WO2024137641A1

WO2024137641A1 - Panel assembly with convective heat function

Info

Publication number: WO2024137641A1
Application number: PCT/US2023/084842
Authority: WO
Inventors: Daniel C. WYATT
Original assignee: Magna Seating Inc
Current assignee: Magna Seating Inc
Priority date: 2022-12-19
Filing date: 2023-12-19
Publication date: 2024-06-27
Anticipated expiration: 2025-06-19

Abstract

A panel assembly for an automotive seat assembly includes a cover having an outlet vent and an inner panel fixedly coupled to the cover and defining a cavity having an outlet duct connected to the outlet vent, an inlet duct, and an airflow channel fluidly connecting the inlet duct to the outlet duct. The panel assembly also includes a heater mat extending along the airflow channel and a blower having a blower inlet fluidly connected to a blower outlet which is fluidly connected to the inlet duct. The blower is configured to draw in ambient airflow into the blower inlet and provide forced ambient airflow to the inlet duct, through the airflow channel, into the outlet duct, and through the outlet vent. During operation of the panel assembly, the heater mat warms the forced ambient airflow as the forced ambient airflow travels along the airflow channel.

Description

PANEL ASSEMBLY WITH CONVECTIVE HEAT FUNCTION

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application 63/433,725, filed on December 19, 2022, the disclosure of which is hereby incorporated by reference in its entirety.

FIELD AND BACKGROUND OF THE INVENTION

[0002] The present invention relates to a panel assembly for use in an automotive vehicle. More particularly, the invention relates to a panel assembly with a convective heat function for use in an automotive seat assembly.

DESCRIPTION OF RELATED ART

[0003] Automotive vehicles typically include one or more seat assemblies having a seat cushion and a seat back for supporting a passenger above a vehicle floor. Certain automotive vehicles include a front row and a rear row of seat assemblies. It is commonly known for the automotive vehicle to include a forced air heating system configured to provide heated air blown towards the front row of seat assemblies. The forced air heating system typically provides heated air through vents and ducts in an instrument panel positioned forward of the front row of seat assemblies. In addition, the forced air heating system typically includes a temperature control on the instrument panel for adjusting the temperature of the heated air.

[0004] However, the forced air heating systems within the instrument panel might provide inadequate heated air blown towards the rear row of seat assemblies. Further, occupants of the rear row of seat assemblies typically are unable to adjust the temperature control on the instrument panel.

[0005] Therefore, it is desirable to provide efficient forced air heating to occupants of the rear row of seat assemblies.

SUMMARY OF THE INVENTION

[0006] According to one embodiment, there is provided a panel assembly for an automotive seat assembly. The panel assembly includes a cover having an outlet vent and an inner panel fixedly coupled to the cover and defining a cavity therebetween. In addition, the cavity includes an outlet duct fluidly connected to the outlet vent, an inlet duct spaced apart from the outlet duct, and an airflow channel fluidly connecting the inlet duct to the outlet duct. The panel assembly also includes a heater mat extending along the airflow channel and configured to warm air within the airflow channel. The panel assembly also includes a blower having a blower inlet fluidly connected to a blower outlet which is fluidly connected to the inlet duct, wherein the blower is configured to draw in ambient airflow into the blower inlet and provide forced ambient airflow to the inlet duct, through the airflow channel, into the outlet duct, and through the outlet vent. During operation of the panel assembly, the heater mat warms the forced ambient airflow as the forced ambient airflow travels along the airflow channel.

[0007] According to another embodiment, there is provided a panel assembly for use in an automotive seat assembly. The panel assembly includes a back panel for use in a seat assembly and having an outlet vent. The panel assembly also includes an inner panel fixedly coupled to the back panel and defining a cavity therebetween wherein the cavity includes an outlet duct fluidly connected to the outlet vent, an inlet duct spaced apart from the outlet duct, and an airflow channel fluidly connecting the inlet duct to the outlet duct. The panel assembly also includes a heater mat extending along the airflow channel and configured to warm air within the airflow channel. Further, the panel assembly includes a blower having a blower inlet fluidly connected to a blower outlet which is fluidly connected to the inlet duct, wherein the blower is configured to draw in ambient airflow into the blower inlet and provide forced ambient airflow to the inlet duct, through the airflow channel, into the outlet duct, and through the outlet vent. During operation of the panel assembly, the heater mat warms the forced ambient airflow as the forced ambient airflow travels along the airflow channel.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0009] Figure 1 is a rear perspective view of an automotive seat assembly which includes a panel assembly for providing forced heated air, according to one embodiment of the present invention;

[0010] Figure 2 is a rear perspective view of the panel assembly of Figure 1 removed from the seat assembly; [0011] Figure 3 is a front perspective view of the panel assembly of Figure 2;

[0012] Figure 4 is a cut-away perspective view of the panel assembly of Figure 3;

[0013] Figure 5 is a cross-sectional view of the panel assembly of Figure 4 taken along line 5- 5;

