阅读说明：本技术 悬置织物座椅加热系统 (Suspended fabric seat heating system ) 是由 克雷格·马丁·欧门 兰迪·詹姆斯·塞耶斯 塞缪尔·史密斯 曼弗雷德·穆勒 于 2019-08-02 设计创作，主要内容包括：一种悬置织物座椅包含织物座椅表面,该织物座椅表面由具有加热元件纤维的编织织物材料形成。加热元件纤维与导体电连通。载体被包覆模制到座椅表面上。载体和导体设置在框架中,并且连接器安装到框架、与导体电连通。(A suspended fabric seat includes a fabric seating surface formed from a woven fabric material having heating element fibers. The heating element fibers are in electrical communication with the conductor. The carrier is overmolded onto the seating surface. The carrier and the conductor are disposed in the frame, and the connector is mounted to the frame in electrical communication with the conductor.)

1. A seat, comprising:

a fabric seating surface formed from a woven fabric material, the fabric having heating element fibers in electrical communication with a conductor;

a carrier overmolded onto the seating surface;

a frame, wherein the carrier and the conductor are disposed in the frame; and

a connector in electrical communication with the conductor.

2. The seat of claim 1 wherein said heating element fibers are woven into said fabric.

3. The seat of claim 2 wherein the heating element fibers are woven into the fabric to define a relaxed region in the heating element fibers.

4. The seat of claim 2 wherein said fabric is woven from warp and weft fibers and wherein said heating element fibers are positioned side-by-side with said warp fibers.

5. The seat of claim 1 wherein the carrier is disposed in a channel in the frame.

6. The seat of claim 1, wherein the conductor is disposed in a channel in the frame.

7. The seat of claim 5, wherein the conductor is disposed in the channel.

8. The seat of claim 1, wherein the conductor is a conductive strip.

9. The seat of claim 8 wherein the strap is positioned in a strap socket and wherein the heating element fiber is captured between the conductive strap and the strap socket.

10. The seat of claim 8 wherein the carrier and the conductor are overmolded onto the seat surface such that ends of the heating element fibers extend beyond a perimeter of the carrier.

11. The seat of claim 1 wherein a portion of the carrier is formed of an electrically conductive polymer material and another portion is formed of a non-electrically conductive polymer material, the fabric being disposed between the electrically conductive polymer material and the non-electrically conductive polymer material, and wherein the heating element fibers extend into the carrier.

12. The seat of claim 1 wherein some of said fabric is formed from monofilaments.

13. The seat of claim 12 wherein the monofilament is formed of a block copolymer.

14. The seat of claim 1 wherein the heating element fibers have a target ohmic resistance for achieving a temperature of about 30 ℃ to about 50 ℃.

15. The seat of claim 1, comprising a temperature sensor.

16. The seat of claim 15, wherein the temperature sensor is a fiber incorporated into the seat surface.

17. A method for manufacturing a seat, comprising:

overmolding a carrier onto a fabric seating surface formed from a woven fabric material having heating element fibers;

contacting the heating element fiber with a conductor; and

positioning the carrier and the conductor in a frame.

18. The method of claim 17, wherein the carrier is positioned in a channel in the frame.

19. The method of claim 17, wherein the conductor is positioned in a channel in the frame.

20. The method of claim 18, wherein the conductor is positioned in the channel.

Background

The present invention relates to suspended fabric seats, and more particularly to suspended fabric seat heating systems incorporated into the seat fabric.

Suspended or suspended fabrics have been commonly used as replacements for hard surfaces of seats and foam padding surfaces. Such a suspended fabric seating surface can provide the comfort of a foam cushioned surface at a weight similar to a hard plastic seat and at a relatively low cost. Advantageously, the suspended fabric seat provides better comfort using a preset tension in the suspended fabric, which can be adjusted for comfort requirements, for reaction forces, provides tension regionally across the seat surface, and is accommodated in a curved frame for styling characteristics and comfort profiles in tilt kinematics.

