; Figure 8 This is a schematic diagram of the structure of a diffusion-type airway according to one embodiment of the present invention; Figure 9 This is a schematic diagram of the structure of a diffusion-type airway according to one embodiment of the present invention; icon: 100 - Controller; 110 - Upper housing; 111 - Heat dissipation branch; 112 - First directional spray vent; 113 - Second directional spray vent; 114 - Third directional spray vent; 115 - Fourth directional spray vent; 120 - Lower housing; 121 - Exhaust port; 122 - Main air passage; 200 - Gas source device; 300 - Active cooling control valve; 400 - Overflow valve; 500 - Airflow switching device; 600 - Noise-absorbing and buffering element; 700 - First air intake; 800-Integrated Circuit Board; 900 - Second air intake. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0020] In the description of this invention, it should be noted that the terms "inner," "outer," "upper," "lower," "left," and "right," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this application is in use. They are only used for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. In addition, the terms "first," "second," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0021] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0022] like Figures 1 to 9As shown, this invention provides a controller intelligent cooling structure, which includes an air source device 200, a main air passage 122, a heat dissipation branch 111, an airflow switching device 500, and a controller 100. The air source device 200 is used to provide airflow; the main air passage 122 is fluidly connected to the air outlet of the air source device 200; the heat dissipation branch 111 is used to cool the internal components of the controller 100; the airflow switching device 500 is connected to the main air passage 122, and the airflow switching device 500 is configured to remove excess air from the main air passage 122 when the main function of the system is working. The gas is diverted to the heat dissipation branch 111. When the main function of the system is suspended, all the gas in the main air passage 122 is introduced into the heat dissipation branch 111. The heat dissipation branch 111 is a diffused air passage located inside the housing of the controller 100 and connected to it. The inner surface of the controller 100 is provided with several directional spray vents that communicate with the diffused air passage. The directional spray vents are used to spray cooling gas directionally onto the internal components of the controller 100. The airflow switching device 500 automatically switches according to the working status of the main function of the system, switching between passive diversion cooling mode and active full-flow cooling mode.

[0023] The intelligent cooling structure of the controller of this invention automatically switches between passive diversion cooling mode and active full-flow cooling mode according to the working status of the main function of the system through the airflow switching device 500, realizing intelligent adaptation of zero-energy passive heat dissipation and efficient active heat dissipation. By setting a diffused air channel and directional spray vents in the housing of the controller, the high-heat area of ​​the integrated circuit board 800 is precisely sprayed with airflow, which significantly improves the heat dissipation efficiency. The overall structure is compact, requiring no additional fan or heat sink, effectively reducing noise, reducing space occupation, and improving the working stability of the controller 100 and the reliability of the system.

[0024] In some embodiments, the airflow switching device 500 includes an overflow valve 400 and an active cooling control valve 300, which work together or independently as needed to switch between passive diversion cooling mode and active full-flow cooling mode. By specifically configuring the airflow switching device 500 to include an overflow valve 400 and an active cooling control valve 300, and enabling them to work together or independently as needed, flexible adaptation and functional redundancy of the heat dissipation control strategy are achieved. When the system only requires basic heat dissipation, only the overflow valve 400 can be activated to utilize the excess gas in the main air path 122 to achieve zero-energy passive heat dissipation, or only the active cooling control valve 300 can be activated to enhance heat dissipation during specific periods, simplifying the air path structure and control logic. When the system requires intelligent switching functionality, the two work together to achieve seamless connection and smooth transition between active and passive modes through electrical interlocking or timing control. This dual-valve configuration not only significantly reduces hardware costs and system complexity through function reuse and selective activation, but also improves system reliability by having the two valves act as backups for each other. That is, when one valve fails, the other valve can still maintain basic heat dissipation function. At the same time, its flexible configuration allows manufacturers to select the optimal valve combination scheme according to different vehicle models, different climate zones, or seat products with different cost positions, realizing refined configuration and full-scenario coverage of platform products.

