Vehicle Subassembly

Abstract

Aspects of the present invention relate to a vehicle subassembly and a vehicle. The vehicle subassembly (50) includes a non-planar surface (63) and an air flow device (10) having an outlet (16) through which an air flow is discharged. The air flow device (10) is positioned relative to the non-planar surface (63) such that the outlet (16) directs the discharged air flow substantially parallel to or toward a portion of the non-planar surface (63), and the air flow follows the contour of the non-planar surface (63).

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE Aspects of the present disclosure relate to a vehicle subassembly and a vehicle. [Background technology]

[0002] It is known to heat or cool one or more occupants in a vehicle by heating or cooling the air inside the vehicle cabin. This type of heating and cooling system consumes a relatively large amount of energy due to the large volume of air inside the vehicle cabin. Summary of the Invention [Problem to be solved by the invention]

[0003] SUMMARY OF THE INVENTION It is an object of the present invention to overcome one or more of the disadvantages associated with the prior art.

[0004] Aspects and embodiments of the present invention provide a vehicle subassembly and a vehicle as set out in the accompanying claims. [Means for solving the problem]

[0005] According to one aspect of the present invention, there is provided an airflow device having an outlet through which airflow is discharged, the airflow device being mountable to a non-planar surface of a vehicle, the outlet directing the discharged airflow substantially parallel to or towards a portion of the non-planar surface such that the airflow follows the contours of the non-planar surface.

[0006] According to another aspect of the present invention, there is provided a vehicle subassembly including a non-planar surface and an airflow device having an outlet through which an airflow is discharged, the airflow device being positioned relative to the non-planar surface such that the outlet directs the discharged airflow substantially parallel to or toward a portion of the non-planar surface, the airflow following the contour of the non-planar surface.

[0007] Directing airflow over a non-planar surface in this manner utilizes the Coanda effect, allowing the airflow to follow the contours of the surface. This allows the airflow device to be located away from the vehicle surface that generates the airflow. Therefore, the airflow device can be hidden or located away from the surface so as not to interfere with other functions of the surface.

[0008] In certain embodiments, the vehicle subassembly includes a heater and / or cooler for heating and / or cooling the air flow before it is discharged through the outlet.

[0009] In certain embodiments, the airflow device includes an airflow generator and a duct, the duct including an inlet at a first end and an outlet at a second end, the inlet positioned to receive airflow from the airflow generator and direct the airflow toward the outlet.

[0010] The presence of a duct can be advantageous in controlling the direction of air exiting the airflow generator to the outlet.

[0011] In certain embodiments, the first cross-sectional dimension of the duct increases along a path within the duct from the inlet to the outlet, and the first cross-sectional dimension is perpendicular to the path at any point along the path.

[0012] Alternatively, in certain embodiments, the second cross-sectional dimension of the duct decreases along a path within the duct from the inlet to the outlet, the second cross-sectional dimension being perpendicular to the path at any point along the path.

[0013] In certain embodiments in which a first cross-sectional dimension of the duct increases along the path, a second cross-sectional dimension of the duct decreases along the path, the second cross-sectional dimension is orthogonal to the path at any point along the path, and the second cross-sectional dimension is orthogonal to the first cross-sectional dimension.

[0014] By widening the duct in the first dimension and narrowing it in the second dimension, it is possible to create airflow that is favorable for enhancing the Coanda effect.

[0015] In certain embodiments, the outlet comprises an elongated opening that, when parallel to a majority of the non-planar surface, allows for particularly effective air evacuation and can enhance the Coanda effect: the Coanda effect of the airflow is enhanced when a substantial periphery of the cross section (perpendicular to the direction of flow) of the airflow exiting the outlet contacts the non-planar surface.

[0016] Optionally, the vehicle subassembly may include a deflector positioned adjacent to or coincident with the outlet to deflect the flow of air, the deflector being able to advantageously direct the air from the outlet.

[0017] In certain embodiments, the vehicle subassembly may include a deflector positioned adjacent to the outlet of the duct, the deflector including first and second opposing side walls that diverge in a downstream direction of airflow through the deflector such that a cross-sectional area of ​​the deflector increases in the downstream direction.

[0018] The deflector may include a plurality of vanes substantially evenly spaced between a first sidewall and a second sidewall, and in certain embodiments, the plurality of vanes are arranged in a fan shape between the first and second sidewalls of the deflector.

[0019] Optionally, the deflector is positioned to deflect the air flow towards a portion of the non-planar surface. Deflecting the air flow towards a portion of the non-planar surface may enhance the Coanda effect.

[0020] In certain embodiments, the non-planar surface has at least one protrusion, and the air flow device is positioned relative to the at least one protrusion such that, in use, the discharged air flow follows the contour of the at least one protrusion. In such embodiments, the Coanda effect can be utilized to effectively redirect the air flow around a corner defined by the protrusion.

[0021] Optionally, the radius of curvature of at least one convex portion is at least 10 mm, or at least 15 mm. The cohesion (or adhesion) of the air flow to the surface, and therefore its ability to follow the convex surface, is particularly effective at such radii.

[0022] In certain embodiments, the non-planar surface includes a plurality of recesses arranged to manipulate the attachment or separation of the exhausted airflow. The presence of the plurality of recesses may facilitate the attachment or separation of the airflow from the surface, depending on the configuration of the plurality of recesses.

[0023] In certain embodiments, the plurality of recesses are uniformly distributed. In certain embodiments, each of the plurality of recesses is located on a vertex of a tessellated polygon. Optionally, the tessellated polygon is one of a triangle, a square, or a hexagon.

