Seat design with a heating element that provides variable temperature electric heating for a zone along a predetermined path

Abstract

Seat assembly (10) with: a seat body (12) with a seat body seat surface (16), seat body seat surface (16), a backrest (14) coupled to the seat body (12), wherein the backrest (14) has a backrest seat surface (18), and wherein at least one of the seat body seat surface (16) and the backrest seat surface (18) has a zone (20) whose temperature is controlled, a heating element (26) arranged along a predetermined path (28) in the zone (20), wherein the heating element (26) is configured to provide electrical heating with variable temperature to the zone (20) along the predetermined path (28), wherein the heating element (26) comprises: first and second sections (32, 34) that alternate continuously along the predetermined path (28), each of the first sections (32) providing electric heating to the zone (20) at a first temperature and each of the second sections (34) providing electric heating to the zone (20) at a second temperature, the second temperature being higher than the first temperature, a continuous wire (36) that runs continuously through each of the alternating first and second sections (32, 34) along the predetermined path (28), a plurality of wire sections (38), each having a wire section length (L SS) define and are electrically connected to the continuous wire (36) and are arranged adjacent to each other in series along the specified path (28), such that each of the first sections (32) comprises one of the first wire sections and a first region (56) of the continuous wire (36) extending along the wire section length (L SS ) runs, and wherein each of the wire sections (38) is spaced apart from an adjacent wire section (38) by a gap (54), wherein the continuous wire (36) extends over each of the gaps (54) such that each of the second sections (34) comprises a second region (58) of the continuous wire (36) extending over the gap length (L) g ) extends.

Description

Background of the invention 1. Field of the invention

[0001] The present invention relates generally to seat assemblies having a seating surface with a temperature controlled zone, and more particularly to a seat assembly having a heating element disposed in the zone along a predetermined path for providing electrical heating to the zone at a variable temperature along the predetermined path. 2. Description of related art

[0002] Almost every vehicle today has a seat assembly with a seat bottom comprising a backrest and a seat bottom body. Often, the backrest and seat bottom body each have a temperature-controlled zone. A heating element is usually arranged along a tortuous path within the zone to provide electrical heating to the zone. The heating element typically includes one or more electrically conductive heating wires. A power source is connected to the heating element to energize the heating wires, causing the heating element to generate electrical heat for the zone. Each heating wire has a uniform cross-section across the tortuous path. Furthermore, the heating element conventionally has a uniform number of heating wires along the tortuous path, allowing the heating element to provide uniform electrical heating along the tortuous path.In other words, the heating element delivers a uniform temperature along every point along the winding path. As a result, conventional heating elements consume a uniform amount of energy per unit length, i.e., per meter.

[0003] The document DE 103 93 741 T5 discloses a coated conductor and a heating device produced thereby.

[0004] However, conventional heating elements have several disadvantages. First, conventional heating elements consume a lot of energy. Since conventional heating elements consume a uniform amount of energy per unit length, energy consumption is maximized along the tortuous path of the heating element. Second, conventional heating elements can often cause discomfort to a occupant of the seat assembly. Between tortuous sections of the heating element, there are regions of the heating surface that experience less electrical heating. Conventional heating elements essentially concentrate the electrical heating along the tortuous path compared to the regions of the seat surface that lie between tortuous sections of the heating element. Therefore, those regions of the seat surface that experience less electrical heating are often cooler than the surrounding areas, causing a temperature difference or a temperature gap in the region.The person sitting feels the temperature difference on the seat surface, which ultimately causes discomfort for the person sitting.

[0005] Therefore, one possibility remains to develop a seat assembly that has a heating element arranged in the zone to provide variable-temperature electric heating at different points along a predetermined path. Furthermore, one possibility remains to develop a seat assembly that has a heating element that consumes less energy than conventional heating elements. Furthermore, one possibility remains to develop a seat assembly that has a heating element that avoids discomfort for the occupant of the seat assembly by minimizing temperature differences on the seat surface.

[0006] The object of the invention is to provide a more energy efficient or more comfortable seat assembly or a seat assembly that provides a variable temperature electric heater.

[0007] The object is achieved by a seat structure according to claim 1 or 8 or by a structure according to claim 17. Summary of the invention and advantages

[0008] The present invention provides a seat assembly having a seat base body and a backrest. The backrest is connected to the seat base body. The seat base body has a seat base body surface, and the backrest has a backrest seat surface. At least one of the seat base body seat surface and the backrest seat surface has a temperature-controlled zone. A heating element is disposed along a predetermined path in the zone. The heating element is configured to provide variable-temperature electrical heating to the zone along the predetermined path. The heating element includes first and second sections that continuously alternate along the predetermined path. Each of the first sections provides electrical heating to the zone at a first temperature. Each of the second sections provides electrical heating to the zone at a second temperature. The second temperature is greater than the first temperature.

[0009] According to one embodiment, the present invention provides a heating element including a continuous wire extending continuously through each of the alternating first and second sections along the predetermined path. The heating element includes a plurality of wire sections. Each of the wire sections defines a wire section length. Each of the wire sections is connected to the continuous wire. All of the wire sections are arranged adjacent to one another in series along the predetermined path such that each of the first sections includes one of the wire sections and a first region of the continuous wire extending along the wire section length. Each of the wire sections is spaced from an adjacent wire section by a gap defining a gap length.The continuous wire extends across all gaps such that each of the second sections includes a second region of the continuous wire extending across one of the gap lengths.