[0014] Figure 6 is a cross-sectional view of a mold lid and a mold base illustrating a molding process of forming an inner panel and showing an inner cover vacuum formed against the mold base, according to another embodiment of the present invention;

[0015] Figure 7 is a cross-sectional view of the mold lid, the mold base, and the inner cover of Figure 6, after a molded foam backing is formed within the cavity between the inner cover and the mold lid;

[0016] Figure 8 is a perspective view of a heater mat, according to one embodiment of the present invention;

[0017] Figure 9 is a side view of an automotive vehicle showing panel assemblies for providing heated air in additional locations within the automotive vehicle, according to other embodiments of the present invention;

[0018] Figure 10 is a right rear perspective view of a panel assembly including a heater assembly having heater mat within an insulative layer and surrounding a spacer fabric, according to a second embodiment of the present invention;

[0019] Figure 11 is a cut-away perspective view of heater assembly of Figure 10, showing the spacer fabric within the heater mat and the insulative layer;

[0020] Figure 12 is a rear perspective view of a panel assembly, according to a third embodiment of the present invention;

[0021] Figure 13 is a front perspective view of the panel assembly of Figure 12;

[0022] Figure 14 is a cross-sectional view of the panel assembly of Figure 13 taken along line 14-14;

[0023] Figure 15 is a cross-sectional view of a panel assembly, according to a fourth embodiment of the present invention; and [0024] Figure 16 is a cross-sectional view of a panel assembly, according to a fifth embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0025] Figures 1-16 illustrate a panel assembly 10 and components thereof for use in a seat assembly 12 of an automotive vehicle 14, according to embodiments described herein. Directional references employed or shown in the description, figures, or claims, such as top, bottom, upper, lower, upward, downward, lengthwise, widthwise, left, right, and the like, are relative terms employed for ease of description and are not intended to limit the scope of the invention in any respect. Referring to the Figures, like numerals indicate like or corresponding parts throughout the several views.

[0026] Depicted in Figure 1, the seat assembly 12 includes a seat cushion 16 and a seat back 18 pivotably coupled to the seat cushion 16. The seat back 18 includes a back panel 20 fixedly coupled to a rearward portion of the seat back 18. The back panel 20 includes one or more outlet vents 22 extending therethrough. The seat assembly 12 also includes the panel assembly 10 fixedly coupled to the back panel 20 and/or integrated within the seat back 18. The panel assembly 10 includes a convective heat function and is configured to provide forced heated air (arrow 24) through the outlet vent 22, as further described below.

[0027] Referring to Figures 2-5, the panel assembly 10 includes an inner panel 26, opposing side walls 28, opposing end walls 30, and a cover 32. The side walls 28 and the end walls 30 project away from the inner panel 26 and extend around an outer perimeter of the inner panel 26. In certain embodiments, the inner panel 26 is integrally formed with the side walls 28 and the end walls 30 and might include a rim 34 extending around an outer perimeter of the distal ends of the side walls 28 and the end walls 30. The inner panel 26, along with the side walls 28 and the end walls 30, function as a thermal insulator in certain embodiments. The cover 32 is a thermal insulator that is fixedly coupled to the distal portions of the opposing side walls 28 and end walls 30 and/or to the rim 34. In certain embodiments, the cover 32 might be integrally formed with, fixedly coupled to, and/or spaced apart from the back panel 20 without altering the scope of the present invention.

[0028] The panel assembly 10 includes an interior cavity 36 spaced between the inner panel 26, the side walls 28, the end walls 30, and the cover 32. The interior cavity 36 further comprises an inlet duct 38, an outlet duct 40, and a plurality of airflow channels 42 fluidly connecting the inlet duct 38 to the outlet duct 40. The outlet duct 40 is fluidly connected to one or more outlet vents 22 extending through the cover 32 and through the back panel 20 (Figure 1 ). The outlet vent 22 is configured to allow airflow to travel between the outlet duct 40 and the ambient air exterior of the panel assembly 10, as illustrated by arrow 24. The inner panel 26 also includes one or more inlet openings 46 extending therethrough and adjoining the inlet duct 38 for providing inlet air (arrow 48 in Figures 2 and 3) to the inlet duct 38. Referring to Figures 4 and 5, the panel assembly 10 includes a flexible heater mat 50 extending at least partially along the airflow channels 42 and configured to warm the airflow (arrow 52) passing along the airflow channels 42. An exemplary heater mat 50 is depicted in Figure 8. The heater mat 50 includes one or more flexible heat elements 50a having heating surface 50b and which is electrically connected to a wiring harness 50c for providing power to the heater mat 50. In more detail, the heater mat 50 might comprise sinusoidal resistive wires, carbon fiber, or the like as non-limiting examples, which are configured to provide active heating by warming the heating surface 50b when power is provided to the heater mat 50.