However, vehicle seats are typically of the foam cushion type and are designed for comfort. Such foam cushioned seats comprise steel structures and stamped components that are welded together to form a seat structure subassembly. A steel suspension layer under the occupant is added to bridge the distance between the seat structure beams. The steel suspension provides some hammock effect between structural struts in the seat structure to enhance comfort characteristics. A foam padding material, such as Polyurethane (PU), covers the steel structure and suspension and provides force and deflection compliance (force vs. deflection) for occupant comfort during use. In a typical configuration, the foam layer is covered with a trim cover that may include leather, vinyl and/or polyester textiles, a lofted fabric breather layer, and a felt or tie layer to prevent wrinkling. These layers are typically used for aesthetics and to manage comfort requirements as well as gravity during a crash event.

However, a disadvantage of foam is that, although it provides comfort, it is difficult to heat. PU foam has a high R-value or high thermal insulation properties, which makes it difficult to transfer heat from the vehicle passenger compartment to the seat surface. The foam is also typically very thick 50mm to 150mm (about 2 inches to 6 inches) and is generally void-free, which impedes air flow from the seat environment to the skin of the occupant. The heating module is used to compensate for the R value of the foam in the current car seat and the specific heat of the seat trim cover. The trim cover is, for example, leather, cloth, vinyl, etc., which covers the foam cushion and increases the resistance to the transfer of passenger compartment heat to the occupant.

The suspended fabric seat may be heated using a number of approaches. One known way of such seats is to use a blower system. The conditioned (heated or cooled) forced air may be funneled to blow against the backside of the fabric. The porosity of the suspended fabric allows forced air to heat or cool the occupant's skin. The forced air provides a cooling sensation to the seat user by extracting heat and moisture from the seat (through evaporative cooling). The blower module may be used to vary the speed of the air and may adjust the air temperature to a target temperature via a forced air device to assist in the heating or cooling function.

Another way in which the suspended fabric seat may be heated is by using heating elements that are sewn, welded or otherwise attached to the back of the seating surface. However, this design involves a barrier or distance between the occupant and the heating source, creating an air gap. The air gap acts as a thermal barrier, thus reducing the heating efficiency of the heating element. The reduced efficiency requires increased power (taken from the entire vehicle system) to be provided to the heating element. This may be particularly important with the transition to hybrid electric and all-electric vehicles.

In addition, the pad heaters attached to the back of the seat surface impede the stretching of the suspended fabric and limit the hammock effect required for seat comfort. That is, when the hammock effect is limited, comfort is reduced, adversely affecting the fabric fiber stretch/elongation and changing the deflection retraction force (IFD) of the seat. Furthermore, suspended seats with attached heater modules may create hard spots or uneven hard locations in the suspended fabric, again reducing occupant comfort. Further, the heating element system is costly due to the parts and labor required for assembly.

Another disadvantage of the heating element system is that the overall aesthetics of the seat may be compromised. If the fabric is very porous, light colored or transparent/translucent, the heating element can be seen through the fabric. Furthermore, thermocouples and other connectors/conductors require wiring harnesses that can be difficult to locate and do not conform to the modern aesthetics of brevity.

Accordingly, there is a need for a suspended fabric seat heating system that is incorporated into the seat fabric. Desirably, such a system allows for the use of less current (reduced amperage) to heat the seat. It is still more desirable that such a system heat the seat close to the occupant's skin in order to provide an efficient heating scheme, resulting in shorter heating times and reduced current consumption. It is still more desirable in such systems that the electronic circuitry within the seat is minimally visible or invisible to the vehicle occupant and does not affect the deflection of the suspended fabric to reduce occupant comfort.

Disclosure of Invention

In one aspect, a suspended seat includes a fabric seat surface formed from a woven fabric material having heating element fibers therein. The heating element fibers are in electrical communication with the conductor. The carrier is overmolded onto the seating surface. The carrier and the conductor are disposed in the frame, and the connector is in electrical communication with the conductor.

Advantageously, a suspension seat according to the present disclosure includes a heating system incorporated into the suspension seat fabric. The system allows for the use of less current to heat the seat and heat the seat close to the occupant's skin to provide an efficient heating scheme.

In an embodiment, the heating element fibers are woven into the fabric. Alternatively, the heating element fibers may be disposed on the surface of the fabric. The fabric is woven by warp fibers and weft fibers. In an embodiment, the heating element fibers are arranged side by side with the warp fibers. Heating element fibers may replace some of the warp fibers. The heating element fibers may also replace some of the weft fibers.