[0025] In some embodiments, the airflow switching device 500 uses a temperature-controlled valve to divert excess gas from the main air path 122 to the heat dissipation branch 111 during the main function operation of the system. The temperature-controlled valve is connected to a temperature sensor signal and automatically opens and closes based on a comparison between the real-time internal temperature of the controller 100 and a preset threshold, achieving precise passive heat dissipation control based on the temperature threshold. By replacing the overflow valve 400 with a temperature-controlled valve and having this temperature-controlled valve work in conjunction with the temperature sensor, the passive heat dissipation mode can be automatically triggered based on the real-time internal temperature of the controller 100 rather than simply relying on the pressure state of the main air path 122, achieving precise passive control based on the temperature threshold. When the temperature sensor detects that the temperature exceeds the preset value, the temperature-controlled valve automatically opens to divert heat dissipation; when the temperature is below the threshold, it automatically closes, avoiding unnecessary heat dissipation when the main system is operating but the temperature is normal. This temperature control replacement design not only significantly improves the accuracy and responsiveness of heat dissipation control, preventing energy waste and temperature fluctuations caused by overcooling, but also effectively reduces the number of invalid valve actions and mechanical wear, extending the service life of pneumatic control components. At the same time, it achieves a more refined thermal management strategy through the linkage logic of temperature and airflow, making it particularly suitable for scenarios with drastic ambient temperature fluctuations or periodic changes in controller load. It can maximize the system energy efficiency ratio while ensuring heat dissipation reliability.

[0026] like Figure 4As shown, in some embodiments, the controller 100 includes an upper housing 110 and a lower housing 120, with a diffusion-type airway disposed on the inner sidewall of the upper housing 110 or the lower housing 120, such as... Figures 7 to 9 As shown, the diffused airflow is oriented in one or more combinations of a grid shape, a ring shape, or a star shape. By designing the controller 100 as a split structure including an upper housing 110 and a lower housing 120, and setting the diffused airflow and the main airflow 122 in different housings (e.g., the airflow is located in the upper housing 110 and the main airflow 122 is located in the lower housing 120, or vice versa), the heat dissipation branch 111 is completely isolated from the main functional airflow in physical space, avoiding interference from the high-pressure pulsation of the main airflow 122 on the heat dissipation airflow, and preventing the heat dissipation exhaust from affecting the sealing performance of the main airflow 122. By setting the diffused airflow orientation to one or more combinations of a grid shape, a ring shape, or a star shape, the airflow distribution can accurately match the heat source shapes with different layouts inside the controller 100. For example, a grid shape is suitable for linear heating elements distributed along the length direction, a ring shape is suitable for 360° uniform heat dissipation around a central high-heat chip, and a star shape is suitable for radial coverage of multiple dispersed heat sources. This split-type air duct design not only significantly reduces the difficulty of shell processing and mold complexity, making it easy to integrally form complex air ducts through injection molding or machining, but also enables visualized management and rapid maintenance of the air duct through the detachable assembly of the upper box 110 and the lower box 120. The multiple selectable directions and combination usage methods allow the controller 100 to flexibly configure the optimal heat dissipation topology according to the specific heat distribution characteristics of the integrated circuit board 800, effectively improving heat dissipation efficiency and structural adaptability.

[0027] In some embodiments, the aperture of the directional spray vents is configured differently according to the internal temperature distribution of the controller 100. By differentiating the aperture of the directional spray vents according to the temperature distribution of the controller 100, the differentiated aperture design allows the cooling gas per unit volume to be optimally distributed according to the actual heat load of the integrated circuit board 800, avoiding the energy waste and temperature unevenness caused by "insufficient heat dissipation in high-heat areas and over-cooling in low-heat areas" resulting from traditional uniformly distributed vents. This structure not only significantly improves heat dissipation efficiency and air source utilization, maximizing the temperature drop of the controller 100 under the same air source power, but also effectively reduces unnecessary airflow disturbance and aerodynamic noise in low-heat areas, prevents the risk of condensation caused by over-cooling, and extends the service life of electronic components. At the same time, the differentiated aperture processing achieves an "adaptive" heat dissipation effect without the need for additional sensors or complex control logic, simplifying the system control strategy and reducing manufacturing costs.