[0024] In certain embodiments, the successive spacing between adjacent recesses of the plurality of recesses increases in at least one direction along the surface, hi certain embodiments, the successive spacing between adjacent recesses of the plurality of recesses decreases in at least one direction along the surface.

[0025] In certain embodiments, the spacing between adjacent recesses in the plurality of recesses (72) is between 0.5 mm and 5 mm, optionally between 1 mm and 4 mm. In certain embodiments, each of the plurality of recesses has a width between 1 mm and 5 mm, optionally between 2 mm and 4 mm. In certain embodiments, each of the plurality of recesses has a depth between 0.1 mm and 2 mm, optionally between 0.2 mm and 1.5 mm.

[0026] In certain embodiments, at least some of the plurality of recesses are each formed as part of a sphere or a polyhedron.

[0027] Optionally, the plurality of recesses are all identical to one another. In certain embodiments, the plurality of recesses comprises recesses that are different from one another.

[0028] In certain embodiments, the surface comprises a polymeric material.

[0029] In certain embodiments, a plurality of recesses are embossed into the surface. Embossing can be a particularly effective method of forming recesses in a surface (e.g., a polymeric material such as seat trim).

[0030] In certain embodiments, the vehicle subassembly comprises a vehicle seat, and the non-planar surface forms a surface of the seat, and the above arrangement is particularly suited to directing airflow along the surface of the seat, which can be used to provide heating or cooling to an occupant of the seat.

[0031] Optionally, the seat includes a seat pad, and the non-planar surface forms a surface of the seat pad. Directing airflow along the surface of the seat pad can be a particularly effective way of providing heating or cooling to a seat occupant.

[0032] Optionally, the surface of the seat pad includes an upper surface for receiving a seated occupant and at least one side surface, and the air flow device is mounted such that the outlet directs the discharged air flow substantially parallel to or towards the at least one side surface, and such that the air flow follows the contour of the surface along at least a portion of the upper surface.

[0033] By directing the air flow to the sides of the seat pad, the air flow device can be placed out of sight and / or in a location that does not interfere with other functions of the seat.

[0034] Optionally, the vehicle subassembly includes a connection between the top surface and each of the at least one side surface, the connection being convex. In such an embodiment, air flow may be advantageously directed around the convex connection from the at least one side surface to the top surface.

[0035] In certain embodiments, the connection forms a bolster for the seat, such that the upper surface can be separated from the outlet of the airflow device by the bolster, and airflow can travel along and around the bolster to reach the upper surface and an occupant therein.

[0036] In certain embodiments, the vehicle subassembly includes an additional airflow device, the outlet of which is mounted to direct the additional exhaust airflow substantially parallel to or toward another of the at least one side surface and to cause the airflow to follow the surface contour and along at least a portion of the top surface. The use of additional airflow devices can further enhance the above benefits and provide additional airflow at different locations.

[0037] In certain embodiments, the seat includes a seat back, and the non-planar surface forms a surface of the seat back. Directing airflow along the surface of the seat back can be a particularly effective way to provide heating or cooling to a seat occupant.

[0038] In certain embodiments, the seat back surface includes a back surface for receiving a seated occupant and at least one side of the seat back, and the air flow device is mounted such that the outlet directs the discharged air flow substantially parallel to or toward at least one side of the seat back, such that the air flow follows the contour of the surface and along at least a portion of the back surface.

[0039] By directing the air flow toward the sides of the seat back, the air flow device can be placed in a location that is out of sight and / or does not interfere with other functions of the seat.

[0040] Optionally, the vehicle subassembly includes a seat back connection between the back surface and each of the at least one seat back side, the seat back connection being convex. In such an embodiment, air flow may be advantageously directed around the convex seat back connection from the at least one side to the back surface.

[0041] Optionally, the seat back connection forms a protruding wing of the seat. In this way, the back surface can be separated from the outlet of the air flow device by the protruding wing, and air flow can be directed along and around the protruding wing to reach the back surface and the seat occupant.

[0042] In certain embodiments, the vehicle subassembly includes a further airflow device mounted such that an outlet of the further airflow device directs a further exhaust airflow substantially parallel to or toward another of the at least one seat back side surface, the airflow following the contour of the surface and along at least a portion of the seat back surface. The use of additional airflow devices can further enhance the above benefits and provide additional airflow at different locations.

[0043] In certain embodiments, the airflow device is located substantially within the boundaries of the seat, for example, only the outlet or only a portion of the duct may be located outside the boundaries of the seat, such that substantially all of the airflow device is hidden.

[0044] According to another aspect of the present invention, there is provided a vehicle including the vehicle subassembly described above.

[0045] According to one aspect of the present invention, there is provided a vehicle subassembly including an air flow device and a surface of a vehicle component having a plurality of recesses formed therein and positioned to manipulate the attachment or separation of air flow from an outlet of the air flow device substantially parallel to or toward a portion of the surface.

[0046] By providing a surface with a plurality of depressions, the attachment and / or separation of air flow can be manipulated, thereby enhancing or manipulating the Coanda effect exhibited by air flow along the surface.

[0047] In certain embodiments, the surface is a non-planar surface and the plurality of recesses are arranged to direct the air flow along the contours of the surface.

[0048] The Coanda effect allows airflow to follow the contours of the road surface, allowing airflow devices to be located away from the vehicle surface that generates the airflow, so that the airflow device can be concealed or otherwise located away from the surface so as not to interfere with other functions of that surface.

[0049] In certain embodiments, the plurality of recesses are uniformly distributed. In certain embodiments, each of the plurality of recesses is located on a vertex of a tessellated polygon. Optionally, the tessellated polygon is one of a triangle, a square, or a hexagon.

