Neck warmer with materials and geometry providing variable infrared heating

Abstract

A seat includes a headrest that has a first material stack and a second material stack respectively corresponding to first and second head regions. The first and second material stacks respectively include first and second effusivities. The first effusivity is less than the second effusivity. An infrared heater is arranged in the headrest beneath the first and second materials. The infrared heater is configured to provide a first radiant heat and a second radiant heat to an occupant head and / or an occupant neck through the first and second material stacks, respectively.

Description

NECK WARMER WITH MATERIALS AND GEOMETRY PROVIDING VARIABLE INFRARED HEATINGCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to United States Provisional Patent Application No. 63 / 601 ,419 filed November 21 , 2023.TECHNICAL FIELD

[0002] This disclosure relates to a seat that provides personalized thermal comfort using infrared heating.BACKGROUND

[0003] Vehicles have become increasingly sophisticated, particularly in their use of personalized thermal conditioning for occupants. Vehicle seats have been a primary focal point for personalizing thermal comfort. Typically, simple conductive wire heating elements provide heat, and a thermoelectric device provides cooling through passages in the seat.

[0004] Extreme temperatures create a challenging environment to provide thermal comfort to the occupant. In extreme cold, it is desirable to bring seating surfaces and the environment immediately surrounding the occupant quickly up to a comfortable temperature. Infrared heaters have been proposed more recently for use in the seat headrest, but using infrared heating as proposed can result in hot spots on the back of the occupant’s head.SUMMARY

[0005] In one exemplary embodiment, a seat includes a headrest that has a first material stack and a second material stack respectively corresponding to first and second head regions. The first and second material stacks respectively include first and second effusivities. The first effusivity is less than the second effusivity. An infrared heater is arranged in the headrest beneath the first and second materials. The infrared heater is configured to provide a first radiant heat and a second radiant heatto an occupant head and / or an occupant neck through the first and second material stacks, respectively.

[0006] In a further embodiment of any of the above, the infrared heater is provided by a single infrared heater.

[0007] In a further embodiment of any of the above, the infrared heater provides an infrared power density in a range of 1000 W / m2to 4000 W / m2.

[0008] In a further embodiment of any of the above, the infrared heater provides a heat flux that is configured to provide an occupant skin temperature target in a range of 33 C to 43 C.

[0009] In a further embodiment of any of the above, the headrest includes an aesthetic covering that provides at least a portion of each of the first and second material stacks.

[0010] In a further embodiment of any of the above, the second material stack includes a mesh material as the aesthetic covering.

[0011] In a further embodiment of any of the above, the first material stack includes a substantially unperforated material as the aesthetic covering.

[0012] In a further embodiment of any of the above, the first material stack includes an outer surface of the aesthetic covering with protrusions extending therefrom.

[0013] In a further embodiment of any of the above, the first and second material stacks respectively include first and second spacer materials that are different than one another and arranged between the infrared heater and the aesthetic covering.

[0014] In a further embodiment of any of the above, the seat includes a speaker that is arranged in the headrest. The infrared heater is arranged between the speaker and the aesthetic covering. The second material stack includes a mesh that provides the portion of the aesthetic covering over the speaker.

[0015] In a further embodiment of any of the above, the second material stack is arranged vertically beneath the first material stack. The second material stack is configured to provide the second radiant heat to the occupant neck.

[0016] In a further embodiment of any of the above, the second material stack is arranged laterally on either side of the first material stack. The second material stack is configured to provide the second radiant heat to sides of the occupant head.

[0017] In a further embodiment of any of the above, the second material stack is arranged at an obtuse angle relative to the first material stack.

[0018] In a further embodiment of any of the above, the seat includes a controller and a power supply in communication with one another. The power supply is in communication with the infrared heater, and the controller is configured to energize the infrared heater via the power supply in response to a signal from an input.

[0019] In a further embodiment of any of the above, the seat includes a seat back. The headrest is adjustable relative to the seat back.