[0028] In some embodiments, the aperture of the directional spray vents gradually increases from the central region to the edge region of the diffusion-type airway, such as... Figures 7 to 9As shown, the apertures of the first directional spray vent 112, the second directional spray vent 113, the third directional spray vent 114, and the fourth directional spray vent 115 gradually increase in size. This achieves differentiated heat dissipation by concentrating airflow in the central high-heat zone and dispersing airflow in the peripheral low-heat zone. By setting the aperture of the directional spray vents to gradually increase from the central region to the peripheral region of the self-diffusing airflow channel, a high-speed jet is formed in the central region due to the narrowing aperture, generating high dynamic pressure and penetrating force. This allows the jet to directly impact the high-heat chip or power device at the center of the integrated circuit board 800, achieving high-intensity convective heat transfer. Meanwhile, the peripheral region forms a low-pressure diffusion flow due to the expansion of the aperture, covering a large area with a gentle flow velocity, suitable for removing the heat accumulated in the peripheral components of the low-heat zone. This gradient aperture structure not only achieves precise matching between the cooling airflow and the spatial distribution of the heat source, avoiding the energy waste caused by insufficient heat dissipation at the center and excessive cooling at the edges due to traditional uniformly distributed air holes, but also effectively suppresses the generation of local hot spots, improves the uniformity of the internal temperature field of the controller 100, and reduces aerodynamic noise through the slow flow design in the edge region, thereby maximizing heat dissipation efficiency under limited air source flow.

[0029] In some embodiments, the airflow of the heat dissipation branch 111 is ultimately discharged to the outside of the controller 100 through the exhaust port 121 or exhaust pipe provided on the housing of the controller 100.

[0030] Specifically, in some embodiments, the automotive seat control system also includes an exhaust channel (not shown in the figure) for discharging the sprayed gas. By adding an exhaust channel to the automotive seat control system, the gas that has absorbed heat after spraying inside the controller 100 is discharged in a timely manner, preventing the high-temperature gas from accumulating and forming back pressure that would hinder the directional introduction of subsequent cooling airflow. This ensures the continuous circulation of airflow within the diffused air duct and the dynamic balance of spray pressure. The exhaust channel directionally guides the heat-carrying exhaust gas to the gaps in the seat frame or the external environment of the seat. This not only effectively prevents the backflow of heat and moisture condensation caused by heat accumulation inside the controller 100, and avoids the risk of secondary heating of the integrated circuit board 800 and corrosion of electrical interfaces by hot gas, but also prevents the hot airflow from directly impacting the seat foam layer or the occupant contact area through the concealed exhaust path design, thus improving the long-term operational reliability, electrical safety, and ride comfort of the system.

[0031] In some embodiments, the exhaust passage is an exhaust port 121 located on the controller 100. By directly setting the exhaust passage as an exhaust port 121 on the controller 100, the exhaust gas after heat dissipation can be directly connected to the external environment through the housing wall, without the need for additional complex exhaust pipes or external exhaust connectors. This integrated opening design not only significantly simplifies the air passage structure inside the seat, reduces the number of pipe connection points and potential leakage risks, and lowers material costs and assembly time, but also ensures the durability of the exhaust passage through the structural strength of the housing itself. This avoids the blockage and damage of external pipes due to bending, compression, or aging during seat adjustment, making it particularly suitable for the space-constrained interior environment of car seats with stringent reliability requirements, effectively improving the long-term operational stability and maintenance convenience of the system.