[0050] In certain embodiments, the successive spacing between adjacent recesses of the plurality of recesses increases in at least one direction along the surface. In certain embodiments, the successive spacing between adjacent recesses of the plurality of recesses decreases in at least one direction along the surface. In certain embodiments, the spacing between adjacent recesses of each of the plurality of recesses is between 0.5 mm and 5 mm, optionally between 1 mm and 4 mm. In certain embodiments, the width of each of the plurality of recesses is between 1 mm and 5 mm, optionally between 2 mm and 4 mm. In certain embodiments, the depth of each of the plurality of recesses is between 0.1 mm and 2 mm, optionally between 0.2 mm and 1.5 mm.

[0051] In certain embodiments, at least some of the plurality of recesses are each formed as part of a sphere or a polyhedron. Optionally, all of the plurality of recesses are identical to one another. In certain embodiments, the plurality of recesses includes different recesses.

[0052] In certain embodiments, the surface comprises a polymeric material.

[0053] In certain embodiments, a plurality of recesses are embossed into the surface. Embossing can be a particularly effective method of forming recesses in a surface (e.g., a polymeric material such as seat trim).

[0054] In a particular embodiment, the vehicle subassembly includes a seat and the surface is a seat surface, and the above arrangement is particularly suited to directing airflow along the seat surface, which can be used to provide heating or cooling to an occupant sitting in the seat.

[0055] Optionally, the seat includes a seat pad, and said surface forms a surface of the seat pad. Directing airflow along the surface of the seat pad can be a particularly effective way of providing heating or cooling to a seat occupant.

[0056] Optionally, the surface of the seat pad includes an upper surface for receiving a seated occupant and at least one side surface, and the airflow device is mounted such that the outlet directs the discharged airflow substantially parallel to or towards the at least one side surface, causing the airflow to flow along at least a portion of the upper surface following the contour of the surface.

[0057] By directing the air flow to the sides of the seat pad, the air flow device can be placed out of sight and / or in a location that does not interfere with other functions of the seat.

[0058] Optionally, the vehicle subassembly includes a convex connection between the top surface and at least one side surface. Optionally, the connection forms a bolster for the seat.

[0059] In certain embodiments, the vehicle subassembly includes an additional airflow device mounted to direct the outlet discharged airflow substantially parallel to or toward another of the at least one side surface, causing the airflow to follow the surface contour and flow along at least a portion of the top surface. The use of additional airflow devices can further enhance the above benefits and provide additional airflow at different locations.

[0060] In certain embodiments, the seat includes a seat back, and the non-planar surface forms a surface of the seat back. Directing airflow along the surface of the seat back can be a particularly effective way to provide heating or cooling to a seat occupant.

[0061] In certain embodiments, the seat back surface includes a backrest surface for receiving a seated occupant and at least one seat back side surface, and the air flow device is mounted such that the outlet directs the discharged air flow substantially parallel to or toward at least one seat back side surface, causing the air flow to follow the contours of the surface and along at least a portion of the backrest surface.

[0062] By directing the air flow toward the sides of the seat back, the air flow device can be placed in a location that is out of sight and / or does not interfere with other functions of the seat.

[0063] Optionally, the vehicle subassembly includes a seat back connection between the back surface and each of the at least one seat back side, the seat back connection being convex. In such an embodiment, air flow may be advantageously directed around the convex seat back connection from the at least one side to the back surface.

[0064] Optionally, the seat back connection forms a protruding wing on the seat, whereby the back surface is separated from the outlet of the air flow device by the protruding wing and the air flow is directed along and around the protruding wing to reach the back surface and an occupant in the seat.

[0065] In certain embodiments, the vehicle subassembly includes an additional airflow device mounted to direct the outlet discharged airflow substantially parallel to or toward another of the at least one seat back side surface, causing the airflow to follow the surface contour and along at least a portion of the seat back surface. The use of additional airflow devices can further enhance the above benefits and provide additional airflow at different locations.

[0066] In certain embodiments, the airflow device is located substantially within the boundaries of the seat, for example, only the outlet or only a portion of the duct may be located outside the boundaries of the seat, so that substantially all of the airflow device may be hidden.

[0067] According to another aspect of the present invention, there is provided a vehicle including a vehicle subassembly as described above.

[0068] Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples, and alternatives described in the preceding paragraphs, claims, and / or the following description and drawings, in particular their individual features, may be employed independently or in any combination. That is, all embodiments and / or features of embodiments may be combined in any manner and / or combination, unless such features are incompatible. The applicant reserves the right to modify the originally filed claims or to submit new claims accordingly, including the right to amend the originally filed claims to depend on and / or incorporate features of other claims, even if not originally claimed as such.

[0069] One or more embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings. [Brief explanation of the drawings]