[0010] According to another embodiment, the present invention provides a heating element including a first continuous conductor and a second continuous conductor, each extending continuously across alternating first and second sections along the predetermined path. The heating element includes a plurality of first conductor sections, each defining a first conductor section length. Each of the first conductor sections is connected to the first continuous conductor. All of the first conductor sections are arranged adjacent to one another in series along the predetermined path. The heating element includes a plurality of second conductor sections, each defining a second conductor section length. All of the second conductor sections are electrically connected to the second continuous conductor and arranged adjacent to one another in series along the predetermined path.The first conductor section lengths are substantially aligned with the second conductor section lengths along the predetermined path such that each of the first sections includes the aligned first and second conductor sections and a first portion of each of the first and second continuous conductors extending along the aligned first and second conductor section lengths. Each of the first conductor sections is spaced from an adjacent first conductor section by a gap defining a first gap length. Each of the second conductor sections is spaced from an adjacent second conductor section by a gap defining a second gap length. The first gap lengths are substantially aligned with the second gap lengths along the predetermined path.Each of the second sections includes a second region of the first and second continuous conductors extending across the aligned first and second gap lengths.

[0011] In yet another embodiment, the present invention provides an assembly including a vehicle component having at least one temperature-controlled zone. The heating element is connected to the vehicle component and disposed along the predetermined path in the zone, the heating element being configured to provide electrical heating to the zone at a temperature variable along the predetermined path. The heating element has first and second sections that continuously alternate along the predetermined path. Each of the first sections provides electrical heating to the zone at a first temperature. Each of the second sections provides electrical heating to the zone at the second temperature, the second temperature being higher than the first temperature.The heating element includes a continuous conductor extending continuously through each of the alternating first and second sections along the predetermined path. The heating element includes the plurality of conductor sections, each conductor section defining a conductor segment length and being electrically connected to the continuous conductor. The plurality of conductor sections are arranged adjacent to one another in series along the predetermined path such that each of the first sections includes one of the conductor sections and the first region of the continuous conductor extending along the conductor segment length. Each of the conductor sections is spaced from the adjacent conductor section by a gap defining a gap length. The continuous conductor extends through all of the gaps such that each of the second sections includes the second region of the continuous conductor extending across each gap length.

[0012] Accordingly, the seat assembly includes a heating element disposed in the zone of the seat surface to provide variable temperature electrical heating along the predetermined path. The heating element consumes less energy than conventional heating elements. In particular, the heating element consumes variable amounts of energy per unit length. Thus, energy consumption is minimized at all initial portions of the heating element along the predetermined path. Furthermore, the heating element of the seat assembly maximizes energy consumption to improve occupant comfort. In addition, the heating element minimizes discomfort to the occupant of the seat assembly. By providing a variable temperature along the predetermined path, the heating element can concentrate the electrical heating on regions of the seat surface that are less exposed to electrical heating, such as those regions between turns of the heating element.As a result, the heating element minimizes temperature differences on the seat surface, which improves the comfort for the person sitting on the seat structure. Brief description of the drawings

[0013] Other advantages of the present invention will be readily appreciated as the invention becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings. Fig. 1 is a perspective view of the seat assembly including a seat base body and a backrest connected to the seat base body, with a heating element disposed along a predetermined path in a zone. Fig. 1A is an enlarged plan view of the heating element of Fig. 1. Fig. 2 is an enlarged perspective view of a heating element according to an embodiment of the present invention including a continuous wire and a plurality of wire sections. Fig. 3 is an enlarged perspective view of a heating element according to another embodiment of the present invention having a continuous wire surrounded by groups of wire sections, the wire sections having constant lengths and spaced apart by constant gaps. Fig. 4 is an enlarged perspective view of a heating element according to yet another embodiment of the present invention having the continuous wire arranged at the edge of the wire section groups, the wire sections having variable lengths and spaced from each other by varying gaps. Fig. 5 is a cross-sectional area through one of the wire section groups from Fig. 4. Fig. 6 is an enlarged perspective view of a heating element according to an embodiment of the present invention having a first continuous core with first coating portions and a second continuous core with second coating portions aligned with the first coating portions, the first and second coating portions having constant lengths and spaced apart by constant gaps. Fig. 7 is an enlarged perspective view of a heating element according to another embodiment of the present invention, wherein the aligned first and second coating portions have varying lengths and are spaced from each other by varying gaps. Fig. 8 is an enlarged perspective view of a heating element according to an embodiment of the present invention, comprising a first continuous wire having first wire portions and a second continuous wire having second wire portions aligned with the first wire portions, the first and second wire portions having constant lengths and spaced apart by constant gaps. Fig. 9 is an enlarged perspective view of a heating element according to yet another embodiment of the present invention, the heating element having aligned first and second wire portions of varying lengths and spaced apart by varying gaps. Detailed description of the invention

[0014] In the figures, in which like or corresponding parts are designated by like reference numerals throughout the different views, a vehicle component is shown in Fig. 1 with the reference number 10. In the Fig. 1, the vehicle component is further defined as a seat assembly. For simplicity, the vehicle component is described below and numbered according to the seat assembly embodiment as shown in Fig. 1. However, the vehicle component may also comprise another suitable device in a vehicle that is heated, such as a steering wheel or the like.

[0015] The seat assembly 10 is used in a vehicle, such as an automobile. The seat assembly 10 includes a seat bottom body 12 and a backrest 14 connected to the seat bottom body 12. The seat bottom body 12 has a seat body seating surface 16, and the backrest 14 has a backrest seating surface 18.

[0016] The vehicle component has at least one zone 20 that is temperature controlled. In cases where the vehicle component is the seat assembly 10, at least one of the seat base body 12 and the backrest 14 comprises the zone 20. In one embodiment, as shown in Fig. 1, the seat base body 12 includes the zone 20. In another embodiment, both the seat base body 12 and the backrest 14 include the zone 20. Each zone generally defines a zone boundary 22 that defines an area 24 of the zone 20.