[0032] In some embodiments, the exhaust channel is an exhaust pipe connecting the controller 100 to the outside of the seat. By setting the exhaust channel as an exhaust pipe connecting the controller 100 to the outside of the seat, the high-temperature gas after heat dissipation is directed to the external space away from the controller 100 and the occupant area of ​​the seat, avoiding the heat radiation impact on electronic components and surrounding foam materials caused by heat accumulation inside the seat. At the same time, it prevents moisture and dust from flowing back into the controller 100 through the exhaust port. This external exhaust design not only effectively reduces the temperature rise of the environment around the controller 100 and prevents heat from being conducted to the occupant through the seat filling layer and fabric layer, significantly improving riding comfort, but also allows the exhaust gas to be concealed and discharged to locations far away from the occupant's perception area, such as the gaps in the seat frame, the bottom of the seat, or the floor of the vehicle, through the directional extension of the pipe, avoiding direct impact of hot airflow on the occupant's skin or causing discomfort. At the same time, the curved design of the pipe can form a natural air seal structure, blocking the intrusion of external pollutants, ensuring the long-term reliability of electronic components and the environmental adaptability of the system, which is particularly suitable for applications involving high-power controllers 100 or high-temperature environments.

[0033] In some embodiments, the air source device 200 is an air pump, an air tank, or an intermittent air supply device. By configuring the air source device 200 as one of these three devices, the system can flexibly select the optimal air supply solution based on the functional complexity, cost positioning, and usage scenarios of the car seat. When an air pump is used, continuous and active air supply can be achieved, meeting the immediate response requirements of high-frequency massage or complex adjustment functions. When an air tank is used, pre-stored compressed gas can be used to achieve silent and vibration-free air supply, avoiding the impact of air pump operating noise on occupant comfort and reducing continuous energy consumption. When an intermittent air supply device is used, it is activated only when heat dissipation is needed or when seat functions are activated, minimizing standby energy consumption. This multi-select configuration not only significantly broadens the vehicle model compatibility of the controller's intelligent cooling structure, enabling matching air source solutions to be found for seats ranging from economy to luxury models, but also achieves an optimal balance between energy consumption, noise, and response speed through on-demand selection of the air source form, improving the system's platform versatility.

[0034] In some embodiments, the air pump or air tank is housed within a reserved space inside the seat body. By integrating the air source device 200 into the reserved space inside the seat body, the air source device 200 shares the same installation space with the seat's pneumatic functions, eliminating the need for an additional independent air source outside the seat. Simultaneously, the proximity of the air source device 200 to the controller 100 shortens the air path connection distance, reducing pressure loss and leakage risks during gas delivery. Furthermore, the modular integration design of the air pump or air tank allows the controller 100's heat dissipation and the seat's pneumatic functions to reuse the same air source, achieving both active and passive cooling while avoiding the need for additional dedicated cooling power components. This significantly reduces system complexity and manufacturing costs, improves the utilization of the seat's internal space, and enhances the overall compactness of the system.

[0035] In some embodiments, the airflow switching device 500 may be integrated inside the controller 100, or disposed in the air path between the air source device 200 and the controller 100, or integrated into the air outlet of the air source device 200.

[0036] Specifically, such as Figures 2 to 4As shown, in some embodiments, the overflow valve 400 and the active cooling valve are integrated inside the housing of the controller 100. The overflow valve 400 and the active cooling valve are fluidly connected to the diffusion-type air passage through a multi-way valve. By integrating the overflow valve 400 and the active cooling valve inside the housing of the controller 100 and using a multi-way valve to achieve fluid communication with the diffusion-type air passage, the valve body control mechanism and the controller 100 form an integrated structure, eliminating the need for lengthy external connecting air pipes and additional installation space. At the same time, the multi-way valve, as an internal air passage hub, simplifies the air passage structure. This integrated design not only significantly reduces the space occupied inside the seat and lowers the risk of leakage due to aging of external pipes or loose joints, improving the air passage response speed and system reliability, but also makes the cooling module of the controller 100 a highly integrated modular unit, facilitating rapid assembly, disassembly, and subsequent maintenance in the confined space of a car seat, and effectively reducing system manufacturing costs.