[0070] [Figure 1] FIG. 1 shows an air flow device according to one embodiment of the present invention. [Figure 2]FIG. 2 is a cross-sectional view of a vehicle subassembly including a portion of a vehicle seat and the air flow device of FIG. [Figure 3] FIG. 3 is a perspective view of the vehicle subassembly of FIG. [Figure 4] FIG. 4 shows a vehicle seat incorporating a plurality of air flow devices according to claim 1. [Figure 5] FIG. 5 illustrates modeling of fluid dynamic behavior for a vehicle subassembly including a surface with a 5 mm radius of curvature, according to one embodiment of the present invention. [Figure 6] FIG. 6 illustrates modeling of fluid dynamic behavior for a vehicle subassembly including a surface with a 10 mm radius of curvature, according to one embodiment of the present invention. [Figure 7] FIG. 7 illustrates modeling of fluid dynamic behavior for a vehicle subassembly including a surface with a 15 mm radius of curvature, according to one embodiment of the present invention. [Figure 8] FIG. 8 illustrates modeling of fluid dynamic behavior for a vehicle subassembly including a surface with a 20 mm radius of curvature, according to one embodiment of the present invention. [Figure 9] FIG. 9 illustrates modeling of fluid dynamic behavior for a vehicle subassembly including a surface with a 25 mm radius of curvature, according to one embodiment of the present invention. [Figure 10] FIG. 10 illustrates modeling of fluid dynamic behavior for a vehicle subassembly including a surface with a 30 mm radius of curvature, according to one embodiment of the present invention. [Figure 11] FIG. 11 illustrates modeling of fluid dynamic behavior for a vehicle subassembly including a surface with a 35 mm radius of curvature, according to one embodiment of the present invention. [Figure 12] FIG. 12 illustrates modeling of fluid dynamic behavior for a vehicle subassembly including a surface with a 40 mm radius of curvature, according to one embodiment of the present invention. [Figure 13] FIG. 13 shows a portion of the surface of a vehicle part according to one embodiment of the present invention. [Figure 14] FIG. 14 shows a portion of the surface of a vehicle part according to another embodiment of the present invention. [Figure 15]FIG. 15 shows a portion of the surface of a vehicle part according to another embodiment of the present invention. [Figure 16] FIG. 16 shows a portion of the surface of a vehicle part according to another embodiment of the present invention. [Figure 17] FIG. 17 shows a vehicle according to one embodiment of the present invention. [Figure 18a] 18a and 18b are front and rear views of a deflector of an air flow device according to one embodiment of the present invention. [Figure 18b] 18a and 18b are front and rear views of a deflector of an air flow device according to one embodiment of the present invention. [Figure 19] Figure 19 is a perspective view of the underside of a vehicle seat with the seat pad removed, showing a cutaway view of the duct of an air flow device according to one embodiment of the present invention, as well as the deflector of Figures 18a and 18b. DETAILED DESCRIPTION OF THE INVENTION

[0071] An air flow device 10 according to one embodiment of the present invention will now be described with reference to accompanying Figure 1. As shown in Figures 2 and 3, the air flow device 10 forms part of a vehicle subassembly 50 which further includes a non-planar surface 63. As shown in Figure 4, the subassembly 50 may form part of a vehicle seat 60. The subassembly 50 may be installed in a vehicle 100 as shown in Figure 17, either as part of the vehicle seat 60 or as part of another vehicle assembly. The vehicle 100 in this embodiment is an automobile, such as a wheeled vehicle, although it will be appreciated that the vehicle subassembly may also be used in other types of vehicles, such as aircraft or watercraft.

[0072] As will be described in more detail below, in accordance with embodiments of the present invention, airflow device 10 is positioned relative to non-planar surface 63 such that the discharged airflow is directed substantially parallel to or toward a portion of non-planar surface 63, and such that the airflow follows the contours of non-planar surface 63. In particular, embodiments of the present invention are configured to utilise the Coanda effect to steer the airflow along the contours of non-planar surface 63.

[0073] 1, airflow device 10 is configured to generate a flow of air that is discharged from airflow device 10 through outlet 16. In the non-limiting embodiment shown in FIGS. 1 and 2, airflow device 10 includes an airflow generator 12 for generating the air flow and a duct 14 that directs the air flow from airflow generator 12 to outlet 16, which forms part of duct 14. Airflow generator 12 may include any suitable means for generating the air flow, including, but not limited to, a fan, a pump, or any device configured to generate a pressure differential.

[0074] As shown in FIG. 2 , the duct 14 has an inlet 15 at a first end 14 a connected to the airflow generator 12, and an outlet 16 is located at a second end 14 b of the duct 14 opposite the first end 14 a. The inlet 15 is positioned to receive the airflow from the airflow generator 12, and the duct 14 directs the airflow to and discharges it from the outlet 16. In the non-limiting embodiment shown in FIG. 2 , the airflow device 10 includes a deflector 18 at the outlet 16, which is configured to deflect the airflow discharging from the outlet 16, thereby determining the direction of the airflow. In embodiments of the present invention, the deflector 18 may be any suitable component capable of directing the airflow in a desired direction. While the non-limiting embodiment of FIG. 2 shows the deflector 18 aligned with the outlet 16, in alternative embodiments including the deflector 18, the deflector 18 may be positioned near the outlet 16 to deflect and direct the airflow. Indeed, in certain embodiments, deflector 18 may form part of duct 12, while in other embodiments, deflector 18 may be a separate component that may be optionally positioned separate from duct 14. In certain embodiments, air flow device 10 may be positioned relative to non-planar surface 63 so that the flow of air discharged from outlet 16 is directed toward non-planar surface 63, i.e., so that the direction of the discharged air flow forms an oblique angle with the portion of non-planar surface 63 upon which it is incident. In another embodiment, air flow device 10 may be positioned relative to non-planar surface 63 so that the flow of air discharged from outlet 16 is substantially parallel to non-planar surface 63. As noted above, in embodiments that include deflector 18, it is deflector 18 that determines the direction of the discharged flow or air.

[0075] 2, airflow device 10 includes a temperature controller 13, which may include a heater and / or cooler for heating and / or cooling the airflow before it is discharged through outlet 16. In such an embodiment, airflow device 10 may provide heated / cooled air to one or more vehicle occupants, and / or the cabin of the vehicle, and / or one or more components of the vehicle.

