CROSS-REFERENCE TO RELATED APPLICATIONS

1 0011 This application claims pr ority to United States Provisional Application No.

62/269,526, filed on December 18, 2015.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002 ^' j The present invention relates to a heating and cooling engme. More particularly, the invention relates to a heating and cooling mat for rapidly heating and cooling the surface of a seat assembly for seat occupant comfort.

2. Dcscriprioti of Related Art 00031 Automotive vehicles include one or more seat assemblies having a seat cushion and a seat back for supporting a passenger or occupant above a vehicle floor. The seat assembly is commonly mounted to the vehicle floor by a riser assembly. The seat back is typically operative ly coupled to the seat cushion by a ree liner assembly for providing selective pivotal adjustment of the seat back relative to the seat cushion. Each of the seat cushion and seat: back commonly comprise a base foam pad supported by a rigid frame structure and encased in a fabric trim cover of fabric, leather, and/or Vinyl. The base foam pad provides the firm support and durability to the seat cushion and seat back. A trim padding is also commonly disposed between the base foam pad and the trim cover to provide a softer surface tor seat occupant comfort.

{0004} It is commonly known to provide seat assemblies with heating and/or cooling mechanisms ^' for selectively heating and cooling the surface of the seat for seat occupant comfort. These known heating and cooling mechanisms are typically independent mechanisms, For example, h is common to provide an electric wire heating pad between th foam pad and trim cover of the scat cushion or seat back which is electrically actuated by the power from the vehicle battery to electrically charge the electric wire heating pad and provide heat to the surface of the seat cushion or seat back. If is also known to provide fans and air ducts to force cool air through the foarn pad and trim cover and provide cool air to the surface

I of the seat cushion or scat back. It is also known to provide fans and duets to draw warm, moist air away from the seating surface to prov ide a gradual cooling effect.

{0005} However, current heatin and cooling mechanisms require a fair amount of time and power to generate sufficient heat or cool air to affect the temperature of the seat assembly and the desired comfort for the seat occupant.

{fl0t)6} it is desirable, therefore, to provide a heating and cooling engine- hich can rapidly or almost instantly provide heating -or cooling to the surface of the seat assembly.

SUMMARY OF TOR INVEN ION

[Θ0β?| A heating and cooling engine is provided comprising a center isolator for isolating electric and thermal energy. The center isolator has a top surface and an opposite bottom surface. A plurality of spaced apart thermoelectric elements are supported b the center isolator between the top and bottom surface. The thermoelectric elements, have a top side and an opposite bottom side. A first plurality of electrically and thermally conductive buss bars are secured to the top surface of the center isolator and electrically connected to the top side of at least a pair of the thermoelectric elements. A second plurality of electrically and thermally conductive buss bars are secured to the bottom surface of the center isolator and electrically connected to the bottom side of at l east a pair of the thermoelectric elements wherein thermal energy is generated to the first and second plurality of buss bars by the thermoelectric elem nts,

BRIEF _,, DESCRIPTION OF TOE DRAWINGS 0008 Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description whe considered in connection with the accompanying drawings wherein:

(0009) Figure 1 is a top view of a plurality of buss bars ^*

(00!0] Figure 2 is a top view of a plurality of alternative buss bars;

[0011] Figure 3 is perspective view of a plurality of thermoelectric elements;. {00121 Figure 4 Is a perspective view of a silicone center isolator;

|WI3| Figure 5 is a tope view of a wool center isolator;

}WI.4 ^' j Figure 6 is a perspective view of a bottom plate;

[WI S] Figure 7 Is a perspective view of the bottom plate supporting a plurality of spaced apart buss bars;

[1*016] Figure 8 is a perspecti ve view of the bottom piaie supporting die buss bars and center isolator;

{0017] Figure 9 is a perspective view of applying solder to the buss bars of Figure 8;

{0018) Figure 10 is a perspective view of a plurality of spaced apart the-mioefeetrk- elements seated in the center isolator;

|W { Figure .1 1 is a perspective view of applying solder to the thermoelectric dements;

|W>2#{ Figure 12 is a perspective view of a plurality of buss bars seated against the thermoelectric elements;