[0037] In some embodiments, the overflow valve 400 and the active cooling valve are connected in parallel on the main air passage 122 between the air source device 200 and the controller 100. Both the overflow valve 400 and the active cooling valve are connected to the diffusion-type air passage through air inlets. Specifically, such as Figures 4 to 6 As shown, the overflow valve 400 and the active cooling valve are connected to the diffusion-type air passage through the first air inlet 700 and the second air inlet 900, respectively. By arranging the overflow valve 400 and the active cooling valve in parallel on the main air passage 122 between the air source device 200 and the controller 100, and connecting both to the diffusion-type air passage through standardized air inlets, the valve body control mechanism is placed outside the housing of the controller 100. While maintaining a short-range air passage connection, this achieves physical isolation between the internal space of the controller 100 and the air passage control module. The parallel layout ensures independent air passage control for the overflow valve 400 and the active cooling valve, preventing interference between them. When one valve fails, the other valve can still maintain basic heat dissipation function, improving system redundancy and reliability. This external design not only significantly reduces the internal structural complexity of the controller 100 housing, but also facilitates independent maintenance, quick replacement, and troubleshooting of the valve bodies.

[0038] like Figure 6As shown, in some embodiments, the overflow valve 400 and the active cooling valve are integrated at the outlet of the air source device 200. By integrating the overflow valve 400 and the active cooling valve at the outlet of the air source device 200, the valve body control mechanism and the air source device 200 form a front-mounted integrated air circuit module, completely freeing up the internal space of the controller 100, so that it only needs to retain the air passage interface and does not need to accommodate the valve body and multi-way valve and other complex control mechanisms; at the same time, this layout allows the cooling gas output from the air source to complete the passive diversion or active full conduction mode switching as soon as it leaves the air source module, and the gas entering the diffusion air passage is a precisely controlled directional pressure-stabilized airflow, avoiding pressure fluctuations of the gas at the port of the controller 100. This front-mounted integrated design not only significantly reduces the structural complexity and manufacturing difficulty of the controller 100 body, achieving miniaturization and lightweighting of the controller 100, but also integrates the vulnerable air circuit control components and power components into an independent module that can be replaced as a whole. This allows for later maintenance to be performed by simply disassembling and assembling the air source module without touching the electronic parts of the controller 100, effectively reducing maintenance costs and improving system reliability. It is especially suitable for automotive seat environments where the sealing and vibration resistance of the controller 100 are critical.

[0039] In some embodiments, the controller 100 is also connected to a temperature sensor (not shown in the figure). The active cooling valve opens and closes according to the feedback signal from the temperature sensor, realizing active heat dissipation control based on temperature. By connecting the controller 100 to the temperature sensor and controlling the active cooling valve to open and close according to the feedback signal from the temperature sensor, a closed-loop regulation of active heat dissipation based on real-time temperature is achieved. This allows the heat dissipation intensity to be dynamically matched according to the actual internal temperature rise of the controller 100. When the temperature sensor detects that the temperature exceeds a preset threshold, the active cooling valve opens immediately to enhance heat dissipation; when the temperature is below the threshold, it closes or reduces the flow rate. This avoids energy waste and overcooling caused by traditional continuous heat dissipation and also prevents heat dissipation lag when the temperature rises abnormally. This temperature control closed-loop design not only significantly improves the accuracy and response speed of heat dissipation control and achieves precise and constant temperature control of the controller 100, but also effectively extends the service life of electronic components, prevents performance degradation or failure risks caused by abnormal temperature rise, and reduces the ineffective power consumption of the air source device 200 by starting and stopping on demand, thereby improving the overall energy efficiency ratio and intelligence level of the system. It is particularly suitable for application scenarios with large ambient temperature fluctuations or drastic changes in the load of the controller 100.

[0040] In some embodiments, the controller 100 is modularly integrated with the air source device 200, the overflow valve 400, and the active cooling valve to form an independently assembleable seat control module. This module is connected to the vehicle wiring harness via connector components. By modularly integrating the controller 100 with the air source device 200, the overflow valve 400, and the active cooling valve to form an independently assembleable seat control module, and connecting this module to the vehicle wiring harness via standardized connector components, the originally dispersed electrical control, pneumatic drive, and thermal management functions are pre-integrated and functionally tested before leaving the factory, forming a plug-and-play functional unit. This modular design means that the vehicle assembly process only requires mechanical fixing and connector mating, eliminating the need for complex air circuit connections, circuit soldering, or control parameter calibration. This integrated structure not only significantly reduces the number of parts and assembly steps on the seat assembly line, lowering the rate of human error in assembly and quality control costs, but also shortens the vehicle development cycle through modular independent testing and verification. In the event of a system failure, the entire module can be replaced without disassembling the seat, greatly improving after-sales maintenance efficiency and user experience. It also facilitates rapid configuration iteration for platform-based models by replacing modules of different specifications, effectively reducing the overall cost throughout the entire life cycle.