The heating element fibers are in electrical communication with the conductor. In an embodiment, the conductor may be a conductive strip, and the strip is positioned in a strip socket with the heating element fiber captured between the conductive strip and the strip socket.

The carrier is overmolded onto the seating surface. The carrier is disposed in a channel in the frame and the conductor is disposed in a channel in the frame. In an embodiment, the conductor and the carrier are arranged in a common channel in the frame.

In an embodiment, the carrier and the conductor are overmolded onto the seat surface such that the ends of the heating element fibers extend beyond the perimeter of the carrier.

The carrier and conductor may be overmolded onto the seating surface such that the ends of the heating element fibers extend beyond the perimeter of the carrier. The seating surface and the carrier are disposed in the frame, and the connector is in electrical communication with the conductor.

In an embodiment, the conductor is formed as part of the carrier. In an embodiment, one portion of the carrier is formed of a conductive polymer material and another portion is formed of a non-conductive polymer material. The fabric is disposed between the conductive polymer material and the non-conductive polymer material. One suitable conductive polymer material is a conductive thermoplastic material.

In one embodiment, the conductor is a powdered metal coated onto the fabric. In such an embodiment, the carrier is overmolded onto the fabric and the powder metal. In another embodiment, the conductor is a conductive strip with the fabric in contact with the conductive strip. In this embodiment, the carrier is overmolded onto the fabric and conductive strips. The frame may contain a channel, and the conductive strip may be positioned in the channel.

In embodiments, some of the fabrics are formed from monofilaments. The monofilaments can be formed, for example, from block copolymers. The monofilaments may be weft fibers and may provide elasticity to the seat surface to achieve a desired occupant pressure profile for the seat shape, thereby making the seat more comfortable.

In an embodiment, the heating element fiber has a target ohmic resistance for achieving a temperature of about 30 ℃ to about 50 ℃. 15. In an embodiment, the seat may contain a temperature sensor. The temperature sensor may be a fiber incorporated into the seat surface.

A method for manufacturing a seat includes overmolding a carrier onto a fabric seat surface formed from a woven fabric material having heating element fibers. In the method, the heating element fibers are brought into contact with the conductors, and the carrier and conductors are positioned in the frame. In the method, the carrier is positioned in a channel in the frame and the conductor is positioned in a channel in the frame. In some methods, the conductor and the carrier are positioned in a common channel.

In some methods, the ends of the heating element fibers extend beyond the perimeter of the carrier, and the carrier is partially electrically conductive. A frame is formed and the carrier is positioned in the frame.

In one method, the overmolding of the carrier onto the fabric is in the form of a first overmolding of the conductive polymeric material to which the fabric is positioned and a second overmolding of the non-conductive polymeric material onto the fabric and the conductive polymeric material.

In another method, the overmolding of the carrier onto the fabric is in the form of a first overmolding of a conductive polymer material with the fabric of powder metal positioned thereto and a second overmolding of a non-conductive polymer material onto the fabric, powder metal and conductive polymer material.

In yet another method, overmolding the carrier onto the fabric includes overmolding a non-conductive polymer material onto the fabric and the conductive strips. In the method, the frame has a channel, and the conductive adhesive is disposed in the channel. The carrier is positioned on the adhesive with the ends of the heating element fibers in contact with the conductive adhesive.

These methods may all include positioning a connector on the frame in electrical connection with the conductor.

These and other features and advantages of the present device will become apparent from the following description, taken in conjunction with the accompanying drawings and the appended claims.

Drawings

The benefits and advantages of embodiments of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:

FIG. 1 is an example of a suspended seat fabric according to the present disclosure;

fig. 2 illustrates an embodiment of a seat bottom surface in a seat surface carrier according to aspects of the present disclosure;

FIGS. 3A and 3B illustrate the basic configuration of an embodiment of the seat bottom in an assembled view (FIG. 3A) and an exploded view (FIG. 3B), showing the seat bottom surface, conductors and seat frame in a carrier;

FIG. 4 is a diagram of an embodiment of a seating surface showing heating element fibers or conductive wires woven into the fabric;

FIG. 5 shows a conductive strip and strip socket;

FIG. 6 is a perspective view of the strap socket;

FIG. 7 shows the conductive strip and socket in place on the opposite side of the heating element fiber;