[0017] The seat assembly 10 includes a heating element 26 disposed along a predetermined path 28 within the zone 20. The heating element 26 is configured to provide variable temperature electrical heating to the zone 20 along the predetermined path 28. The heating element 26 is generally enclosed within the area of ​​the zone 20. In one embodiment, the heating element 26 is embedded within the seat assembly 10 beneath at least one of the seat body seating surface 16 and the backrest seating surface 18. A power source 30 is connected to the heating element 26 to supply power to the heating element 26 such that the heating element 26 provides variable temperature electrical heating. Typically, the power source 30 is a direct current source, such as a vehicle battery, for supplying electrical current through the heating element 26.

[0018] The predetermined path 28 may have any suitable shape to enable the heating element 26 to distribute electrical heating in the zone 20. In one embodiment, as shown in Fig. 1 and Fig. 1A, the predetermined path 28 has a winding shape. In particular, the predetermined path 28 may have a serpentine configuration. However, the predetermined path 28 may also have other configurations, such as a zigzag configuration and the like. Furthermore, the heating element 26 may extend any suitable length along the predetermined path. In one embodiment, the heating element 26 spans a length of approximately 5 m.

[0019] As in Fig. 1 and Fig. 1A, the heating element 26 has first sections 32 and second sections 34 that continuously alternate along the predetermined path 28. More specifically, the heating element 26 includes a combination of alternating first and second sections 32, 34 disposed adjacent to one another along the length of the predetermined path 28. Generally, each of the first sections 32 is sandwiched between two second sections 34, and vice versa. The heating element 26 includes a plurality of first sections 32 and a plurality of second sections 34. Preferably, the heating element 26 includes between 150 and 200 first sections 32 and between 150 and 200 second sections 34 along the predetermined path 28.

[0020] Each of the first sections 32 of the heating element 26 provides electrical heating to the zone 20 at a first temperature. Each of the second sections 34 of the heating element 26 provides electrical heating to the zone 20 at a second temperature. The second temperature is higher than the first temperature. Generally, each of the second sections 34 provides electrical heating at a higher temperature than each of the first sections 32. In one embodiment, the first temperature is substantially the same for all of the first sections 32 and the second temperature is substantially the same for all of the second sections 34. In another embodiment, the first and second temperatures may vary with respect to specific ranges. In particular, the first temperature may be further defined as being within a first temperature range and the second temperature may be further defined as being within a second temperature range.The first temperature range defines a minimum of the first temperature range and a maximum of the first temperature range. The second temperature range defines a minimum of the second temperature range and a maximum of the second temperature range. According to this embodiment, the minimum of the second temperature range is greater than the maximum of the first temperature range. In other words, the lowest temperature provided by the second sections 34 is higher than the highest temperature provided by the first sections 32. However, other relationships between the first temperature and the second temperature may be realized without departing from the scope of the present invention.

[0021] As in Fig. 2-5, the heating element 26 includes a continuous wire 36 that extends continuously through all of the alternating first and second sections 32, 34 along the predetermined path 28. The continuous wire 36 includes a conductive material such that the continuous conductor 36 is electrically conductive. The conductive material may be copper, a copper alloy, stainless steel, and the like. Furthermore, the continuous wire 36 may comprise any suitable coating, including conductive material such as copper or silver. The continuous wire 36 is typically formed in one piece and continuously along the predetermined path 28. In one embodiment, the continuous wire 36 has a cross-sectional area that is uniform along the predetermined path 28. More specifically, in the embodiment shown in FIGS. Fig. 2-5 has a circular shape. Therefore, in such embodiments, the continuous wire 36 has a shape consistent with the term "wire" as used in this field. Further, the continuous wire 36 preferably has an electrical resistance per unit length that is consistent along the predetermined path 28. For example, the electrical resistance per unit length of the continuous wire 36 may be 10 ohms / meter. It should be appreciated that the heating element 26 may comprise a bundle of more than one continuous wire 36 extending continuously through all of the alternating first and second sections 32, 34.

[0022] The heating element 26 further includes a plurality of wire sections 38 electrically connected to the continuous wire 36. Each of the wire sections 38 defines a wire section length L SS. More specifically, each of the wire sections 38 has a first end 40 and a second end 42, and the wire section length L SS is defined between the first and second ends 40, 42. In one embodiment, as shown in Fig. 3, all wire section lengths L SS substantially constant along the predetermined path 38. In another embodiment, as in Fig. 4, at least one of the wire section lengths L SS different from another of the wire section lengths L SS along the specified route 28.

[0023] In another embodiment, as in Fig. 2-5, each of the wire sections 38 is arranged substantially parallel to the continuous wire 36. Generally, each of the wire sections 38 directly contacts at least one other wire section 38 and / or the continuous wire 36. The wire sections 38 may be connected to each other and / or to the continuous wire 36. The wire sections 38 may be connected to each other and / or to the continuous wire by any suitable method, such as soldering, bundling, crimping, and the like.

[0024] As in Fig. 2-4, the wire sections 38 in at least one of the first sections 32 are arranged in a wire section grouping 44. All wire sections 38 in the wire section grouping 44 are substantially aligned along the predetermined path 28. As shown in Fig. 5, the wire section grouping 44 has a cross-sectional area 46 that defines a perimeter 50. In one embodiment, as shown in Fig. 5, the cross-sectional area 46 of the wire section grouping 44 has a substantially circular shape. However, the cross-sectional area 46 may also have other shapes, such as a rectangular shape or the like. Fig. 2 and Fig. 5, the continuous wire 36 is disposed substantially at the edge or perimeter 50 of the cross-sectional area 46 of each of the wire section groupings 44. In other embodiments, as in Fig. 3 and Fig. 4, the continuous wire 36 is disposed within the perimeter 50 of the cross-sectional area 46 of each of the wire section groupings 44. In other words, the continuous wire 36 is substantially surrounded by the wire section groupings 44. For example, as shown in Fig. 3, the continuous wire 36 may be disposed substantially at the center of the cross-sectional area 46 of each of the wire section groupings 44. The continuous wire 36 may further be disposed at the perimeter 50 of the cross-sectional area 46 of each of the wire section groupings 44 while simultaneously being disposed within the perimeter 50 of the cross-sectional area 46 of at least one other of the wire section groupings 44. It should be appreciated that the wire section groupings 44 may be configured with respect to the continuous wire 36 according to other configurations not specifically described herein. For example, the wire section groupings 44 may be wrapped around the continuous wire 36 without departing from the scope of the invention.