[0041] like Figure 4 As shown, in some embodiments, the controller 100 has an integrated circuit board 800 inside, and the components of the integrated circuit board 800 are provided with a noise-absorbing buffer element 600 around their periphery to reduce the noise generated during gas spraying. By providing the noise-absorbing buffer element 600 around the components of the integrated circuit board 800 inside the controller 100, when the high-speed airflow impacts the surface of the components through the directional spray vents, it is first blocked and buffered by the noise-absorbing buffer element 600, absorbing the high-frequency noise generated by the airflow pulsation and weakening the direct impact kinetic energy of the airflow; at the same time, the noise-absorbing buffer element 600 fills the gap between the components and the inner wall of the controller 100 housing, forming a local airflow sealed space, preventing the cooling gas from short-circuiting out of the exhaust channel and failing to fully participate in heat exchange. This structure significantly reduces the hissing and turbulent noise generated during gas spraying heat dissipation, and at the same time, through the sound absorption and damping characteristics of the material, some kinetic energy is converted into heat energy for dissipation, thus helping to improve heat dissipation efficiency.

[0042] This invention provides an automotive seat control system, which includes a seat body (not shown in the figure), a pneumatic function actuator (not shown in the figure), an air source device 200, and a controller 100. The pneumatic function actuator is used to perform pneumatic functions of the seat (such as massage). The air source device 200 is integrated inside the seat body and is used to provide gas for heat dissipation of the pneumatic function actuator and the controller 100. The controller 100 is used to control each pneumatic function actuator and is equipped with an intelligent cooling structure. The intelligent cooling structure includes an overflow valve 400, an active cooling valve, and a controller 100 with a main air passage 122 and a diffusion air passage inside. The overflow valve 400 is connected to the main air passage 122 and is used to divert excess gas to the diffusion air passage when the seat pneumatic function is activated. The active cooling valve is connected to the main air passage 122 and is used to guide airflow to the diffusion air passage when the seat pneumatic function is dormant. The diffusion air passage is provided with several directional spray vents, which are used to spray gas to cool the inside of the controller 100. Through the coordinated control of the overflow valve 400 and the active cooling valve, the controller 100 automatically switches between passive diversion cooling and active full-flow cooling modes according to the working status of the seat function actuator. This allows the controller 100 to utilize excess gas for zero-energy heat dissipation when the main function is activated, and actively enhance heat dissipation when the main function is in sleep mode, achieving intelligent adaptive temperature regulation. Through the internal air passages and directional spray vents, the controller 100's internal integrated circuit board 800 receives precise airflow spraying, significantly improving heat dissipation efficiency. The controller 100's heat dissipation function is independent of the seat's pneumatic main functions (such as massage and adjustment), and does not affect the normal operation of the seat's pneumatic functions. The integrated and modular structure of this control system significantly reduces space occupation, eliminates traditional fan noise, effectively extends the lifespan of the controller 100, and improves the reliability and ride comfort of the automotive seat system.

[0043] This invention also provides a method for intelligent cooling of a controller, comprising the following steps: Detect the operating status of the main system of the controller 100; When the main system is in operation, the overflow valve 400 in the control airflow switching device 500 is opened and the active cooling control valve 300 is closed, so that the excess gas in the main air passage 122 is passively diverted to the control heat dissipation branch 111 to passively cool the controller 100. When the main system is in standby mode, the overflow valve 400 is closed and the active cooling control valve 300 is opened, so that all the gas in the main gas path 122 is actively introduced into the heat dissipation branch 111 of the controller 100 to actively cool the controller 100.