[0029] As illustrated in Figure 3, the panel assembly 10 includes a plenum 54 and a blower 56. The plenum 54 is fixedly coupled to the inner panel 26 and includes a plenum outlet 58 fluidly connected to the inlet opening(s) 46 in the inner panel 26. In addition, the plenum 54 includes a plenum inlet 60 for receiving airflow (arrow 48) into the plenum 54. The plenum 54 is shaped to divert the airflow coming into the plenum inlet 60 and direct the airflow through the plenum outlet 58 and into the inlet duct 38. The blower 56 is fixedly coupled to the inner panel 26 and includes a blower outlet 62 fluidly coupled to the plenum inlet 60. It will be appreciated that the blower 56 might be spaced apart from the inner panel 26 without altering the scope of the present invention. Further, the blower 56 includes a blower inlet 64 fluidly connected to ambient air outside of the panel assembly 10. The blower 56 also includes a fan 66 which is selectively rotated to draw in ambient air (arrow 68) from outside of the panel assembly 10 through the blower inlet 64 and provide forced airflow (arrow 48) to the plenum inlet 60. It will be appreciated that the blower 56 might be any type of commonly known blower and/or fan configured to draw in ambient air and provide forced airflow to the blower outlet 62 without altering the scope of the present invention.

[0030] Referring to Figures 4 and 5, the airflow channels 42 are formed by laterally spaced apart pairs of opposing channel walls 70, 72 extending in a longitudinal direction with each airflow channel 42 having a generally triangular-shaped cross section. The adjacent distal ends of the opposing channel walls 70, 72 form channel peaks 74 between the adjacent airflow channels 42. In addition, the adjacent proximal ends of the opposing channel walls 70, 72 form channel valleys 76. It will be appreciated that the airflow channels 42 might comprise channel walls 70, 72 having alternate cross-sectional shapes without altering the scope of the present invention. As shown in Figure 5, the inner panel 26 comprises an inner cover 78 which is adhered to and/or integrally formed with a molded portion 80 having the channel walls 70, 72. The inner cover 78 optionally comprises a fabric or a laminate blank comprising one or more layers of fabric, foam, and the like. Optionally, the inner cover 78 is molded out of a plastic or a foam material or formed out of a metal. In the embodiment shown in Figure 5, the molded portion 80 is formed out of a foam and/or a plastic and includes one or more channel walls 70, 72.

[0031] Figures 6 and 7 illustrate an exemplary method of forming the inner panel 26 using a FreeFomi™ High Pressure Closed Pour molding process which is described in U.S. Patent No. 11,427,117 and is incorporated by reference herein in its entirety. In the embodiment shown in Figure 6, the inner cover 78 comprises a fabric, a vinyl, a leather, or a laminate blank. The laminate blank comprises an outer layer of fabric, vinyl, and/or leather which is assembled with and/or fixedly coupled to at least one additional layer which might comprise a fabric, a vinyl, a leather, secondary components, functional components, and/or a foam as non-limiting examples.

[0032] During the molding process, the inner panel 26 is formed by adhering the inner cover 78 to a molded portion 80 formed out of a foam and having airflow channels 42. The molding process includes a mold lid 82 and a mold base 84. The mold lid 82 includes a plurality of protrusions 86 extending in a longitudinal direction and having a generally triangular-shaped cross-section. The mold base 84 includes a 3-dimensional mold bowl 88 having a desired molded shape for an outer surface of the inner panel 26. The mold bowl 88 includes a plurality of vacuum holes 90 distributed across a lower surface of the mold bowl 88. The mold lid 82 is configured to be assembled with the mold base 84 forming a cavity 92 between the mold lid 82 and the mold bowl 86.

[0033] The mold lid 82 also includes an inlet port 94 for injecting a mixed liquid 96 into the cavity 92 formed after closing the mold lid 82 against the mold base 84. The inlet port 94 is fluidly connected to an inlet channel 98 passing through the mold lid 82. The inlet channel 98 is fluidly coupled to at least a first fill line 100 and a second fill line 102 configured to provide a first liquid 104 and a second liquid 106, respectively, into the inlet channel 98. The first and second liquids 104, 106 are mixed within the inlet channel 98 to form the mixed liquid 96 that is injected through the inlet port 94 and into the cavity 92. The first and second liquids 104, 106, along with potentially other selected components based on the specific requirements of a selected molded portion 80, might comprise in part a blended polyol 104 and isocyanate (ISO) 106, as a non-limiting example.

[0034] To form the inner panel 26, the inner cover 78 is inserted between the mold lid 82 and the mold base 84. Optionally, the heater mat 50 is attached to the mold lid 82 against the protrusions 86 when the heater mat 50 is to be insert-molded into the inner panel 26. Next, air (arrow 108) is drawn through the vacuum holes 90 in the lower surface of the mold bowl 88 during a vacuum-forming process which vacuum-forms the inner cover 78 against the mold bowl 88. The vacuum-forming process can be performed before or after placing the mold lid 82 against the mold base 84.