[0020] In another exemplary embodiment, a method of heating an occupant head and / or an occupant neck, includes directing a first radiant heat from an infrared heater in a headrest through a first material stack to a first head and / or neck region, the first material stack has a first effusivity, and directing a second radiant heat from the infrared heater in the headrest through a second material stack to a second head and / or neck region that is different than the first head and / or neck region, the second material stack has a second effusivity different than the first effusivity.

[0021] In a further embodiment of any of the above, the infrared heater provides an infrared power density in a range of 1000 W / m2to 4000 W / m2.

[0022] In a further embodiment of any of the above, the infrared heater provides a heat flux that is configured to provide an occupant skin temperature target in a range of 33 C to 43 C.

[0023] In a further embodiment of any of the above, the method incudes the step of commanding a power supply that is in communication with the infrared heater in response to an input, and performing the directing steps in response to energizing the infrared heater with the power supply.

[0024] In a further embodiment of any of the above, the first effusivity is less than the second effusivity, and the second radiant heat directing step is aimed toward at least one of an occupant neck and an occupant face.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The disclosure can be further understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0026] Figures 1 A and 1 B schematically illustrate example seats using an infrared (IR) heater in a headrest.

[0027] Figure 2 schematically illustrates a disclosed thermal conditioning system for the seat.

[0028] Figure 3 is a chart illustrating the effusivity of various materials and their surfaces by temperature range.

[0029] Figure 4 is a schematic of an example material stack in relation to an IR heater.

[0030] Figure 5 is a schematic of another example material stack in relation to the IR heater.

[0031] Figures 6A-6D illustrate different zones or regions in the headrest providing different IR heating.

[0032] Figure 7 is a schematic of a speaker in a headrest used in connection with the disclosed IR heater and material stack.

[0033] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible. Like reference numbers and designations in the various drawings indicate like elements.DETAILED DESCRIPTION

[0034] Example seats 10, 1 10 are respectively illustrated in Figures 1 A and 1 B. For the seat 10, a seat back 14 is secured to a seat cushion 12. A non-integrated, adjustable headrest 16 is supported relative to the seat back 14 by one or more posts18. The seat 1 10 illustrated in Figure 1 B has its headrest 16 integrated with the seat back 114, which is connected to the seat cushion 1 12. Both types of seats are referred to generally as “seat 10”.

[0035] Regardless of seating configuration, the headrest 16, 116 (generally, “headrest 16”) includes an infrared heater 20 that may be comprised of one or more IR heating elements. The disclosed IR heater 20, as contrasted with a typical conductive wire heater, has a much greater power density, for example, at least 1 ,000 W / m2or 1 ,800 W / m2, and in one example, in a range of 1000 W / m2to 4000 W / m2. In one example, a heater designed with 1000 W / m2in the perimeter and 500 W / m2in the center could be what is needed to maintain a 100 C / 50 C surface temperature, but so could a 2000 W / m2 / 1000 W / m2heater config pulse width modulated to 50%. The advantage to higher power density is the fast time to temperature. The IR heater 20 is able to provide a heat flux configured to provide an occupant skin temperature target in a range of 33 C to 43 C, for example. This can be achieved by a variety of approaches, as the above examples illustrate. One suitable type of conductive wire heating element is provided by Gentherm’s Mechanical Structuring Process (MSP) technology, which allows a higher power density and may employ a foil element, if desired.

[0036] A material stack 22, which comprises at least two different material stacks (see, e.g., FIGS. 6A-6D) are arranged over the IR heater 20. The density, layering, and materials of the various material stacks provided in the headrest 16 can be varied to vary the IR heating provided by different regions to different zones of the occupant (e.g., head (back and / or sides of head) and / or neck (back and / or sides of neck).

[0037] A simple system schematic is illustrated in Figure 2. The system includes a controller 24 that receives a signal from an input 26, which may be a switch, touchscreen, or other device typically found in a modern vehicle to control thermal conditioning. A power supply 28 is in communication with the controller 24 and the IR heater 20. The controller 24 is configured to energize the IR heater 20 via the power supply 28 in response to the signal from the input 26. That is, the signal may be used to initiate and / or terminate heating. A feedback sensor can also be used once heatinghas commenced. The feedback sensor can be accomplished with PTC materials (selfregulates as temperatures rise) and / or a thermostat in the IR heater 20. In one example, the controller 24 and the power supply 28 are provided in or on the seat 10. The input 26 is typically provided on the vehicle’s instrument panel, although the input 26 may be located elsewhere if desired.