[0076] 2, the airflow generated by the airflow generator 12 passes through the duct 14 along a flow path 20 and is discharged through the outlet 16. Depending on the shape of the duct 14, the flow path 20 may not be a straight line as shown in FIG.

[0077] The shape of the duct 14 can be configured to provide a desired airflow rate and profile at the outlet 16. For example, referring to FIG. 1, a first cross-sectional dimension of the duct 14 increases along a path within the duct from the inlet 15 to the outlet 16. This is evident by comparing the dimensions W1 and W2 at the first and second ends 14a and 14b of the duct 14 in FIG. 1. This first cross-sectional area is perpendicular to the path at any point along the path. Conversely, a second cross-sectional area of ​​the duct 14 decreases along the path from the inlet 15 to the outlet 16. This is evident by comparing the dimensions L1 and L2 at the first and second ends 14a and 14b of the duct 14 in FIG. 1. The second cross-sectional dimension is perpendicular to both the first cross-sectional dimension and the path at any point along the path.

[0078] By widening the duct 14 in one dimension and narrowing it in an orthogonal direction, an airflow is created that enhances the downstream Coanda effect. In certain embodiments, beneficial airflow may be created by widening the duct without narrowing it in an orthogonal direction, or by narrowing the duct in one dimension without widening it in an orthogonal direction. In certain embodiments, the outlet 16 may have other configurations and still include an elongated opening to produce a similar beneficial effect.

[0079] As mentioned above, the airflow device 10 forms part of a vehicle subassembly 50 that includes a combination of the airflow device 10 and a non-planar surface 63. In the illustrated embodiment, the non-planar surface 63 is shown as a surface of a vehicle seat 60, although embodiments of the present invention are not limited in this regard. Indeed, in alternative embodiments, the non-planar surface of the vehicle subassembly 50 can include any non-planar surface of a vehicle component along whose contour it is desired that air flow follow.

[0080] 3 shows a perspective view of the vehicle subassembly 50 of FIG. 2, showing a portion of the vehicle seat 60 and the outlet 16 and associated deflector 18 of the air flow device 10. The remainder of the air flow device 10 cannot be seen, as it is located within the confines of the vehicle seat 60 and is hidden from view.

[0081] As shown in FIGS. 2 and 3, the seat 60 includes a seat pad 62, and the non-planar surface 63 forms the surface of the seat pad 62. The surface 63 of the seat pad 62 includes an upper surface 63b that receives a seated occupant and a pair of side surfaces 63a that are connected to opposite sides of the upper surface 63b along connecting portions 62a. The connecting portions 62a are generally convex, such that at least a portion of the side surfaces 63a is approximately perpendicular to the upper surface 63b. As shown in FIGS. 3 and 4, in certain embodiments, the connecting portions 62a each extend from the side surfaces 63a to a height higher than the height of the upper surface 63b and transition downward to the upper surface 63b. As a result, the connecting portions 62a form the surfaces of bolsters that protrude on both sides of the seat pad 62.

[0082] The outlet 16 of the air flow device 10 passes through or is positioned near at least one of the side surfaces 63a and is positioned (together with the deflector 18, if present) to direct the discharged air flow substantially parallel to or toward a portion of each side surface 63a, causing the air flow to follow the contour of the surface 63 along each side surface 63a, the connecting portion 62a, and the top surface 63b. That is, by directing the air flow substantially parallel to or toward a portion of the side surfaces 63a, the Coanda effect can be utilized to generate air flow along the top surface 63b. Furthermore, because the air flow can be provided along the desired surface without first ejecting the air flow from the air flow device 10 toward that surface, the outlet 16 of the air flow device 10 (and the air flow device 10 as a whole) can be positioned in a more discreet location within the vehicle (e.g., a location that is not visible or is less visible to vehicle occupants).

[0083] In certain embodiments, multiple airflow devices 10 may be employed to provide multiple airflows across the surface of a vehicle seat 60 (or other vehicle component). In certain embodiments, each side 63a of the seat pad 62 is provided with a corresponding outlet 16 of an airflow device 10, with each airflow device 10 positioned to ultimately provide an airflow across the upper surface 63b. In use, the airflow impinges on a seated occupant on the upper surface 63b. The temperature of the airflow may be heated or cooled by a temperature controller 13 to provide an airflow of a desired temperature to the occupant.

[0084] As shown in FIG. 4, the seat 60 includes a seat pad 62, a seat back 64, and a headrest 66. A second non-planar surface 65 forms the surface of the seat back 64 and includes two opposing seat back side surfaces 65a and a backrest surface 65b against which a seat occupant can lean. The pair of seat back side surfaces 65a are connected to opposite sides of the backrest surface 65b along seat back connection portions 64a. The seat back connection portions 64a are generally convex so that at least a portion of the seat back side surfaces 65a is approximately perpendicular to the backrest surface 65b. In the particular embodiment shown in FIG. 4, each seat back connection portion 64a extends forward from the seat back side surfaces 65a, is located forward of the plane of the backrest surface 65b, and then transitions rearward to the backrest surface 65b. As a result, the seat back connection portions 64a form protruding wings on both sides of the seat back 64.

[0085] The outlets 16 of the additional airflow devices 10 are positioned through or near at least one of the seatback sides 63 a and are arranged (together with deflectors 18, if present) to direct the discharged airflow substantially parallel to or toward a portion of the seatback side 65 a of the respective seat, such that the airflow follows the contours of the surface 65 along the respective seatback side 65 a, seatback connection 64 a, and backrest surface 65 b. That is, by directing the airflow substantially parallel to or toward a portion of the seatback side 65 a, the Coanda effect can be utilized to generate an airflow along the backrest surface 65 b. In certain embodiments, each seatback side 65 a of the seatback 64 is provided with a corresponding outlet 16 of an airflow device 10, and each airflow device 10 is arranged to provide an airflow that ultimately crosses the backrest surface 65 b. In use, the airflow impinges on the top of the seat occupant. The air in the air stream is heated or cooled by a temperature controller 13 to provide the air stream at the desired temperature for the occupant.