FIG. 8 illustrates the conductive strip and the feed socket when the conductive strip is positioned for insertion into the strip socket with the heating element fibers captured therein;

FIG. 9 illustrates trimming of the heating element fibers after the conductive strips and strip receptacles have been engaged with the heating element fibers;

FIG. 10 illustrates two ways in which the conductive strip and strip socket (with the heating element fibers captured) can be mounted to the seat frame;

11A-11C are detailed views of the construction of the embodiment of the seat bottom showing various routing of conductors and electrical connectors;

12A-12D illustrate various examples of configurations of heating element fibers in a seat frame; and

fig. 13 is a flow chart of a method for manufacturing a suspended fabric seat and heating system according to the present disclosure.

Detailed Description

While the present disclosure is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described one or more embodiments with the understanding that the present disclosure is to be considered as illustrative only and is not intended to limit the disclosure to any particular embodiment described or illustrated.

Referring to the drawings and in particular to FIG. 1, an example of a woven fabric 10 for suspending a fabric seating surface 12 is shown. The fabric 10 is woven from fibers or yarns (used interchangeably herein) and includes a series of warp fibers 14 (shown as vertical fibers) and weft fibers 16 (shown as horizontal fibers). Typically, the warp fibers 14 are filling yarns (fill yarns) and extend in the front-rear direction of the seat bottom surface or the up-down direction of the seat back surface or the headrest. The weft fibers 16 are typically monofilament fibers that extend in a left-right direction transverse to the warp fibers 14. An example of a woven fabric is disclosed in US 8,329,281 to Coffield, commonly assigned with the present application, the disclosure of which is incorporated herein in its entirety. Examples of monofilament fibers are disclosed in US 8,857,033 to Coffield et al and US 9,156,211 to Coffield, which are commonly assigned with the present application, the disclosures of which are incorporated herein in their entirety.

The warp fibers 14 or yarns are relatively inelastic and have an elongation of less than about 12% to 15%, and preferably less than about 5%. The warp fibers 14 impart bulk and thickness to the fabric 10 and can color the colored fabric suspension components. The warp fibers 14 are used to shape the seat surface 12 by pulling the monofilament (weft) fibers 16 out of a straight position to form a parabolic shape throughout the suspended fabric seat surface 10. The warp fibers 14 may be formed of a suitable material such as polyester yarn.

Typically, the weft fibers 16 are elastic and may be formed of, for example, block copolymer monofilaments. The fibers 16 may be oriented and elongate more than 10% and below about 30% when measured on a stress-strain curve. The monofilament weft fibers 16 may be oriented and conditioned (e.g., at elevated temperatures) and may be zoned to achieve a desired occupant pressure profile for the seat shape, thereby making the seat more comfortable.

As seen in fig. 1, a heating element fiber or conductive wire 18 is interposed with the warp fill fiber or yarn 14. In embodiments, the heating element fibers 18 may replace all or some of the stuffer yarns 14, or they may supplement the stuffer yarns 14. In an embodiment, the heating element fibers 18 are semiconductors having a target ohmic resistance for achieving a temperature of about 30 ℃ to about 50 ℃ when powered. Some examples of heating element fibers 18 are coated stainless steel wires, copper, nanotube material such as nanotube polyester, carbon yarn, and the like. Those skilled in the art will recognize other suitable heating element fibers 18. In some embodiments, some of the weft fibers 14 may also contain, or be replaced or supplemented by, heating element fibers 18.

As noted above, in embodiments, the heating element fibers 18 are woven in place of some of the warp fibers or yarns in order to limit the amount of increased volume and thickness and reduce the visual and aesthetic impact on the seat surface 12. It should be appreciated that the heating element fibers 18 may also be attached to the bottom of the seating surface 12 by, for example, stitching, adhesives, etc. In some embodiments, the heating element fibers 18 may be woven into the fabric 10 with some amount of slack, as indicated at 11 in fig. 4. As will be appreciated by those skilled in the art, the heating element fibers 18 may be formed of a material that is less elastic than one or both of the warp and weft fibers. Thus, to allow the heating element fibers 18 to conform to the seat surface 12 when the seat surface 12 conforms to the user's body, the slack 11 in the heating element fibers 18 allows for such a fit while preventing overstressing or overstretching of the heating element fibers 18.