[0035] Next, the blended polyol 104 and the isocyanate 106 are injected and/or poured through the first fill line 100 and the second fill line 102, respectively, and into the inlet channel 98. Mixing and injecting the blended polyol 104 and isocyanate 106 through the inlet port 94 into the cavity 92 between the mold lid 82 and the mold bowl 88 causes the blended polyol 104 and the isocyanate 106 to react and form a molded polyurethane foam backing (i.e., “molded portion 80”) within the cavity 92. Referring to Figure 7, the molded portion 80 is adhered to the inner cover 78 and the optional heater mat 50 during the reaction process. The assembly of the molded portion 80 and the inner cover 78 forms the inner panel 26 shown in Figures 4 and 5.

[0036] It will be appreciated that liquid plastic might be provided directly to the inlet port 94 and into the cavity 92 when the molded portion 80 is formed out of a plastic, without altering the scope of the present invention. In addition, it will be appreciated that the inner cover 78 might be omitted during the molding process when the inner cover 78 is integrally formed with the molded portion 80, without altering the scope of the present invention. Further, it will be appreciated that the inner cover 78 might be formed out of a metal or a plastic in a separate process and inserted into the mold bowl 86 prior to forming the molded portion 80 with the vacuum-forming process optionally omitted. In addition, the heater mat 50 might be layered against and/or fixedly coupled to the airflow channels 42 in the molded portion 80 after forming the inner panel 26, without altering the scope of the present invention. For example, the heater mat 50 might include a pressure sensitive adhesive (PSA) or a peel and stick adhesive wherein the heater mat 50 is applied and adhered to the airflow channels 42 as a secondary operation.

[0037] It will be appreciated that during the molding process, airflow channels 42 might be molded onto the back side of the back panel 20, the cover 32, and/or the inner panel 26 based on the specific configurations of various embodiments. Further, it will be appreciated that the back panel 20 might be integrally formed with the cover 32 and might optionally include the airflow channels 42. In addition, the outlet vent(s) 22 and the inlet vent(s) 46 might be formed with different configurations and in other locations on the panel assembly 10 without altering the scope of the present invention. Further, the designation of the cover 32 and the inner panel 26 might be reversed without altering the scope of the present invention.

[0038] The operation of the panel assembly 10 is described in reference to Figures 1-4. During operation, air is actively pushed by the fan 66 in the blower 56 through the airflow channels 42 and through the outlet vent 22 to provide a sensation of warmth to a vehicle occupant. In more detail and referring to Figure 3, when operation of the panel assembly 10 is initiated by the occupant, power is provided to the blower 56 which causes the fan 66 to rotate and draw ambient air (arrow 68) through the blower inlet 64 and into the blower 56. The rotating fan 66 provides forced ambient air (arrow 48) to the blower outlet 62, through the plenum inlet 60 into the plenum 54, through the plenum outlet 58, and through the inlet opening 46 in the inlet duct 38. Next, the forced ambient air (arrow 110) travels from the inlet duct 38 into the airflow channels 42. Referring to Figures 2 and 4, power is provided to the heater mat 50 during operation of the panel assembly 10 which causes the heater mat 50 to warm the air as the forced airflow travels along the airflow channels 42 (arrow 52). Depicted in Figure 2, the forced heated airflow travels from the airflow channels 42 and into the outlet duct 40, as illustrated by arrow 112. Next, the heated forced airflow travels from the outlet duct 40 and through the outlet vent 22, as illustrated by arrow 24, and is exhausted to the ambient air exterior of the seat assembly 12. Operation of the panel assembly 10 is selectively terminated based on input from the occupant, as a non-limiting example.

[0039] Depicted in Figure 9, the panel assembly 10 might be configured to be integrated within the back panel 20 of the seat assembly 12 as described in the above embodiments. Further, the panel assembly 10 might be positioned in different locations within the seat assembly 12 and/or integrated within other components of the seat assembly 12 without altering the scope of the present invention. In addition, the panel assembly 10 might be integrated into other components within the automotive vehicle 14, such as within a floor panel 114, a door panel 116, a side wall panel 118, a roof panel 120, and the like, as non-limiting examples.

[0040] A second embodiment of the panel assembly 10' is shown in Figures 10 and 11, where like primed reference numerals represent similar elements as those described above. The panel assembly 10' of the second embodiment includes a spacer fabric 122 in place of the airflow channels 42 in the panel assembly 10 described above in Figures 1-5. Only significant differences between the two embodiments are reflected in the Figures and the description below.

|0041| Referring to Figure 10, the panel assembly 10' includes opposing side walls 28' and opposing end walls 30' extending from an inner panel 26'. The panel assembly 10' also includes a cover 32' fixedly coupled to the distal ends of side walls 28' and the end walls 30' defining an interior cavity 36' spaced between the cover 32' and the inner panel 26'. The cover 32' is fixedly coupled to and/or integrally formed with the back panel 20'. The cover 32' includes at least one outlet vent 22' extending through the cover 32' and the back panel 20' and is fluidly connected to the exterior ambient air. In addition, the inner panel 26' includes at least one inlet opening 46' extending therethrough. The internal cavity 36' includes an inlet duct 38' fluidly connected to the inlet opening 46', an outlet duct 40' fluidly connected to the outlet vent 22', and a heating chamber 124 fluidly connected between the inlet duct 38' and the outlet duct 40'. The panel assembly 10' also includes a heater assembly 126 inserted into the heating chamber 124.