[0086] In certain embodiments, the seat 60 may include one or more air flow devices 10 that provide air flow to either or both of the seat pad 62 and the seat back 64 , or any other portion of the seat 60 .

[0087] FIGS. 5 through 12 each visually illustrate the computational fluid dynamics (CFD) modeled behavior of a vehicle subassembly 50 according to the embodiment shown in FIGS. 2 through 4. The grayscale in the images represents "velocity:magnitude (m / s)," i.e., the magnitude of air velocity in meters per second. Each vehicle subassembly 50 in FIGS. 5 through 12 has a different radius of curvature for the convex connector 62a connecting the side surface 63a to the top surface 63b, and each illustration shows how this affects the airflow from the outlet 16 along the non-planar surface 63. In FIG. 5, the radius of curvature of connector 62a is 5 mm, in FIG. 6 it is 10 mm, in FIG. 7 it is 15 mm, in FIG. 8 it is 20 mm, in FIG. 9 it is 25 mm, in FIG. 10 it is 30 mm, in FIG. 11 it is 35 mm, and in FIG. 12 it is 40 mm.

[0088] As shown in FIG. 5, when the radius of curvature is 5 mm, although some air flows around the convex connecting portion 62a, the air flows separate before reaching the upper surface 63b and do not flow along the upper surface 63b.

[0089] Figure 6 shows that for a slightly larger radius of curvature of 10 mm, the attachment of the air flow to the non-planar surface 63 results in a greater deflection (i.e., change of direction) of the air flow compared to the flow shown in Figure 5. However, again, the air flow separates before reaching upper surface 63b, so it does not flow along upper surface 63b. Nevertheless, the deflection of the air flow direction due to the Coanda effect may be sufficient to direct the air flow toward the seat occupant.

[0090] In FIG. 7 , where the radius of curvature is 15 mm, it can be clearly seen that the Coanda effect causes airflow to attach to non-planar surface 63 and follow its convex contour around and above connecting portion 62a and 63b. This air attachment and resulting flow around and above connecting portion 62a and 63b also manifests at larger radii or curvatures, as shown in FIGS. 8-12 . In certain embodiments of the present invention, non-planar surface 63 may have at least one convex portion (e.g., connecting portion 62a or seatback connecting portion 64a) having a radius of curvature of at least 10 mm. In certain embodiments, the radius of curvature of at least one convex portion may be at least 15 mm. As noted above, in use, airflow device 10 is positioned relative to at least one convex portion such that the discharged airflow follows the contour of the at least one convex portion. In embodiments in which non-planar surface 63 forms part of a vehicle component (e.g., a vehicle seat) with which a user or occupant interacts, the presence of the user or occupant may change the radius of curvature of the convex portion of non-planar surface 63. Thus, in certain embodiments, the radius of curvature of the convex portion is selected taking into account deformations that may be caused by the presence of a user or occupant, such that a desired, or at least acceptable (i.e., greater than the minimum desired radius) radius of curvature is achieved when the user or occupant interacts with the non-planar surface 63 (e.g., when the occupant sits in the vehicle seat). As a non-limiting illustrative example, in embodiments where the non-planar surface 63 is the surface of the vehicle seat 60, the nominal radius of curvature of the convex portion may be greater than the minimum desired radius of curvature, and a radius of curvature greater than the minimum desired radius of curvature may be achieved when the occupant sits in the seat 60. Thus, the nominal radius of curvature may be offset from the minimum desired radius of curvature by a predetermined amount. This predetermined offset may be derived taking into account the average characteristics (e.g., weight, size, etc.) of vehicle occupants and their effects on the non-planar surface 63, such that the resulting radius of curvature remains higher than the minimum desired radius of curvature when the occupant interacts with the non-planar surface 63.

[0091] As discussed above, varying the radius of curvature of the non-planar surface 63 can alter the location and / or distance of the separation point from the outlet 16 of the air flow device 10. Other parameters that may affect the location and / or distance of the air flow separation point include, but are not limited to, the flow rate of air discharged from the air flow device 10 and the angle of incidence of the discharged air flow relative to the portion of the non-planar surface 63 upon which it is incident.

[0092] Embodiments of the present invention have the advantage of being able to direct air along a surface from an airflow device 10 mounted away from the surface. Therefore, the airflow device 10 can be mounted away from the surface and hidden from the vehicle occupants. Therefore, the airflow device 10 can be installed without compromising the aesthetics or functionality of vehicle components or features. Furthermore, providing airflow across the entire surface of a vehicle component allows for efficient heating and / or cooling of vehicle occupants. Such heating and / or cooling eliminates the need for conventional seat heating / cooling systems that rely on heating / cooling seat pads (and therefore require relatively high amounts of energy) and also eliminates the need to heat large amounts of air within the vehicle cabin (and therefore require relatively high amounts of energy) as with conventional vehicle HVAC systems. Embodiments of the present invention can provide an alternative heating / cooling system for vehicle occupants or can complement one or more other heating / cooling systems.

[0093] Although at least some of the above-described embodiments relate to arrangements in which the non-planar surface 63 is a surface of a vehicle seat (which may be a front or rear seat), in other embodiments, the non-planar surface 63 may be a surface of any vehicle component. Examples of such vehicle components include, but are not limited to, a B-post, C-post, or D-post, a counterrail, a fascia, a center console, or a headliner.