[0025] The wire segments 38 contain a conductive material such that the wire segments 38 are electrically conductive. The conductive material may be copper, a copper alloy, stainless steel, and the like. Furthermore, the wire segments 38 may include any suitable coating containing conductive material. Each of the wire segments 38 may be formed in one piece. Each of the wire segments 38 has a cross-sectional area. In one embodiment, the cross-sectional area of ​​all wire segments 38 is substantially similar. As shown in Fig. 2-5, the wire sections 38 all have a cross-sectional area with a circular shape. In such embodiments, the wire sections 38 have a shape consistent with the term "wire" as used in this field of technology. Furthermore, the wire sections 38 all have a substantially similar electrical resistance per unit length. Preferably, the electrical resistance per unit length of the wire sections 38 is lower than the electrical resistance per unit length of the continuous wire 36.

[0026] The wire sections 38 are arranged adjacent to each other in series along the predetermined path 28. As in Fig. As shown in Figures 2-5, each wire section 38 is spaced from an adjacent wire section 38 by a gap 54. The first and second ends 40, 42 of each wire section 38 are spaced from the first and second ends 40, 42 of a respective adjacent wire section by one of the gaps 44. Each of the gaps 44 is defined by a gap length Lg. The gap length Lg is defined between one of the first and second ends 40, 42 of a wire section 38 and one of the first and second ends 40, 42 of an adjacent wire section 38.

[0027] The continuous wire 36 extends over all gaps 54. In an embodiment as in Fig. 2 and Fig. 3, the gap lengths Lg along the predetermined path 28 are substantially constant. In other words, each gap length Lg has substantially the same length. In another embodiment, as shown in Fig. 4, at least one of the gap lengths Lg is different from another of the gap lengths Lg along the predetermined path. Preferably, each of the gap lengths L g defined within a range between 1 mm and 5 mm.

[0028] The gap length Lg may vary slightly between adjacent wire sections 38, so that each of the adjacent wire sections 38 is unevenly spaced by one of the gaps 54. For example, as shown in Fig. 4, adjacent wire sections 38 may be spaced apart in a tapered configuration such that the gap 54 is V-shaped.

[0029] As in Fig. 2-4, each of the first sections 32 includes one of the wire sections 38 and a first region 56 of the continuous wire 36 extending along the wire section length Lss. Each of the first sections 32 comprises a combination of the first region 56 of the continuous wire 36 and the corresponding wire section or sections 38 disposed adjacent to and electrically connected to the first region 56 of the continuous wire 36. Therefore, each of the first regions 46 extends along the predetermined path 28 according to a wire section length Lss. In one embodiment, as shown in Fig. 2-4, each of the first sections 32 includes a plurality of wire sections 38. Alternatively, each of the first sections 32 may include at least one wire section 38. Further, each of the first sections 32 may preferably include an equal number of wire sections 38.

[0030] In cases where the wire sections 38 belonging to one of the wire section groupings 44 have different wire section lengths L SS have, as in Fig. 4, the first region 56 can be adjusted according to the wire section length L SS be defined according to the shortest or longest of the wire sections 38.

[0031] The continuous wire 36 extends over all of the gaps 54, so that each of the second sections 34 includes a second region 58 of the continuous wire 36 extending over each of the gap lengths L g Each of the second sections 34 includes the second region 58 of the continuous wire 36 disposed between adjacent wire sections 38. Thus, wire sections 38 are generally not present in any of the sections 34. Each of the second sections 34 extends along the predetermined path 28 according to the gap length L gdefined between adjacent wire sections 38.

[0032] In cases where the wire sections 38 belonging to one of the wire section groupings 44 have different wire section lengths L SS have, as in Fig. 4, the second area 58 can be adjusted according to the gap length L g be defined according to a shortest or a longest length between adjacent wire sections 38.

[0033] Each of the first sections 32 has a first section electrical resistance defined along the predetermined path 38. The first section electrical resistance is generally defined with respect to the combination of one of the first regions 56 of the continuous wire 36 extending along the wire section length L SSand the respective wire section or sections 38 electrically connected to the same first region 56. In one embodiment, the electrical resistance of the first section is approximately 1 ohm / meter. The first electrical section resistance may be substantially similar for each of the first sections 32 of the heating element 26. Alternatively, the first electrical section resistance of one of the first sections 32 may differ slightly from the first electrical section resistance of another of the first sections.

[0034] Each of the second sections 34 has a second section electrical resistance defined along the predetermined path 28. The second section electrical resistance is generally defined with respect to the second region 58 of the continuous wire 36 extending across the gap length L gextends. The second section electrical resistance is greater than the first section electrical resistance. Primarily, the amount of conductive material in each of the second sections 34 is reduced, thereby increasing the electrical resistance in the second region 58. As a result, electrical energy supplied by the heating element 26 is concentrated in the second regions 58 of the continuous wire 36. In one embodiment, the second section electrical resistance is approximately 10 ohms / meter, such that the second section electrical resistance is 10 times greater than the first section electrical resistance. However, the second section electrical resistance may also be greater than the first section electrical resistance by other suitable ratios or amounts without departing from the scope of the invention. The second section electrical resistance may be substantially similar for each of the second sections 34 of the heating element 26.Alternatively, the electrical resistance of second portions at a second portion 34 may differ slightly from the electrical resistance of second portions of another of the second portions 34.