{0021 \ Figure 3 is a bottom perspective view of an upper piaie;

{0022} Figure .14 is a perspective view of the upper piste clamped to the lower plate;

{0023| Figure 15 is a perspective view of a heating and cooling mat;

[0024] Figure 16 is a perspective view of an alternative heating and cooling mat; 0i)25] Figure 17 is a cross-sectional view of the heating and cooling mat of Figure

1 5; and

[0026} Figure I is a. fragmentary perspective view of a seat assembly using the heating and cooling mat DETAILED DESCRIP IO OF THE EMBODIMENTS

10027} Referring to the Figures, wherein like, numerals indicate like or corresponding parts throughout the several views, a heating and cooling engine, or mat, according to a preferred embodiment of the invention for use in providing rapid heating and cooling to a surface area includes- a plurality of thermoelectric elements for creating heating a d cooling energy; a plurality of buss bars for the heating and cooling energy from the thermoelectric elements; a center isolator to separate the heating and cooling energy produced from the thermoelectric elements and for providing electrical and thermal isolation; and a solder material for mechanically bonding the thermoelectric elements and isolator between the buss bars a d create an electric- connection therebetween.

[0028} More specifically- referring to Figures 1 and 2* the buss bars are generally shown at 10 and comprises generally thin square or rectangular shaped bars constructed of any electrically and thermally conductive materials including but not limited to copper or aluminum. In order to maximize the thermal energy transfer from the thermoelectric elements to the surface area, the size of the buss bars 10 preferably make up seventy (70} percent or more of the total surface area of the heating and cooling mat. Further,, it is also preferable thai the electrically and thermally conductive material of the. buss fears 10 is- flexible, and allowed to be contoured to the shape of the surface area of use. Such suitable material of copper or aluminum may include foil or thin sheets of material forming, the buss ^' bars as shown at 10 in Figure 1. Alternatively, small diameter, elongated woven- or braided wire of copper or aluminum may be utilized forming a buss bar as shown at 10' in Figure 2.

[0 29} Referring to Figure 3. the thermoelectric elements are shown at 12 forming a plurality of cube shaped elements. The elements 12 use the Peltier effect to create cold on one side, or tope side 14, of the element and heat on the opposite side, or bottom side 16, of the element 12 when electrically activated. That is, positive (P) and negative (N) elements 12 are arranged in alternating order in the mat to achieve the Peltier e fect of cooling on one side and heating on the other as will be further described herembelow. The dimensions: of each element 12- may vary in size and shape,, but the optimized dimensions are defined by a cuboid of the following ratio: 0.004ra<W¾- .005m . Further, many materials are suitable for the elements 12. but the preferred material is a Bismuth Teliuride alloy that is doped Into both N and P varieties. Additionally,, the elements 12 are preferable plated in nickel and/or tin to aid in thermal conductivity connecting with the buss bars 1 0, £0030 j Referring to Figures 4 and 5, the center isolator may include a planar panel of cast silicone as shown at 8 in Figure 4 or alternatively a planar panel of wool, as shown at 1 8 ^s in Figure 5. Aramids or other suitable high temperature isolator materials are also possible alternatives. The silicone isolator 18 of Figure 4 includes a plurality of speed apart openings 20 extending between opposite lop and bottom -surface 2-2, 24 thereof for receivin and supporting the thermoelectric elements 12 therein. The buss bars 10 are arranged on both the top and bottom surface 22, 24. The purpose of the center isolator 18. I 8 ^! is to electrically isolate the plurality of buss bars 10 from shorting and so that heat will not. thermally back- flow from the top and bottom of the mat. The center isolator 18, 18 ^'* of -silicone, or wool is very flexible to allow contouring to the surface area, and has high temperature resistance to handle m-piace re-flow soldering methods as will be further described.