[0042] Depicted in Figure 11, the heater assembly 126 includes the spacer fabric 122, a heater mat 50', and an insulative layer 132. The spacer fabric 122 is an air-permeable fabric having an outer circumferential surface 134 extending between opposing end surfaces 136, 138. Further, the spacer fabric 122 is configured to allow airflow to enter one end surface 136 of the spacer fabric 122 (arrow 140), travel longitudinally through the spacer fabric 122 (arrow 52'), and exit the other end 138 of the spacer fabric 122 (arrow 144). The heater mat 50' has a generally oblong cylindrical shape having inner and outer surfaces 146, 148 extending between opposing ends 150, 152 and having a passageway 154 extending longitudinally therethrough. The heater mat 50' extends around the outer circumferential surface 134 of the spacer fabric 122 with the inner surface 146 adjacent and/or fixedly coupled to the outer circumferential surface 134 of the spacer fabric 122. The spacer fabric 122 forms a pocket acting as a passageway 154 within the heater mat 50' to maintain the heater mat 50' in a generally oblong cylindrical shape. It will be appreciated that the heater mat 50' might be a flexible mat that is wrapped around the outer circumferential surface 134 of the spacer fabric 122 to form the generally oblong cylindrical shape without altering the scope of the present invention. The insulative layer 132 extends around the outer surface 148 of the heater mat 50' to provide a thermal insulating barrier.

[0043] When operation of the panel assembly 10' is initiated, power is provided to the blower 56' causing the fan 66' to rotate and draw in ambient air (arrow 68') into the blower inlet 64', as illustrated in Figure 10. Next, the fan 66' causes the forced ambient airflow to travel through the blower 56', through the plenum 54', and into the inlet duct 38', as illustrated by arrow 48'. Next, the forced ambient airflow travels from the inlet duct 38' longitudinally through the spacer fabric 122 and/or through the pocket 154 in the heater mat 50', as illustrated by arrow 52' in Figures 10 and 11. The fan 66' actively pushes the forced ambient airflow through the pocket 154 formed in the heater assembly 126 by the spacer fabric 122. The heater mat 50' heats (i.e., “warms”) the airflow as the forced ambient airflow travels through the spacer fabric 122 and/or through the pocket 154. The heated forced airflow travels from the spacer fabric 122 into the outlet duct 40', illustrated by arrow 112' in Figure 10. Next, the heated forced airflow travels from the outlet duct 40', through the outlet vent 22', and is exhausted into the ambient air outside of the panel assembly 10', as illustrated by arrow 24'.

[0044] A third embodiment of the panel assembly 10" is shown in Figures 12-14, where like double primed reference numerals represent similar elements as those described above. The panel assembly 10" of the third embodiment includes the airflow channels 42" integrally formed as part of the back panel 20" instead of being integrally formed as part of the inner panel 26 as described above in reference to Figures 1 -7. Only significant differences between the two embodiments are reflected in the Figures and the description below.

[0045] Referring to Figure 12, the panel assembly 10" includes the back panel 20” for use in the seat assembly 12 of Figure 1. The back panel 20" includes one or more outlet vents 22" which are configured to exhaust heated forced airflow exterior of the panel assembly 10", as illustrated by arrows 24". Depicted in Figure 14, the back panel 20" includes an outer cover 156 forming an outer surface 157 of the back panel 20”. The outer cover 156 might be a fabric, a vinyl, a leather, a plastic, and/or a laminated blank comprising one or more layers. The back panel 20" includes a molded portion 158 formed on the outer cover 156 and comprising a plastic and/or a molded foam. The molded portion 158 includes a plurality of molded airflow channels 42" formed by laterally spaced apart pairs of opposing channel walls 70", 72" extending in a longitudinal direction with each airflow channel 42" having a generally triangular-shaped cross-section. The adjacent distal ends of the opposing channel walls 70", 72" form channel peaks 74" between the adjacent airflow channels 42". In addition, the adjacent proximal ends of the opposing channel walls 70", 72" form channel valleys 76". It will be appreciated that the airflow channels 42" might comprise channel walls 70", 72" having alternate cross-sectional shapes without altering the scope of the present invention. In addition, the molded portion 158 includes a flange 160 extending circumferentially around an outer perimeter of the airflow channels 42". The flange 160 includes an outward facing channel 162 extending along the flange 160.