[0035] As in Fig. 1A, each of the first sections 32 defines a first heating region 60 on at least one of the seat body and backrest seating surfaces 16, 18. Each of the first heating regions 60 extends from each of the first sections 32. More specifically, the first heating regions 60 extend from the combination of the first region 56 of the continuous wire 36 and the wire sections 38 of the respective first section 32. As shown in Fig. 1A, the first heating region 60 may be substantially similar for each of the first sections 32 of the heating element 26. Alternatively, the heating element 60 of one of the first sections 32 may be different from the heating region 60 of another of the first sections 32.

[0036] Each of the second sections 34 defines a second heating region 62 on at least one of the seat body and backrest seating surfaces 16, 18. The second heating region 62 extends from each of the second sections 34. More specifically, the second heating region 62 extends from the second region 58 of the continuous wire 36 of the respective second section 34. As shown in Fig. 1A, the second heating region 62 may be substantially similar for all second sections 34 of the heating element 26. Alternatively, the second heating region 62 of one of the second sections 34 may be different from the second heating region 62 of another of the second sections 34.

[0037] The second heating region 62 is larger than the first heating region 60. As discussed above, each of the second sections 34 has a relatively higher electrical resistance than each of the first sections 32. Further, each of the second sections 34 provides electrical heating at a relatively higher temperature than each of the first sections 32. As a result, each of the second heating regions 62 extends away from the predetermined path 28 of the heating element 26. In other words, each of the second heating regions 62 heats a region of the zone 20 covered by the respective second section 34 of the heating element 26, in addition to an adjacent region of the zone 20 that is substantially free of the respective second section 34 of the heating element 26. As a result, the second heating regions 62 provide a plurality of “hot spots” for the zone 20. In one embodiment, as shown in Fig. 1 and Fig. 1A, each of the second heating regions 62 extends radially from the predetermined path 28, such that each of the second heating regions 62 has a substantially elliptical or circular shape. Alternatively, each of the second heating regions 62 may extend from the predetermined path 28 in any suitable configuration not specifically described herein.

[0038] On the other hand, each of the first heating areas 60 essentially follows the predetermined path 28, as in Fig. 1A. In other words, each of the first heating regions 60 heats a region of the zone 20 substantially occupied by the respective first portion 32 of the heating element 26. In one embodiment, each of the first heating regions 60 has a linear shape that closely follows the predetermined path 28 of the heating element 26.

[0039] In one embodiment, as in Fig. 1A, the heating element 26 has a first portion 64 extending along the predetermined path 28 and a second portion 66 adjacent to the first portion 64 and extending along the predetermined path 28. The first and second portions 64, 66 of the heating element 26 are substantially parallel to one another and are connected by a curve 68 in the predetermined path 28. The curve 68 has a substantially U-shaped configuration. The predetermined path 28 thus generally has a serpentine configuration. A region 70 is defined in the zone 20 between the first and second portions 64, 66 of the heating element 66. Generally, the region 70 is subjected to only a relatively limited amount of electrical heating because the region 70 is spaced apart from the predetermined path 28 of the heating element 26.As a result, a temperature difference may develop at one of the seat body and backrest seating surfaces 16, 18 in the region 70, creating "cold spots" in the zone 20, which may be uncomfortable for a occupant of the seat assembly 10. At least one of the second sections 34 is defined along at least one of the first and second portions 64, 66 of the heating element 26 such that the second heating area 62 extends into the region 70. Thus, "hot spots" provided by at least one of the second sections 34 concentrate electrical heating in the region 70 between the first and second portions 64, 66 of the heating element 26 to reduce the presence of "cold spots." As a result, the heating element 26 minimizes the temperature differences at one of the seat body and backrest seating surfaces 16, 18, thereby increasing the comfort of a occupant of the seat assembly 10.Furthermore, the heating element 26 provides electrical heating as effectively as conventional heating elements while consuming less energy than conventional heating elements. Energy consumption is reduced because the heating element 26 provides varying temperatures along the length of the predetermined path 28 and consumes varying amounts of energy per unit length. In particular, energy consumption is minimized at the first portions 32 of the heating element 26 along the predetermined path 28.

[0040] In one embodiment, as in Fig. 1A, the plurality of second sections 34 are arranged and aligned along the first and second portions 64, 66 of the heating element 26 such that the second heating regions 62 are aligned with each other within the region 70. In other words, the second sections 34 are spaced apart from each other at predetermined distances such that the second heating regions 62 emanate from approximately the same corresponding position on the first portion 64 of the heating element 26 as on the second portion 66. Alternatively, the second sections 34 may be arranged and aligned along the first and second portions 64, 66 of the heating element 26 in any other pattern or configuration without departing from the scope of the present invention.

[0041] According to another embodiment of the present invention, as described in Fig. 6-9, the heating element 26 has a first continuous conductor 136 and a second continuous conductor 137. Each of the first and second continuous conductors 136, 137 continuously and alternately passes through the first and second sections 32, 34 along the predetermined path. It should be appreciated that each of the first and second continuous conductors 136, 137 of the Fig. 6 - 9 are generally analogous to the continuous wire 36 of the Fig. 2-4. In other words, each of the first and second continuous conductors 136, 137 performs substantially the same function in substantially the same manner as the continuous wire 36.

[0042] The heating element 26 further comprises a plurality of first conductor sections 138. Each of the first conductor sections 138 defines a first conductor section length L cs1and is electrically connected to the first continuous conductor 136. Each of the first conductor sections 138 is arranged adjacent to one another in series along the predetermined path. The heating element 26 further includes a plurality of second conductor sections 139. Each of the second conductor sections 139 defines a second conductor section length L cs2 and is electrically connected to the second continuous conductor 137. Each of the second conductor sections 139 is arranged adjacent to another in series along the predetermined path 28. The first conductor section lengths L cs1 are essentially connected to the second conductor section lengths L cs2 aligned along the specified path 28.