[0044] The intelligent cooling method for the controller of the present invention detects the working status of the main system of the controller 100, enabling the heat dissipation control to perceive the dynamic correlation between system load changes and heat dissipation requirements in real time. When the main system is detected to be in working state, the overflow valve 400 is opened and the active cooling control valve 300 is closed, and the excess exhaust pressure inherent in the main air passage 122 is passively diverted to form a heat dissipation airflow, achieving zero-energy heat dissipation without additional energy consumption, while ensuring that the air supply pressure of the main air passage 122 to the functional actuator is not affected. When the main system is detected to be in standby state, the overflow valve 400 is closed and the active cooling control valve 300 is opened, actively guiding all air sources into the heat dissipation branch 111 to form a high-intensity spray airflow, quickly removing the heat accumulated during standby due to the deterioration of sealing and heat dissipation. This method not only achieves an optimal balance between energy consumption and heat dissipation efficiency through intelligent switching between active and passive modes—that is, passive heat dissipation with zero additional energy consumption during operation and active heat dissipation to prevent heat accumulation during standby—but also avoids energy waste and overcooling caused by traditional continuous or single-mode heat dissipation through closed-loop coordination of electrical control logic and pneumatic actuators. This significantly improves the temperature control accuracy and long-term operational reliability of the controller 100. At the same time, this method does not require complex closed-loop adjustment of temperature sensors; it can achieve a basic intelligent heat dissipation strategy based solely on system status signals, greatly simplifying the complexity of the control algorithm and reducing hardware costs.

[0045] In some embodiments, during the passive and active cooling steps, the heat dissipation airflow is directly discharged to the outside of the controller 100 through the housing exhaust port 121 or exhaust pipe. By directly discharging the heat dissipation airflow to the outside of the controller 100 through the housing exhaust port 121 or exhaust pipe during the passive and active cooling steps, the high-temperature exhaust gas after heat absorption is discharged immediately through an open circuit, rather than returning to the main air path 122 to form a closed loop. This completely avoids secondary pollution and heat backflow caused by the return of heat-carrying gas to the air source or the main air path 122. At the same time, the direct discharge design eliminates the influence of the heat dissipation branch 111 on the back pressure of the main air path 122, ensuring the stability and response speed of the air supply pressure of the main air path 122, simplifying the air path topology, and reducing pipeline connection points and potential leakage risks. This open-circuit emission method not only significantly improves heat dissipation efficiency and air source utilization, preventing the backflow of heat caused by heat accumulation inside the controller 100, but also achieves miniaturization and weight reduction of the controller 100 structure by omitting the return pipeline, reducing system complexity and manufacturing costs. It is particularly suitable for the interior environment of car seats with stringent requirements for sealing and reliability.

[0046] In some embodiments, the intelligent cooling method for the controller further includes a temperature monitoring step. When the temperature of the controller 100 exceeds a preset threshold, an active cooling mode is activated, unaffected by the operating state of the main system. By adding a temperature monitoring step to the intelligent cooling method for the controller and setting a safety redundancy mechanism that forces the activation of the active cooling mode when the temperature of the controller 100 exceeds a preset threshold, regardless of the operating state of the main system, the system can break through the conventional active / passive mode switching logic. It can immediately trigger full-power heat dissipation when an abnormal temperature rise is detected, regardless of whether the main system is in operation or standby mode. This threshold-triggered forced intervention not only achieves real-time monitoring and over-limit response to heat accumulation inside the controller 100, effectively preventing chip thermal runaway and permanent damage caused by sudden loads, environmental temperature rises, or heat dissipation failures, but also provides safety redundancy protection through an emergency heat dissipation channel independent of the main system state, ensuring system reliability under extreme conditions. This temperature monitoring linkage mechanism not only significantly improves the thermal safety boundary and fault tolerance capability of the controller 100, realizing a seamless switch from "on-demand energy-saving heat dissipation" to "emergency safety heat dissipation", but also avoids the addition of additional hardware protection circuits through software-level threshold settings, reducing system cost and complexity. It is particularly suitable for high-risk application scenarios with drastic ambient temperature fluctuations or sudden load changes in the controller 100.