[0094] 13-16 each illustrate a surface 70 of a vehicle component according to one embodiment of the present invention. Surface 70 includes a plurality of recesses 72 that are positioned to manipulate the attachment or separation of airflow directed substantially parallel to or toward a portion of the surface. Indeed, the presence of a plurality of recesses 72 on a surface has been found to affect the manifestation of the Coanda effect. Furthermore, the shape and relative placement of the recesses can also increase or decrease the attachment of airflow along surface 70.

[0095] In certain embodiments, the surface 70 including the plurality of recesses 72 may be non-planar and form the non-planar surface 63 described above. That is, the surface 70 including the plurality of recesses described herein may be employed in any embodiment including the non-planar surface 63 described above. The plurality of recesses 72 may manipulate the attachment or separation of the air flow, directing the air flow along the contours of the non-planar surface. For a substantially planar surface, the use of multiple recesses may maximize the attachment of the air flow at the surface. Conversely, locating multiple recesses 72 in specific areas of the surface may promote separation of the air flow from the surface. In certain embodiments, the plurality of recesses 72 may be uniformly distributed. Such an arrangement is shown in Figures 13, 14, and 15, respectively. Each of the plurality of recesses 72 may be located on a vertex of a tessellated polygon. In Figures 13, 14, and 15, the dashed lines represent the edges of the tessellated polygon. In Figure 13, the tessellated polygon is composed of parallelogram-shaped tessellated rectangles. Other tessellated shapes include squares, rectangles, and diamonds. In the arrangement shown in Figure 13, the spacing between adjacent recesses 72 is smaller than the diameter of each recess 72. In contrast, in the arrangement shown in Figure 14, the spacing between adjacent recesses 72 is larger than the diameter (or width) of each recess 72. In the arrangement shown in Figure 14, each of the multiple recesses 72 is located on a vertex of a tessellated quadrilateral (parallelogram), which also corresponds to the vertices of a tessellated triangle, shown by dashed lines in Figure 14. Indeed, in other embodiments, the tessellated polygon may be any suitable single or group of different tessellated polygons, including, but not limited to, hexagons, octagons, and dodecagons.

[0096] In certain embodiments, all of the plurality of recesses 72 may be identical to one another (as shown in the arrangements of FIGS. 13 and 14). In other embodiments, the plurality of recesses 72 are not identical to one another, such as the arrangement shown in FIG. 15. In the arrangement shown in FIG. 15, the plurality of recesses 72 includes a first set of recesses 72a of a first type and a second set of recesses 72b of a second, different type. In the non-limiting example shown in FIG. 15, the first set of recesses 72a each have a circular outline, and the second set of recesses 72b each have a hexagonal outline. In other embodiments, there may be any number of different sets of recesses, and the profile of each set is not limited to a particular shape or profile.

[0097] In certain embodiments, the spacing between adjacent recesses 72 in the plurality of recesses 72 increases in at least one direction along the surface 70. Additionally, or alternatively, the spacing between adjacent recesses 72 in the plurality of recesses 72 decreases in at least one direction along the surface 70. As an example, in the arrangement shown in Figure 16, successive spacings d1, d2, d3, d4 between adjacent recesses 72 in the plurality of recesses 72 decrease in the direction D1 along the surface 70. Viewed another way, successive spacings d4, d3, d2, d1 between adjacent recesses 72 in the plurality of recesses 72 increase in the direction D2 along the surface 70.

[0098] The three-dimensional shape of the recesses 72 is not limited to any particular shape. In certain embodiments, at least some of the recesses 72 may be formed as portions of a sphere or a polyhedron (e.g., a regular dodecahedron). The surface 70 of the recesses 72 may be composed of any suitable material and may be determined by the structural and / or aesthetic requirements of the vehicle part of which it forms a part. In certain embodiments, the surface 70 may be composed of a polymeric material (e.g., such as those typically used in vehicle seat trim). Some or each of the recesses may have a depth (i.e., depth into the surface) of 0.1 mm to 2 mm, optionally 0.2 mm to 1.5 mm. Additionally or alternatively, the width (e.g., diameter in the case of circular recesses) of some or each of the recesses may be between 1 mm and 5 mm, optionally 2 mm to 4 mm. Additionally or alternatively, the spacing between some or each of the recesses may be between 0.5 mm and 5 mm, optionally 1 mm to 4 mm.

[0099] The plurality of recesses 72 may be formed in the surface 70 by any suitable process. In certain embodiments, the plurality of recesses 72 may be formed in the surface 70 after the surface 70 is formed (e.g., in certain embodiments, the plurality of recesses 72 may be embossed into the surface 70). In other embodiments, the plurality of recesses 72 may be formed in the surface 70 during the process of forming the surface 70. In certain embodiments, the plurality of recesses 72 may be embossed into the surface 70.

[0100] 18a, 18b, and 19, in one embodiment, the vehicle subassembly 50 (described above with reference to FIGS. 1-3) is provided with a deflector 118 including a plurality of vanes 120 for controlling the flow of air from the outlet 16 of the air flow device 10. FIG. 19 is a perspective view of a portion of a vehicle seat 60 with the seat pad 62 removed. The duct 14 of the air flow device 10 (shown partially cut away for clarity) is disposed within an underside 70 of the vehicle seat 60. The underside 70 defines the exterior surface of the vehicle seat 60 below the seat pad 62 (if attached to the seat pad 62). The underside 70 of the vehicle seat 60 is provided with an opening disposed adjacent the second end 14b of the duct 14. The deflector 118 is attached to the outside of the underside 70 of the vehicle seat 60 and / or the second end 14b of the duct 14, and the air flow exiting the duct 14 is guided by the deflector 118. In some embodiments, the deflector 118 may be mounted to extend beyond the boundary between the underside 70 of the vehicle seat and the connection portion 62 a of the seat pad 62 .