Referring to fig. 4-10, in an embodiment, the heating element fibers 18 are secured to an electrically conductive member 19, such as a highly conductive strip. The heating element fibers 18 may be secured to the conductive strips 19 in a variety of ways. For example, the coating on the heating element fibers 18 may be removed, and the bare heating element fibers 18 may be welded or otherwise attached to the conductive strip. In an embodiment, as illustrated in fig. 5-8, the heating element fibers 18 may be captured between the highly conductive strip 19 and a receiving element 21 (e.g., the illustrated conductive strip receptacle 21) configured to receive the heating element fibers 18 and the conductive strip 19. In such embodiments, the conductive strip 19 and strip socket 21 may be configured, for example, roughened to peel or remove any coating from the heating element fibers 18 when the conductive strip 19 is inserted into the strip socket 21 and the heating element fibers 18 are captured therebetween. This arrangement serves to provide the necessary electrical contact between the heating element fibres 18 and the electrically conductive strips 19.

The woven fabric 10 is overmolded with a carrier 22. The fabric 10 is installed into a carrier mold and the fabric 10 is overmolded with a carrier 22 material. The carrier 22 material may be, for example, a block copolymer chemically similar to the fabric 10 monofilaments (the weft fibers 16). This allows for chemical bonding during the injection molding process. Mechanical bonding also occurs during overmolding. Preferably, the heating element fibers 18 in the fabric 10 are designed as parallel circuits in view of heating efficiency and robustness.

Fig. 2 illustrates an embodiment of the seat bottom surface 12 in which the carrier 22 is overmolded onto the seat surface fabric 10. In the illustrated embodiment, the seat bottom surface 12 and the carrier 22 are shown with the heating element fibers 18 on both sides and outside of the carrier 22. In an embodiment, the heating element fibers 18 are woven into the fabric 10, as illustrated in fig. 1. In fig. 2, the heating element fibers 18 are visible where the fibers 18 extend beyond the carrier perimeter 50. The heating element fibers 18 are continuous (to both sides of the seat and into the carrier 22) to complete the electrical circuit. The heating element fibers 18 may be located in the seating surface 12 to minimize wear.

In the embodiment illustrated in fig. 10, the heating element fibers 18 do not extend beyond the carrier 22 and are not molded into the carrier. Instead, the heating element fibers 18 are captured and clamped between the conductive strip 19 and the strip socket 21 within the perimeter or boundary of the carrier 22.

It should be understood that some types of heating element fibers 18 may be coated fibers, and the coating of the coated fibers 18 (e.g., coated stainless steel fibers) is removed so that an electrical circuit may be completed. The removal of the coating can be carried out, for example, by: sanding the ends of the fibers 18, grinding during installation (as in the heating element fibers 18 and configurations of fig. 4-10), heating, or other methods as will be recognized by those skilled in the art. Removal of the coating exposes the conductive core of the heating element fibers 18.

Fig. 3A and 3B illustrate an assembled view and an exploded view, respectively, of an embodiment of the seating surface 12 and the carrier 22, conductors 24, and frame 26. The conductors 24 are shown as separate components, but the conductors 24 may be incorporated into the carrier 22 as described herein in connection with certain embodiments. In an embodiment, the conductor 24 is disposed in a channel 28 formed in the frame 26. A connector 30, shown in an exploded position, is electrically connected to the conductor 24 to provide power and control to the heating element fiber 18. Fig. 11A-11C show the negative side 32 and the positive side 34, respectively, of the conductor 24 as it is disposed in the channel 28 and the electrical connector 30. The connector 30 is shown in both a front view and a rear view of the frame 26.

Fig. 10 illustrates two ways in which the seating surface 12, carrier 22, and conductor/heating element fibers (conductive strip 19 and strip socket 21 with the heating element fibers 18 captured) may be mounted in the frame 26. On the left side of fig. 10, the conductive ribbon 19/heating element fiber 18/ribbon socket 21 and carrier 22 are mounted in a common channel 28 in the frame, and both are press fit into the channel 28 in the frame 26. On the right side of fig. 10, the conductive strips 19/heating element fibres 18/strip sockets 21 are mounted in conductor channels 28 'in the frame 26, and the carrier 22 is mounted in a carrier channel 28 in the frame 26 separate from the conductor channels 28'. The conductive ribbon 19/heating element fiber 18/ribbon socket 21 and carrier 22 may be press fit into the channel 28/28'. Those skilled in the art will recognize other ways of securing the conductive ribbon 19/heating element fiber 18/ribbon socket 21 and carrier 22 in the frame 26. Once installed and secured in the frame 26, electrical connections (e.g., power and control) may be provided to the conductive strips 19/heating element fibers 18/strip receptacles 21, as shown in fig. 11A-11C.