[0043] In this embodiment of the present invention, each of the first sections 32 includes the aligned first and second conductor sections 138, 139. Each of the first sections 32 further includes a first portion 150 of each of the first and second continuous conductors 136, 137 extending along the aligned first and second conductor section lengths (L cs1 , L cs2 ). Each of the first conductor sections 138 is spaced from an adjacent first conductor section 138 by a first gap 154. Each first gap 154 ​​defines a first gap length L g1 . Each of the second conductor sections 139 is spaced from an adjacent second conductor section 139 by a second gap 156. Each of the second gaps 156 defines a second gap length L g2 . The first gap lengths L g1 are essentially related to the second gap lengths L g2aligned along the predetermined path 28. Each of the second sections 34 includes a second region 158 of each of the first and second continuous conductors 136, 137 extending over the aligned first and second gap lengths L g1 , L g2 get lost.

[0044] According to one embodiment, the first continuous conductor 136 and the first conductor sections 138 are electrically connected in parallel with the second continuous conductor 137 and the second conductor section 139. As shown in Fig. As shown in Figure 7, the heating element 26 includes a first insulating layer 160 that substantially surrounds the first continuous conductor 136 and the first conductor portions 138. The heating element 26 may further include a second insulating layer 162 that substantially surrounds the second continuous conductor 137 and the second conductor portions 139. The first and second insulating layers 160, 162 insulate the first continuous conductor 136 and the respective first conductor portions 138 from the second continuous conductor 137 and respective second conductor portions 139 along the predetermined path. As a result, the first and second insulation layers 160, 162 enable the heating element 26 to provide "hot spots" at controlled positions without disturbances due to electrical contact between the first and second conductors 136, 137 and / or the first and second conductor portions 138, 139 along the predetermined path.Furthermore, any suitable sheath or casing may be used to surround both the first and second insulation layers 160, 162.

[0045] As in Fig. 6 and Fig. 8, each of the aligned first and second conductor section lengths L cs1 , L cs2 be substantially constant along the given path 28. Alternatively, as in Fig. 7 and Fig. 9, at least one of the aligned first and second conductor section lengths L cs1 , L cs2 be different from another of the aligned first and second conductor section lengths L cs1 , L cs2 along the specified route 28.

[0046] Furthermore, as in Fig. 6 and Fig. 8, each of the aligned first and second gap lengths L g1 , L g2be essentially constant along the given path 28. Alternatively, as in Fig. 7 and Fig. 9, at least one of the aligned first and second gap lengths L g1 , L g2 be different from another of the gap lengths L g1 , L g2 along the predetermined path 28. Preferably, each of the aligned first and second gap lengths L g1 , L g2 defined in a range between 1 mm and 5 mm.

[0047] Just like in the Fig. 2-5, each of the first sections 32 has a first electrical resistance defined along the predetermined path 28, and each of the second sections 34 has a second electrical resistance defined along the predetermined path 28. The second electrical resistance is greater than the first electrical resistance. Similarly, each of the first sections 32 defines a first heating region 60 on at least one of the seat bottom body and backrest seating surfaces 16, 18. Each of the second sections 34 defines a second heating region 62 on at least one of the seat bottom body and backrest seating surfaces 16, 18. The second heating region 62 is larger than the first heating region 60. At least one of the second sections 34 can be defined along at least one of the first and second portions 64, 66 of the heating element 26 such that the heating region 62 extends into the region 70, as shown in Fig. 1A shown.

[0048] In one embodiment, the first continuous conductor 136 has a first conductor resistance defined along the predetermined path 28, and each of the plurality of first conductor sections 138 has a first conductor section electrical resistance defined along the length of the path 28. The first conductor electrical resistance is greater than the first conductor section electrical resistance. Similarly, the second continuous conductor 137 has a second conductor electrical resistance defined along the length of the path 28, and each of the plurality of second conductor sections 139 has a second conductor section electrical resistance defined along the length of the path 28. The second conductor electrical resistance is greater than the second conductor section electrical resistance.

[0049] According to one embodiment, the first and second continuous conductors 136, 137 are as shown in Fig. 6 and Fig. 7, each further defined as a core, and each of the plurality of first and second conductor portions 138, 139 is further defined as a cladding portion, each of which substantially surrounds a respective one of the first and second continuous conductors 136, 137. In this embodiment, each of the plurality of first and second conductor portions 138, 139 has a tubular shape with a substantially constant thickness. Each of the first gaps 154 is defined radially with respect to the first continuous conductor 136, and each of the second gaps 156 is defined radially with respect to the second continuous conductor 137. In one embodiment, as shown in Fig. 6 and Fig. 7, the first and second gaps 154, 156 define an annular configuration. Alternatively, the first and second gaps 154, 156 may define other radial configurations, such as a quarter-circle or semi-circle configuration. Further, the first and second gaps 154, 156 may be formed by any suitable method, such as by cutting away material from the first and second conductor portions 138, 139. Additionally, in this embodiment, the plurality of first and second conductor portions 138, 139 may be formed from any suitable conductive coating material, such as gold or silver.

[0050] According to another embodiment, as in Fig. 8 and Fig. 9, the first and second continuous conductors 136, 137 are further defined as a continuous wire, and each of the plurality of first and second conductor portions 138, 139 is further defined as a wire portion. The heating element 26 in the embodiment of Fig. 8 and Fig. 9 includes a combination of two or more heating elements 26 as in Fig. 2 - 4. Therefore, the various aspects, properties and alternative designs of the heating element 26 as shown in Fig. 2 - 4, as described herein, also apply in full to the heating element 26 of the Fig. 8 and Fig. 9. In this embodiment, the first conductor sections 138 are arranged in first conductor section groupings 164, and the second conductor sections 139 are arranged in second conductor section groupings 166. Each of the first conductor section groupings 164 has a common number of first conductor sections 138, and each of the second conductor section groupings 166 has a common number of second conductor sections 139. Each of the first and second conductor section groupings 164, 166 has a cross-sectional area that defines a perimeter. In one embodiment, the first continuous conductor 136, as shown in Fig. 8, the first continuous conductor 137 is arranged at the periphery of the cross-sectional area of ​​the first conductor section groupings 164, and the second continuous conductor 137 is arranged at the periphery of the cross-sectional area of ​​the second conductor section groupings 166. Alternatively, the first and second continuous conductors 136, 137 may be arranged as shown in Fig. 9 may be arranged within the circumference of the cross-sectional areas of the respective first and second conductor section groupings 164, 166.