[0046] Shown in Figures 13 and 14, the panel assembly 10" includes an inner panel 26" which is a thermal insulator configured to enclose the airflow channels 42". The inner panel 26" is fixedly coupled to a rear surface 164 of the back panel 20" as described below.

[0047] In more detail, the inner panel 26" might comprise a molded panel comprising one or more of plastic, fabric, foam, and/or metal as non-limiting examples. The inner panel 26" includes a center portion 166 and a rim 168 extending around an outer perimeter of the center portion 166 and projecting away from the center portion 166. A distal end 170 of the rim 168 is configured to matingly engage with the channel 162 on the molded portion 158 of the back panel 20".

[0048] The panel assembly 10" also includes a heater mat 50" which is fixedly coupled to the channel walls 70". 72". The heater mat 50" might be insert-molded during a molding process to form the back panel 20". Alternatively, the heater mat 50" might be adhered or otherwise attached to the channel walls 70", 72" during a secondary’ operation. After the heater mat 50" is assembled with the channel walls 70", 72", the inner panel 26" is fixedly coupled to back panel 20" by inserting the distal end 170 of the rim 168 on the inner panel 26" into the channel 162 in the molded portion 158 and forming an interior cavity 36" between the back panel 20" and the inner panel 26". The inner panel 26" might be adhered, sonic welded, heat staked, or otherwise fixedly coupled to one or more of the rim 168, the heater mat 50", and/or the peaks 74" of the airflow channels 42", as non-limiting examples. The airflow channels 42" in combination with the inner panel 26" function as a plenum for air flow along the heater mat 50". [0049] Depicted in Figures 12 and 13. the interior cavity 36" between the back panel 20" and the inner panel 26" includes an inlet duct 38" and an outlet duct 40" with the airflow channels 42" fluidly connecting the inlet duct 38" to the outlet duct 40". The outlet vents 22" extend through the back panel 20" and are fluidly connected to the outlet duct 40". The inner panel 26" also includes an inlet opening 46" extending therethrough and aligned with inlet duct 38" for providing forced ambient airflow (arrow 48") into the inlet duct 38".

[0050] The panel assembly 10" also includes a blower 56" configured to direct ambient air through the airflow channels 42" and direct heated air out through the outlet vent 22" facing the occupant of the rear seat. The blower 56" is fixedly coupled to an exterior surface of the inner panel 26". It will be appreciated that the blower 56" might be mounted internally within the seat back 18 (Figure 1) without altering the scope of the present invention. The blower 56" includes a fan 66" configured to draw in ambient air (arrow 68") into a blower inlet 64" and provide forced ambient airflow to a blower outlet 62". The panel assembly 10" also includes a plenum 54" having a plenum inlet 60" fluidly connected the blower outlet 62" and a plenum outlet 58" fluidly connected to the inlet opening 46" in the inner panel 26". The plenum 54" is configured to receive the forced ambient airflow from the blower outlet 62" and provide the forced ambient airflow (arrow 48") through the inlet opening 46" into the inlet duct 38". The panel assembly 10" also includes at least one wiring harness 171 electrically connected to the heater mat 50" and/or the blower 56" and configured to selectively provide power to the heater mat 50" and/or the blower 56".

[0051] The operation of the panel assembly 10" is described in reference to Figure 12. Referring to Figure 12. when operation of the panel assembly 10" is initiated by the occupant, power is provided to the blower 56" which causes the fan 66" to rotate and draw ambient air (arrow 68") through the blower inlet 64" and into the blower 56". The rotating fan 66" provides forced ambient air (arrow 48") to the blower outlet 62" which travels through the plenum inlet 60" into the plenum 54", through the plenum outlet 58", and through the inlet opening 46" in the inlet duct 38". Next, the forced ambient air (arrow 110") travels from the inlet duct 38" into the airflow channels 42". Power is provided to the heater mat 50" during operation of the panel assembly 10" which causes the heater mat 50" to heat the air as the forced airflow travels along the airflow channels 42" (arrow 52"). The forced heated airflow travels from the airflow channels 42 and into the outlet duct 40", as illustrated by arrow 52". Next, the heated forced airflow travels from the outlet duct 40" and through the outlet vents 22", as illustrated by arrow s 24", and is exhausted to the ambient air exterior of the seat assembly 12. Operation of the panel assembly 10" is selectively terminated based on input from the occupant, as a non-limiting example.

[0052] A fourth embodiment of the panel assembly 10-1 is shown in Figure 15, where reference numerals followed by a ^CL-1” represent similar elements as those described above. The panel assembly 10-1 of the fourth embodiment includes a single airflow channel 42-1 formed betw een the inner panel 26-1 and the molded portion 158-1 of the back panel 20-1 instead of a plurality of airflow' channels 42" formed in the molded portion 158 of panel assembly 10" shown in Figure 14. Only significant differences between the embodiments are reflected in the Figures and the description below.