[0038] Referring to Figure 3, various materials and their effusivity is shown. A combination of different materials is used to create different, desired material stacks for different regions of the headrest 16. These different material stacks are used to vary the IR heat provided to different zones of the occupant as well as avoid hot spots to sensitive occupant areas. Effusivity is a heat penetration coefficient, which is the rate at which a material can absorb heat. Effusivity determines the contact temperature of two bodies that engage one another. As can be seen by Figure 3, metals have a much higher effusivity than thermally insulative materials, such as plastics. Effusivity is a function of thermal resistance and heat capacity. Thermal resistance relates to the temperature drop across the material. Materials with relatively high effusivity will have a relatively low temperature drop thermal resistance as the temperature is more easily communicated from one side of the material to the other. Heat capacity is the time it takes for a material to reach a given temperature. Materials with a high effusivity will have a low thermal capacitance, that is, the material will reach the equilibrium temperature relatively quickly.

[0039] Different materials and thicknesses of materials are use to provide different material stacks 22, 122 (Figs. 4 and 5) in the headrest 16 to vary the radiant heat to a particular zone or region of the occupant’s head or neck. Generally speaking, low effusivity materials can be used laterally on either side of an occupant’s head and / or near the neck to provide a relatively high radiant heat to those zones of the occupant, which do not contact the headrest support surface. Conversely, areas of the headrest 16 that are intended to provide a support surface for the occupant’s head will use relatively high effusivity materials to prevent hot spots or areas that are uncomfortably warm to the touch. Examples of this principle are illustrated in Figures 4 and 5.

[0040] The IR heater 20 can be used with the same materials, which have different material geometry and volumes in areas to deliver even sensation to occupant with variable IR power output across back of head and neck. The A-surface (exterior aesthetic covering) may include differing geometry / shapes to achieve variable temperature (perforations, thickness, etc.). The IR heater 20 itself may be constructed with different thickness and perforation to achieve power output variations (i.e. layered carrier material for heater wire to vary thermal resistance).

[0041] Referring to Figure 4, the material stack 22 in one region of the headrest includes an aesthetic covering 30, such as a fabric. The material stack has a relatively low effusivity, for example, in a range of 0 to 0.1 W / cm2 / k / s05. In one example, a fabric such as a mesh that may typically be used as a speaker cover in seating applications. A spacer material 32 (e.g., a three-dimensional woven spacer material or similar material providing low effusivity along with IR transparency, commonly used in the seating industry), is arranged between the aesthetic covering 30 and the IR heater 20. The spacer material 32, which may be an expanded, thick polymer material may be used to provide an air gap and some distance between the IR heater 20 and aesthetic covering 30.

[0042] Another material stack 122 is illustrated in Figure 5. In this example, the aesthetic covering 130 is different than the aesthetic covering 30, e.g., vinyl or leather. The material stack 122 has a relatively high effusivity. For example, if the material stack 122 has higher effusivity than skin and has potential to be in contact with the occupant, the temperature would be kept below 50 C. The aesthetic covering 130 is provided for supporting the occupant’s head in direct contact with the headrest 16. Thus, assuming an IR heater 20 has the same power density and heat flux behind both material stacks 22, 122, it is desirable to have less radiant heat for regions of the headrest 16 directly contacting the occupant. This is accomplished by providing a material stack 122 that overall provides more effusivity than the material stack 22. Protrusions 34 may extend from the surface of the aesthetic covering 130 to further space the occupant’s head from the IR heater 20 and minimize the surface area that the occupant contacts. The protrusions 34 may be provided as large raised dimples,ridges, or any aesthetically desirable pattern (e.g., vehicle manufacturer logo) to minimize contact between the occupant’s head and the aesthetic covering 130.