[0051] The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is for the purpose of description rather than limitation. As will be apparent to those skilled in the art, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, wherein reference numerals are intended to be convenient and not in any way limiting, the invention may be practiced otherwise than as specifically described.

Claims

[1] Seat structure (10) with: a seat body (12) with a seat body seat surface (16), seat body seat surface (16), a backrest (14) coupled to the seat body (12), wherein the backrest (14) has a backrest seating surface (18), and wherein at least one of the seat body seating surface (16) and the backrest seating surface (18) has a zone (20) whose temperature is controlled, a heating element (26) arranged along a predetermined path (28) in the zone (20), the heating element (26) being configured to provide variable temperature electrical heating to the zone (20) along the predetermined path (28), the heating element (26) comprising: first and second sections (32, 34) continuously alternating along the predetermined path (28), each of the first sections (32) of the zone (20) providing electrical heating at a first temperature and each of the second sections (34) of the zone (20) providing electrical heating at a second temperature, the second temperature being higher than the first temperature, a continuous wire (36) extending continuously through each of the alternating first and second sections (32, 34) along the predetermined path (28), a plurality of wire sections (38), each having a wire section length (L SS) and are electrically connected to the continuous wire (36) and are arranged adjacent to one another in series along the predetermined path (28), so that each of the first sections (32) comprises one of the first wire sections and a first region (56) of the continuous wire (36) which is arranged along the wire section length (L SS ) runs, and wherein each of the wire sections (38) is spaced from an adjacent wire section (38) by a gap (54), the continuous wire (36) extending across each of the gaps (54) such that each of the second sections (34) comprises a second region (58) of the continuous wire (36) extending across the gap length (L g ) extends. [2] Seat assembly according to claim 1, wherein the wire section lengths (L SS ) along the predetermined path (28) are substantially constant. [3] Seat assembly according to claim 1, wherein at least one of the wire section lengths (L SS ) from another of the wire section lengths (L SS ) along the given path (28). [4] A seat assembly according to any preceding claim, wherein each of the first sections (32) includes a common number of wire sections (38). [5] A seat assembly according to any preceding claim, wherein each of the wire segments (38) is arranged parallel to the continuous wire (36) and has a first end (40) and a second end (42), the first and second ends (40, 42) of each of the wire sections (38) being spaced from respective first and second ends (40, 42) of a respective adjacent wire section (38), and the wire sections (38) in at least one of the first sections (32) being arranged in a wire section grouping (44) having a cross-sectional area (46) defining a perimeter (50). [6] Seat assembly according to claim 5, wherein the continuous wire (36) is arranged on the periphery (50) of the cross-sectional area (46) of one of the wire section groupings (44). [7] A seat assembly according to any one of claims 5 and 6, wherein the continuous wire (36) is disposed within the perimeter (50) of the cross-sectional area (46) of one of the wire section groupings (44). [8] Seat structure (10) with: a seat body (12) with a seat body seat surface (16); a backrest (14) coupled to the seat body (12), the backrest (14) having a backrest seating surface (18) and at least one of the seat body seating surface (16) and the backrest seating surface (18) having a temperature-controlled zone (20), a heating element (26) arranged along a predetermined path (28) in the zone (20), the heating element (26) being configured to provide variable temperature electrical heating to the zone (20) along the predetermined path (28), the heating element (26) comprising: first and second sections (32, 34) continuously alternating along the predetermined path (28), each of the first sections (32) of the zone (20) providing electrical heating at a first temperature and each of the second sections (34) of the zone (20) providing electrical heating at a second temperature, the second temperature being higher than the first temperature, a first continuous conductor (136) and a second continuous conductor (137) each extending continuously through each of the alternating first and second sections (32, 34) along the predetermined path (28), a plurality of first conductor sections (138), each conductor section having a first conductor section length (L CS1 ) and electrically connected to the first continuous conductor (136) and arranged adjacent to each other in series along the predetermined path (28), a plurality of second conductor sections (139), each second conductor section (139) having a second conductor section length (L CS2 ) and is electrically connected to the second continuous conductor (137) and arranged adjacent to each other in series along the predetermined path (28), where the first conductor section lengths (L CS1 ) to the second conductor section lengths (L CS2) are aligned along the predetermined path (28) such that each of the first sections (32) comprises the aligned first and second conductor sections (138, 139) and a first region (150) of each of the first and second continuous conductors (136, 137) extending along the aligned first and second conductor section lengths (L CS1 , L cs2 ) extends, contains, wherein each of the first conductor sections (138) is spaced from an adjacent first conductor section (138) by a first gap (154) having a first gap length (L g1 ), and wherein each of the second conductor sections (139) is spaced from an adjacent second conductor section (139) by a second gap (156) having a second gap length (L g2 ) and where the first gap lengths (L g1 ) are aligned to the second gap lengths (L g2) along the predetermined path (28), wherein each of the second sections (34) includes a second region (158) of each of the first and second continuous conductors (136, 137) extending across the aligned first and second gap lengths (L g1 , L g2 ) extends. [9] A seat assembly according to claim 8, wherein each of the aligned first and second gap lengths (L g1 , L g2 ) along the predetermined path (28) is substantially constant. [10] Seat assembly according to claim 8, wherein at least one of the aligned first and second gap lengths (L g1 , L g2 ) is different from another of the aligned first and second gap lengths (L g1 , L g2 ) along the specified path (28). [11] Seat assembly according to any one of claims 8-10, wherein each of the aligned first and second gap lengths (L g1 , L g2) is defined in a range between 1 mm and 5 mm. [12] Seat assembly according to any one of claims 8-11, wherein each of the aligned first and second conductor section lengths (L CS1 , L cs2 ) along the predetermined path (28) is substantially constant. [13] Seat