[0053] Referring to Figure 15, the panel assembly 10-1 includes the back panel 20-1 having the molded portion 158-1 formed on the rear side of the outer cover 156-1. The molded portion 158-1 includes a central portion 172 extending laterally between the opposing flanges 160-1 defining a recessed cavity in the molded portion 158-1. A first heater mat 50-1 is fixedly coupled to the central portion 172 of the molded portion 158-1. A second heater mat 50-lb is fixedly coupled to the center portion 166-1 of inner panel 26-1 and spaced between the opposing rims 168-1. In certain embodiments, the heater mats 50-1, 50-lb are adhered to the inner panel 26-1 and the molded portion 158-1, respectively. It will be appreciated that a single heater mat 50-1, 50-lb might be fixedly coupled to the one of the inner panel 26-1 and the central portion 172 of the back panel 20-1 with the other one of the inner panel 26-1 and the central portion 172 of the back panel 20-1 lacking a heater mat 50-1, 50-lb without altering the scope of the present invention. The distal end 170-1 of the rim 168-1 on the inner panel 26- 1 is inserted into the channel 162-1 extending along the flange 160-1 forming an interior cavity 36-1 between the inner panel 26-1 and the recessed cavity in the molded portion 158-1. The interior cavity 36-1 includes the airflow' channel 42-1 between the inner panel 26-1 and the recessed cavity in the molded portion 158-1. During operation, forced ambient airflow 52-1 travels through the airflow channel 42-1 and is heated by the heater mats 50-1, 50-lb.

[0054] A fifth embodiment of the panel assembly 10-2 is shown in Figure 16, where reference numerals followed by a ”-2" represent similar elements as those described above. The panel assembly 10-2 of the fifth embodiment includes a heater mat 50-2 which is folded into a corrugated shape and inserted into the airflow' channel 42-2 betw een the inner panel 26-2 and the molded portion 158-2 of the back panel 20-2 instead of fixedly coupling the heater mats 50-1, 50-1 b to the inner panel 26-1 and/or to the molded portion 158-1, as shown in Figure 15. Only significant differences between the embodiments are reflected in the Figures and the description below.

[0055] Referring to Figure 16, the panel assembly 10-2 includes the back panel 20-2 having the molded portion 158-2 formed on the rear side of the outer cover 156-2. The molded portion 158-2 includes a central portion 172-2 extending laterally between the opposing flanges 160-2 defining a recessed cavity in the molded portion 158-2. The heater mat 50-2 is folded into a generally corrugated shape (i.e., “accordion style”) having alternating peaks 74-2 and valleys 76-2. Next, the folded heater mat 50-2 is inserted into the recessed cavity defined between the central portion 172-2 and the opposing flanges 160-2 of the molded portion 158-2. It will be appreciated that heater mat 50-2 might be formed into alternate shapes, such as an undulating shape as a non-limiting example, with alternating upward facing and downward facing curved portions as a non-limiting example, without altering the scope of the present invention. In addition, the heater mat 50-2 might be fixedly coupled to one or both of the inner panel 26-2 and the molded portion 158-2 without altering the scope of the present invention. Next, the inner panel 26-2 is fixedly coupled to the molded portion 158-2 by inserting the distal end 170- 2 of the rim 168-2 on the inner panel 26-2 into the channel 162-2 extending along the flange 160-2 to form an interior cavity 36-2. The interior cavity 36-2 includes the airflow channel 42- 2 between the inner panel 26-2 and the recessed cavity in the molded portion 158-2. During operation, forced ambient airflow 52-2 travels through the airflow channel 42-2 and is heated by the heater mat 50-2.

[0056] As discussed above, the panel assembly 10, 10', 10", 10-1, 10-2 of the present invention provides efficient forced air heating to occupants of the rear row' of seat assemblies 12 in an automotive vehicle 14. The panel assembly 10, 10', 10", 10-1, 10-2 includes one or more heater mats 50, 50', 50", 50-1, 50-lb, 50-2 configured to warm the airflow' passing through one or more airflow channels 42, 42", 42-1, 42-2. In addition, the panel assembly 10, 10', 10", 10-1, 10-2 includes a blower 56, 56', 56" having a fan 66, 66', 66" which draws in ambient air and provides forced ambient airfl ow through the airflow channels 42, 42", 42-1, 42-2. The heated forced airflow' is exhausted through an outlet vent 22, 22', 22" in panel assembly 10, 10', 10", 10-1, 10-2. The panel assembly 10, 10', 10", 10-1. 10-2 might be fixedly coupled to and/or integrated within a back panel 20, 20'. 20", 20-1, 20-2 for the automotive seat assembly 12. [0057] The invention has been described in an illustrative manner, and it is to be understood that the terminology’, which has been used, is intended 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.