[0043] Different headrest configurations are illustrated in Figures 6A-6D. The headrests provide different IR heating geometries 40, 140, 240, 340 using different material stacks positioned in different locations relative to the IR heater 20. The IR heater 20 may be provided by one or more IR heaters. IR heater 20 and in headrest design can be configured to follow a direct radiant heat path most effectively and evenly to occupant. The headrest 16 may be directed upward towards neck and / or angled in fore / aft directions directed towards the sides of the head for better line of sight and lower distance between occupant skin surface and radiant surface on headrest 16.

[0044] In the example shown in Figure 6A, a head support region 41 is provided centrally in the headrest 16 and includes a lower effusivity (e.g., material stack 122) and radiant heat than adjacent lateral regions 42 (e.g., material stack 22), as the head support region 41 is closest (and perhaps in contact with) the occupant. Figure 6B is similar to Figure 6A but the headrest includes lateral neck regions 43 (e.g., material stack 22) that extend at an acute angle relative to the head support region 41 and are directed at the lower face and neck of the occupant. Figure 6C is similar to Figure 6B except the lateral material stacks (e.g., material stack 22) are further divided into an upper lateral upper head region 44 and a lower lateral head region 45 that are separately directed to the face and neck of the occupant. In the example shown in Figure 6D, a back of neck region 46 (e.g., material stack 22) is arranged vertically beneath the head support region 41 .

[0045] Figure 7 illustrates a material stack 22 that can be incorporated into a headrest 16 along with a speaker 50, which is typically arranged on either side of an occupant’s head. The aesthetic covering 30 over a speaker 50 is typically a fabric mesh. The speaker 50 has a typical construction, with a basket 52 supporting a top plate 56. A bottom plate 54 supports a pole piece 58 is movable relative to the top plate in response to exciting a coil 68. Magnets 66 are provided between the bottom and top plates 54, 56. A spider 60 bridges the cone 62 and basket 52 and includes a centrally located dust cover 64. The IR heater 20 is arranged between the materialstack 22 and the speaker 50. Use of an IR heater behind the aesthetic covering 30 is well suited for radiant heating on the sides of the occupant’s head (neck and face), like the arrangements shown in Figures 6A-6C.

[0046] The controller 24 may be a hardware device for executing software, particularly software stored in memory. The controller 24 can be a custom made or commercially available processor, a central processing unit (CPU), an auxiliary processor among several processors associated with the controller, a semiconductorbased microprocessor (in the form of a microchip or chip set) or generally any device for executing software instructions.

[0047] In terms of hardware architecture, such a computing device can include a processor, memory, and one or more input and / or output (I / O) device interface(s) that are communicatively coupled via a local interface. The local interface can include, for example but not limited to, one or more buses and / or other wired or wireless connections. The local interface may have additional elements, which are omitted for simplicity, such as controllers, buffers (caches), drivers, repeaters, and receivers to enable communications. Further, the local interface may include address, control, and / or data connections to enable appropriate communications among the aforementioned components.

[0048] The memory can include any one or combination of volatile memory elements (e.g., random access memory (RAM, such as DRAM, SRAM, SDRAM, VRAM, etc.)) and / or nonvolatile memory elements (e.g., ROM, hard drive, tape, CD- ROM, etc.). Moreover, the memory may incorporate electronic, magnetic, optical, and / or other types of storage media. The memory can also have a distributed architecture, where various components are situated remotely from one another, but can be accessed by the processor.

[0049] The software in the memory may include one or more separate programs, each of which includes an ordered listing of executable instructions for implementing logical functions. A system component embodied as software may also be construed as a source program, executable program (object code), script, or any other entity comprising a set of instructions to be performed. When constructed as asource program, the program is translated via a compiler, assembler, interpreter, or the like, which may or may not be included within the memory.