assembly according to any one of claims 8-11, wherein at least one of the aligned first and second conductor section lengths (L CS1 , L cs2 ) differs from another of the aligned first and second conductor section lengths (L CS1 , L cs2 ) along the specified path (28). [14] The seat assembly of any one of claims 8-13, wherein the first continuous conductor (136) and the first conductor portions (138) are electrically connected in parallel with the second continuous conductor (137) and the second conductor portions (139), and wherein the heating element (26) includes a first insulating layer (160) surrounding the first continuous conductor (136) and the first conductor portions (138), and a second insulating layer (162) surrounding the second continuous conductor (137) and the second conductor portions (139), such that the first and second insulating layers (160, 162) electrically insulate the first continuous conductor (136) and the first conductor portions (138) from the second continuous conductor (137) and the second conductor portions (139) along the predetermined path (28). [15] The seat assembly of any one of claims 8-14, wherein each of the first and second continuous conductors (136, 137) is defined as a core and each of the plurality of first and second conductor portions (138, 139) is further defined as a covering portion surrounding a respective one of the first and second continuous conductors (136, 137) and having a tubular shape of substantially constant thickness, and wherein each of the first gaps (154) is defined in a radial direction with respect to the first continuous conductor (136) and wherein each of the second gaps (156) is defined in a radial direction with respect to the second continuous conductor (137). [16] The seat assembly of any of claims 8-14, wherein the first and second continuous conductors (136, 137) are further defined as a continuous wire (36) and each of the plurality of first and second conductor sections (138, 139) is further defined as a wire section (38), wherein the first conductor sections (138) are arranged in first conductor section groupings (164) and wherein the second conductor sections (139) are arranged in second conductor section groupings (166), wherein each of the first conductor section groupings (164) has a common number of first conductor sections (138) and each of the second conductor section groupings (166) has a common number of second conductor sections (139). [17] Structure with: a vehicle component having at least one zone (20) whose temperature is controlled, a heating element (26) mounted in the vehicle component and arranged along a predetermined path (28) in the zone (20), the heating element (26) being configured to provide variable temperature electrical heating to the zone (20) along the predetermined path (28), the heating element (26) comprising: first and second sections (32, 34) alternating along the predetermined path (28), each of the first sections (32) of the zone (20) providing electrical heating at a first temperature and each of the second sections (34) of the zone (20) providing electrical heating at a second temperature, the second temperature being higher than the first temperature, a continuous conductor (36) extending continuously through each of the alternating first and second sections (32, 34) along the predetermined path (28), a plurality of conductor sections (138, 139), each defining a conductor section length and electrically connected to the continuous conductor (36) and arranged adjacent to one another in series along the predetermined path (28), such that each of the first sections (32) includes one of the first conductor sections (138) and a first region (150) of the continuous conductor (36) extending along the conductor section length, and wherein each of the conductor sections (138, 139) is spaced from an adjacent conductor section by a gap defining a gap length, the continuous conductor (36) extending through each of these gaps such that each of the second sections (34) includes a second portion (158) of the continuous conductor (36) extending across the gap length. [18] The assembly of claim 17, wherein the vehicle component is further defined as a seat assembly (10) having a seat bottom body (12) with a seat body seating surface (16) and a backrest (14) coupled to the seat bottom body (12), the backrest (14) having a backrest seating surface (18), and at least one of the seat body seating surface (16) and the backrest seating surface (18) having the zone (20), each of the first portions (32) defining a first heating area (60) on at least one of the seat body seating surface (16) and the backrest seating surface (18), and each of the second portions (34) defining a second heating area (62) on at least one of the seat body seating surface (16) and the backrest seating surface (18), the second heating area (62) being larger than the first heating area (60). [19] The assembly of any one of claims 17-18, wherein the heating element (26) has a first portion (64) extending along the predetermined path (28) and a second portion (66) disposed adjacent to the first portion (64) and extending along the predetermined path (28), the first and second portions (64, 66) of the heating element (26) being arranged parallel to each other and connected by a curve (68) in the predetermined path (28), the curve (68) having a U-shaped configuration, and a region (70) being defined in the zone (20) between the first and second portions (64, 66), at least one of the second portions (34) being defined along at least one of the first and second portions (64, 66) of the heating element (26) such that the second heating region (62) extends into the region (70). [20] The assembly of any one of claims 17-19, wherein each of the first sections (32) defines a first electrical spacing resistance along the predetermined path (28) and each of the second sections (34) defines a second electrical spacing resistance along the predetermined path (28), the second electrical spacing resistance being greater than the first electrical spacing resistance. [21] An assembly according to any one of claims 17-20, wherein the gap lengths along the predetermined path (28) are substantially constant. [22] The assembly of any of claims 17-20, wherein at least one of the gap lengths is different from another of the gap lengths along the predetermined path (28). [23] The structure of any one of claims 17-22, wherein each of the gap lengths is defined in a range between 1 mm to 5 mm. [24] The assembly of any one of claims 17-23, wherein the first temperature is further defined as being within a first temperature range including a minimum and a maximum of the first range, and the second temperature is further defined as being within a second temperature range including a minimum and a maximum of the second range, the minimum of the second range being greater than the maximum of the first range. [25] The assembly of any one of claims 17-24, further comprising a power source (30) connected to the heating element (26) for supplying power to the heating element (26) such that the heating element (26) provides the variable temperature electrical heating.

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