Claims

What is claimed is:

1. A panel assembly for an automotive seat assembly, comprising: a cover having an outlet vent; an inner panel fixedly coupled to the cover and defining a cavity therebetween, the cavity’ comprising an outlet duct fluidly connected to the outlet vent, an inlet duct spaced apart from the outlet duct, and an airflow channel fluidly connecting the inlet duct to the outlet duct; a heater mat extending along the airflow channel and configured to warm air within the airflow channel; and a blower having a blower inlet fluidly connected to a blower outlet which is fluidly connected to the inlet duct, wherein the blower is configured to draw in ambient airflow into the blower inlet and provide forced ambient airflow to the inlet duct, through the airflow channel, into the outlet duct, and through the outlet vent; wherein the heater mat warms the forced ambient airflow' as the forced ambient airflow travels along the airflow channel.

2. The panel assembly as set forth in claim 1, wherein: the heater mat is fixedly coupled to the airflow' channel by an adhesive.

3. The panel assembly as set forth in claim 1, wherein: the heater mat is folded into a corrugated shape prior to inserting the heater mat into the airflow channel.

4. The panel assembly as set forth in claim 1, further comprising: a spacer fabric having an outer circumferential surface extending between opposing end surfaces; and an insulative layer; wherein: the heater mat includes an inner surface opposing an outer surface with the inner surface of the heater mat extending at least partially around the outer circumferential surface of the spacer fabric such that the spacer fabric forms a pocket within the heater mat; the insulative layer extends circumferentially around the outer surface of the heater mat to form a heater assembly; and the heater assembly is inserted into the airflow- channel.

5. The panel assembly as set forth in claim 1, further comprising a second heater mat, wherein: the heater mat is fixedly coupled to one of the cover and the inner panel; and the second heater mat is fixedly coupled to the other one of the cover and the inner panel.

6. The panel assembly as set forth in claim 1, wherein: one or more of the inner panel and the cover includes a molded portion; and the airflow channel includes one or more channel walls formed in the molded portion.

7. The panel assembly as set forth in claim 6, wherein: the airflow channel comprises a plurality of channel walls formed in the molded portion which are laterally spaced apart and forming alternating peaks and valleys and extending in a longitudinal direction.

8. The panel assembly as set forth in claim 7, wherein: the heater mat is insert-molded as part of the molded portion.

9. The panel assembly as set forth in claim 8, wherein: the molded portion comprises a molded foam.

10. The panel assembly as set forth in claim 8, wherein: the molded portion comprises a plastic.

11. The panel assembly as set forth in claim 1, wherein: the cover is integrally formed with or fixedly coupled to a back panel for the automotive seat assembly.

12. A panel assembly for use in an automotive seat assembly, comprising: a back panel for use in a seat assembly and having an outlet vent; an inner panel fixedly coupled to the back panel and defining a cavity therebetween, the cavity comprising an outlet duct fluidly connected to the outlet vent, an inlet duct spaced apart from the outlet duct, and an airflow channel fluidly connecting the inlet duct to the outlet duct; a heater mat extending along the airflow channel and configured to warm air within the airflow channel; and a blower having a blower inlet fluidly connected to a blower outlet which is fluidly connected to the inlet duct, wherein the blower is configured to draw in ambient airflow into the blower inlet and provide forced ambient airflow to the inlet duct, through the airflow channel, into the outlet duct, and through the outlet vent; wherein the heater mat warms the forced ambient airflow as the forced ambient airflow travels along the airflow channel.

13. The panel assembly as set forth in claim 12, wherein: the heater mat is folded into a corrugated shape prior to inserting the heater mat into the airflow channel.

14. The panel assembly as set forth in claim 12, further comprising: a spacer fabric having an outer circumferential surface extending between opposing end surfaces; and an insulative layer; wherein: the heater mat includes an inner surface opposing an outer surface with the inner surface of the heater mat extending at least partially around the outer circumferential surface of the spacer fabric such that the spacer fabric forms a pocket within the heater mat; the insulative layer extends circumferentially around the outer surface of the heater mat to form a heater assembly; and the heater assembly is inserted into the airflow channel.

15. The panel assembly as set forth in claim 12, further comprising a second heater mat, wherein: the heater mat is fixedly coupled to one of the back panel and the inner panel: and the second heater mat is fixedly coupled to the other one of the back panel and the inner panel.

16. The panel assembly as set forth in claim 12, wherein: one or more of the back panel and the inner panel includes a molded portion; and the airflow channel includes one or more channel walls formed in the molded portion.

17. The panel assembly as set forth in claim 16, wherein: the airflow channel comprises a plurality of channel walls formed in the molded portion which are laterally spaced apart and forming alternating peaks and valleys and extending in a longitudinal direction.

18. The panel assembly as set forth in claim 17, wherein: the heater mat is insert-molded as part of the molded portion.

19. The panel assembly as set forth in claim 18, wherein: the molded portion comprises a molded foam.

20. The panel assembly as set forth in claim 18, wherein: the molded portion comprises a plastic.