1003 ί I Referring to Figures 6- 14, the apparatus and method- of manufacturing and assembling the heating and cooling engine, or mat. is shown. First, Figure 6 shows a bottom plate 30 having a peripheral edge 32 defining a bottom cavity 34. A plurality of spaced apart and recessed locators 36 are formed in the bottom cavity 34 for receiving, arranging, and retaining the buss bars 1.0. Figure 7 shows a buss bar it) seated in each of the recessed locators 36 in the bottom plate 30. Referring to Figure 8, the center isolator I S is seated in the bottom cavity 34 on top of the plurality of buss bars 10 wherein each opening 20 r f he- isolator 18 exposes a portion -of each respective buss bar H) beneath the isolator 18. In Figure. a d liup or small amount of solder material 38. such as that, available from ester inc.. is applied to the surface of each buss bar 10 exposed by each opening 20. Referring to Figures 10 and i L the bottom -side 16 of a thermoelectric element 1.2 is- placed in each opening 20 of the isolator 18 on top of the buss bar 10 and in contact with the solder material 38, As shown in phantom in figure 1.0, each buss bar 10 supports and interconnects two adjacent thermoelectric elements 12. A second doilup or small amount of solder material 38 is then applied to the top side 14 of the thermoelectric element 12.

|0 321 Referring to Figure 12, another plurality of buss bars 10 is placed in contact with the second amount of solder material and seated against the top side 1-4 of the thermoelectric elements 12 is an arrangement offset by one opening 20 to the bottom side 16 of each element 12. Is Figure 13, an upper plate 40 is shown having a plurality of equally spaced apart raised solder pads 42 corresponding in spacing to each of the openings 20 in the isolator 18. The upper plate 40 is pressed against the second plurality of buss bars 10 such that the solder pads 42 arc aligned with the openings 20 in the isolator and therefore with each ihcrmoelceiric element 12 seated therein as shown in. Figure 1 . ^' The solder material 38 is optimized tor re-flow soldering techniques and mechanically bonds the entire assembly together to form ihe heating and cooling engine, or mat, as shown at 50 in Figure I S, The mat 50 of Figure 1 S includes copper buss bars 1.0 and a silicon isolator. Figure 1 discloses a similar mat 50' with the alternative braided wire buss bars 10 ^* and wool isolator 1 !\

[#0331 .Referring to Figure 1% a cross-section view of the heating and cooling mat 50 is shown wherein the thermoelectric elements 12 are spaced apart and seated in the openings 20 of the cente isolator 18. The solder material 38 electricall bonds each of the first plurality of buzz bar 10 to the top side 1.4 of a pair of spaced apart adjacent thermoelectric elements .12 and bonds each of the second plurality of buss bars 10 to the bottom side 16 of a pair of spaced apart adjacent thermoelectric elements 1.2, however, in an alternative pattern spaced or offset one opening 20 apart from, the top side 1 ,

| 34) In use, in the automotive seating industry, as one example, a seat -assembly generally includes .a horizontal seat cushion for supporting a seat occupant within he vehicle as is commonly known in the art and shown at 60 in Figure 18. The seat cushion -commonly me ksdes a molded resilient cellular foam pad 62 encased kt a trim cover 64, commonly of cloth, vinyl, or leather. The foam pad 62 provides he resilient support to the seat occupant. However; the foam ^' pad 62 currently has a very low thermal conductivity of approximately 0.043 W/m-K., and as such, heat can build up between the seat occupant and foam: pad 62. it is commonly known to provide a heating or cooling mechanism, such as an electric heating pad, in the seat assembly for providing occupant comfort. However, the foam pad 62 acts as an insulator, and therefore, the desired heating and cooling effects take considerable time t be felt by the user. Further, the power le vels of the healing and cooling mechanisms have to be substantial to overcome the insulating effects of the foam pad. The present invention heating and cooling mat.50 may be seated between the foam pad 62 and trim cover 64 of the seat assembly to increase the heating and cooling effects and reduce the time to be felt by the user while minimizing power usage. The mat 50 is also thin, .flexible and may be used in variety of sizes or configurations to obtain optimum efficiency and maximize the beating and cooling effect while maintain comfort to the occupant. | 35| It should be appreciated ihal the healin and cooling engine, or mat, may be used in seat cushions, seat backs, thrmiure, bedding or other applications where- efficient heating, cooling or power generation is desired.

|0036} The invention has been described In an illustrative manner, and It to be understood that the terminology, which has been, used, is intend d to be in the nature of words of description rather than of limitation. 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, the invention may be practiced other than as specifically -described.