[0101] As best shown in FIG. 18a, the deflector 118 includes first and second side walls 118a, 118b that flare outward such that the width of the deflector (i.e., the widthwise dimension of the deflector 118 as viewed in FIGS. 18a and 18b) increases in the downstream direction of the airflow. The flared deflector 118 laterally spreads the airflow exiting the outlet 16, allowing the airflow to spread across a greater length of the connecting portion 62a of the seat pad 62 before flowing across the non-planar surface 63 of the seat pad (or other relevant non-planar surface, depending on the embodiment). In this embodiment, five vanes 120 are evenly spaced across the width of the deflector 118 between each of the side walls 118a, 118b. As best shown in FIG. 18a, the central vane 120a is positioned substantially perpendicular to the widthwise dimension of the deflector 118. Each of the first pair of vanes 120b, located on either side of the central vane 120a, is angled away from the central vane 120a. Similarly, each of the second pair of outermost vanes 120c is angled away from the central vane 120a at an angle greater than that of the first pair of vanes 120b but substantially equal to or less than the respective angles of the first and second side walls 118a, 118b of the deflector 118. Thus, the vanes 120 fan out between the respective side walls 118a, 118b of the deflector. This configuration allows the airflow from the airflow device 10 to be more evenly distributed over a greater surface area of ​​the occupant of the vehicle seat 60, thereby improving occupant comfort and the efficiency of the airflow device 10. In an embodiment, the vanes 120 serve to reduce turbulence in the airflow exiting the outlet 16 and enhance the downstream Coanda effect. It will be appreciated that depending on the overall width of the deflector 118, more or fewer vanes may be used.

[0102] It goes without saying that the present invention is susceptible to various changes and modifications without departing from the scope of the invention.

Claims

1. 1. A vehicle subassembly including a non-planar surface and an airflow device having an outlet through which an airflow is discharged, the airflow device being positioned relative to the non-planar surface such that the outlet directs the discharged airflow substantially parallel to or toward a portion of the non-planar surface, the airflow following a contour of the non-planar surface.

2. 2. The vehicle subassembly of claim 1, wherein the airflow device includes an airflow generator and a duct, the duct having an inlet at a first end and an outlet at a second end, the inlet configured to receive airflow from the airflow generator and direct the airflow toward the outlet.

3. 3. The vehicle subassembly of claim 2, further comprising a deflector disposed adjacent an outlet of the duct, the deflector including first and second opposing side walls, the first and second side walls diverging in a downstream direction of airflow through the deflector, a cross-sectional area of ​​the deflector increasing in the downstream direction.

4. 4. The vehicle subassembly of claim 3, wherein the deflector includes a plurality of vanes substantially evenly spaced between the first and second side walls, preferably the plurality of vanes being arranged in a fan shape between the first and second side walls of the deflector.

5. 5. A vehicle subassembly as claimed in any one of claims 2 to 4, wherein a first cross-sectional dimension of the duct increases along a path within the duct from the inlet to the outlet, the first cross-sectional dimension being perpendicular to the path at any point along the path.

6. 6. A vehicle subassembly as claimed in any one of claims 2 to 5, wherein a second cross-sectional dimension of the duct decreases along a path within the duct from the inlet to the outlet, the second cross-sectional dimension being perpendicular to the path at any point along the path.

7. 7. A vehicle subassembly as claimed in any one of claims 1 to 6, wherein the non-planar surface has at least one protrusion, and wherein the air flow device is positioned relative to the at least one protrusion, in use, such that a flow of discharged air follows the contour of the at least one protrusion.

8. 8. The vehicle subassembly of claim 7, wherein the at least one convex portion has a radius of curvature of at least 10 mm, or at least 15 mm.

9. 9. A vehicle subassembly according to claim 7 or 8, wherein the non-planar surface includes a plurality of recesses formed therein and arranged to manipulate attachment or separation of the discharged air flow.

10. A vehicle subassembly according to any preceding claim, comprising a vehicle seat, said non-planar surface forming a surface of said seat.

11. 11. The vehicle subassembly of claim 10, wherein the seat includes a seat pad, the non-planar surface forming a surface of the seat pad, the surface of the seat pad including an upper surface for receiving a seated occupant and at least one side surface, the airflow device being mounted such that the outlet directs the discharged air flow substantially parallel to or towards the at least one side surface, the air flow following the contour of the surface and along at least a portion of the upper surface, and preferably the vehicle subassembly includes a connection between the upper surface and each of the at least one side surface, the connection being convex and forming a bolster for the seat.

12. 12. The vehicle subassembly of claim 10 or 11, wherein the seat includes a seat back, the non-planar surface forming a surface of the seat back, the surface of the seat back including a seat back surface for receiving a seated occupant and at least one seat back side, and the air flow device is mounted such that the outlet directs the discharged air flow substantially parallel to or toward the at least one seat back side, causing the air flow to follow the contour of the surface and along at least a portion of the seat back surface.

13. 13. The vehicle subassembly of claim 12, including a seat back connection between the back surface and each of at least one seat back side, the seat back connection being convex and forming a protruding wing of the seat.

14. A vehicle subassembly according to any one of claims 10 to 13, wherein the air flow device is located substantially within the confines of the seat.

15. A vehicle comprising a vehicle subassembly according to any one of claims 1 to 14.

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