[0047] It should be noted that, where there is no conflict, the features in the embodiments of this invention can be combined with each other.

[0048] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A controller-based intelligent cooling structure, characterized in that, include: An air supply device (200) is used to provide airflow; The main air passage (122) is in fluid communication with the outlet of the air source device (200); A heat dissipation branch (111) is used to cool down the internal components of the controller (100); An airflow switching device (500) is connected to the main air passage (122). The airflow switching device (500) is configured to divert excess gas in the main air passage (122) to the heat dissipation branch (111) when the main function of the system is working, and to introduce all the gas in the main air passage (122) into the heat dissipation branch (111) when the main function of the system is suspended. The controller (100) has a heat dissipation branch (111) which is a diffused air passage located inside and connected to the controller (100). The inner surface of the controller (100) is provided with a plurality of directional spray vents connected to the diffused air passage, which are used to spray cooling gas directionally onto the internal components of the controller (100). The airflow switching device (500) automatically switches between passive diversion cooling mode and active full-flow cooling mode according to the working status of the main function of the system.

2. The intelligent cooling structure for the controller according to claim 1, characterized in that: The airflow switching device (500) includes an overflow valve (400) and an active cooling control valve (300), which work together or independently as needed to achieve the switching between the passive diversion cooling mode and the active full-flow cooling mode.

3. The intelligent cooling structure for the controller according to claim 1, characterized in that: In the airflow switching device (500), the valve body used to divert excess gas in the main air path (122) to the heat dissipation branch (111) when the main function of the system is working is a temperature control valve. The temperature control valve is connected to the temperature sensor signal and automatically opens and closes according to the comparison result between the real-time temperature inside the controller (100) and the preset threshold, so as to realize precise passive heat dissipation control based on the temperature threshold.

4. The intelligent cooling structure for the controller according to any one of claims 1 to 3, characterized in that: The controller (100) housing includes an upper housing (110) and a lower housing (120). The diffusion-type air passage is disposed on the inner side wall of the upper housing (110) or the lower housing (120). The diffusion-type air passage is arranged in a grid shape, a circumferential shape or a star shape.

5. The intelligent cooling structure for the controller according to claim 1, characterized in that: The aperture of the directional spray vent is configured differently according to the internal temperature zone distribution of the controller (100).

6. The intelligent cooling structure for the controller according to claim 1, characterized in that: The airflow of the heat dissipation branch (111) is finally discharged to the outside of the controller (100) through the exhaust port (121) or exhaust pipe provided on the controller (100).

7. The intelligent cooling structure for the controller according to claim 1, characterized in that: The gas source device (200) is an air pump, an air storage tank, or an intermittent gas supply device.

8. The intelligent cooling structure for the controller according to claim 1, characterized in that: The airflow switching device (500) can be integrated inside the controller (100), or set in the air path between the air source device (200) and the controller (100), or integrated into the air outlet of the air source device (200).

9. A method for intelligent cooling of a controller, characterized in that, Includes the following steps: The main system operating status of the detection controller (100) is monitored; When the main system is in operation, the overflow valve (400) in the control airflow switching device (500) is opened and the active cooling control valve (300) is closed, so that the excess gas in the main air path (122) is passively diverted to the control heat dissipation branch (111) to passively cool the controller (100); When the main system is in standby mode, the overflow valve (400) is closed and the active cooling control valve (300) is opened, so that all the gas in the main gas path (122) is actively introduced into the heat dissipation branch (111) of the controller (100) to actively cool the controller (100).

10. The intelligent cooling method for the controller according to claim 9, characterized in that, In the passive cooling step and the active cooling step, the heat dissipation airflow is directly discharged to the outside of the controller (100) through the housing exhaust port (121) or exhaust pipe.

11. The intelligent cooling method for the controller according to claim 9, characterized in that, It also includes a temperature monitoring step. When the temperature of the controller (100) exceeds the preset threshold, the active cooling mode is activated, which is not limited by the working status of the main system.

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