[0050] The disclosed input and output devices that may be coupled to system I / O interface(s) may include input devices, for example but not limited to, a keyboard, mouse, scanner, microphone, camera, mobile device, proximity device, etc. Further, the output devices, for example but not limited to, a printer, display, etc. Finally, the input and output devices may further include devices that communicate both as inputs and outputs, for instance but not limited to, a modulator / demodulator (modem; for accessing another device, system, or network), a radio frequency (RF) or other transceiver, a telephonic interface, a bridge, a router, etc.

[0051] When the controller 24 is in operation, the processor can be configured to execute software stored within the memory, to communicate data to and from the memory, and to generally control operations of the computing device pursuant to the software. Software in memory, in whole or in part, is read by the processor, perhaps buffered within the processor, and then executed.

[0052] It should also be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom. Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present invention.

[0053] Although the different examples have specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.

[0054] Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.

Claims

CLAIMSWhat is claimed is:

1. A seat comprising: a headrest having a first material stack and a second material stack respectively corresponding to first and second head regions, the first and second material stacks respectively including first and second effusivities, the first effusivity less than the second effusivity; and an infrared heater is arranged in the headrest beneath the first and second materials, the infrared heater is configured to provide a first radiant heat and a second radiant heat to an occupant head and / or an occupant neck through the first and second material stacks, respectively.

2. The seat of claim 1 , wherein the infrared heater is provided by a single infrared heater.

3. The seat of claim 1 , wherein the infrared heater provides an infrared power density in a range of 1000 W / m2to 4000 W / m2.

4. The seat of claim 3, wherein the infrared heater provides a heat flux configured to provide an occupant skin temperature target in a range of 33 C to 43 C.

5. The seat of claim 1 , wherein the headrest includes an aesthetic covering providing at least a portion of each of the first and second material stacks.

6. The seat of claim 5, wherein the second material stack includes a mesh material as the aesthetic covering.

7. The seat of claim 5, wherein the first material stack includes a substantially unperforated material as the aesthetic covering.

8. The seat of claim 7, wherein the first material stack includes an outer surface of the aesthetic covering with protrusions extending therefrom.

9. The seat of claim 5, wherein the first and second material stacks respectively include first and second spacer materials that are different than one another and arranged between the infrared heater and the aesthetic covering.

10. The seat of claim 5, comprising a speaker arranged in the headrest, the infrared heater arranged between the speaker and the aesthetic covering, and the second material stack includes a mesh providing the portion of the aesthetic covering over the speaker.1 1. The seat of claim 1 , wherein the second material stack is arranged vertically beneath the first material stack, the second material stack configured to provide the second radiant heat to the occupant neck.

12. The seat of claim 1 , wherein the second material stack is arranged laterally on either side of the first material stack, the second material stack configured to provide the second radiant heat to sides of the occupant head.

13. The seat of claim 12, wherein the second material stack is arranged at an obtuse angle relative to the first material stack.

14. The seat of claim 1 , comprising a controller and a power supply in communication with one another, the power supply in communication with the infrared heater, and the controller configured to energize the infrared heater via the power supply in response to a signal from an input.

15. The seat of claim 1 , comprising a seat back, wherein the headrest is adjustable relative to the seat back.

16. A method of heating an occupant head and / or an occupant neck, comprising: directing a first radiant heat from an infrared heater in a headrest through a first material stack to a first head and / or neck region, the first material stack having a first effusivity; and directing a second radiant heat from the infrared heater in the headrest through a second material stack to a second head and / or neck region that is different than the first head and / or neck region, the second material stack having a second effusivity different than the first effusivity.

17. The method of claim 16, wherein the infrared heater provides an infrared power density in a range of 1000 W / m2to 4000 W / m2.

18. The method of claim 17, wherein the infrared heater provides a heat flux configured to provide an occupant skin temperature target in a range of 33 C to 43 C.

19. The method of claim 16, comprising the step of commanding a power supply that is in communication with the infrared heater in response to an input, and performing the directing steps in response to energizing the infrared heater with the power supply.

20. The method of claim 16, wherein the first effusivity is less than the second effusivity, and the second radiant heat directing step is aimed toward at least one of an occupant neck and an occupant face.

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