In an embodiment, temperature measurement or sensing is provided in the heating system. Referring briefly again to fig. 1, in an embodiment, a sensor, such as a temperature sensor, is provided in the form of one or more fibers 31. The temperature sensor fiber 31 may be, for example, a thermocouple fiber incorporated into the seat surface 12 along with the weft or monofilament fiber 16. It should be appreciated that the temperature sensor fiber 31 may also be incorporated with the warp fiber 14 or as another fiber. Thus, the temperature sensor fiber 31 may be fabricated to have similar properties as the fibers 14 or 16 around which it is incorporated into the seat surface 12. The temperature sensor fiber 31 may be incorporated into the seat heating system with a switch to provide, isolate or modify power to the heating element fiber 18. Other sensors for temperature measurement may also be used, and are within the scope and spirit of the present disclosure. It is contemplated that the heating element fibers 18 may be controlled or monitored individually, or may be controlled in groups and as a whole.

Fig. 12A-12D illustrate various examples of the manner in which the heating element fibers 18 positioned in and extending through the carrier 22 may be electrically connected to the connector 30 via the frame 26.

Fig. 12A illustrates a conductor 24 that uses a conductive thermoplastic material 36 to which the ends of the heating element fibers 18 are connected. In an embodiment, the electrically conductive thermoplastic material 36 is an overmolded portion of the carrier 22. That is, the first shot or coating of carrier 22 overmold material is an electrically conductive thermoplastic material 36 with exposed fibers 18 laid into the electrically conductive thermoplastic material 36. A second shot of nonconductive thermoplastic material 38 is molded over the ends of the fibers 18 and the conductive thermoplastic material 36 to seal the ends of the fibers 18 and form a seat surface/carrier assembly 48. The seating surface/carrier assembly 48 is then positioned in the frame channel 28.

In fig. 12B, the powder metal 40 is applied to the fabric 10 and the carrier 22 is overmolded onto the fabric 10 and the powder metal 40. The powder metal 40 bridges the spaces between the fibers 18 and the injection pressure during overmolding of the carrier 22 wets the powder metal 40 to form the conductors 24. The seating surface/carrier assembly 48 is then positioned in the frame channel 28.

In fig. 12C, the conductive foil elements 42 (e.g., metal foil strips) are positioned in a carrier mold tool prior to positioning the fabric 10 in the mold tool. The carrier 22 is overmolded pressing the foil 42 onto the heating element fiber 18 ends to form the conductors 24, and then the seat surface/carrier assembly 48 is positioned in the frame channel 28.

In fig. 12D, a conductive adhesive 44 is used. In this embodiment, a conductive adhesive 44 (such as a conductive epoxy that may be applied, for example, in the form of a strip) is positioned in the carrier tool prior to loading the fabric 10. In the molding process, the injected carrier resin flows over the heating element fiber 18 ends and the binder 44, and the injection pressure and resin thermally cures the binder 44 and wets the heating element fiber 18 ends and the fabric 10 to form the conductors 24. Those skilled in the art will recognize other suitable conductive adhesives 44.

It should be appreciated that in each of the disclosed embodiments, the conductor 24 (whether separate from or formed as part of the carrier 22) is reliably electrically attached to each of the heating element fibers 18 over the entire seating surface 12. It is expected that about 2 to 30 yarns spaced about 10 to 30mm apart will provide the required level of heating. The over-molding of carrier 22 maintains fabric 10 under tension and also hides the conductive path (e.g., conductor 24) from heating element fibers 18 until terminating at electrical terminal connector 30.

A method 100 for manufacturing a suspended fabric seat heating system is shown in fig. 13 and comprises: at step 102, the woven fabric 10 is cut as desired; and at step 104, positioning the woven fabric 10 (with the heating element fibers 18 in the fabric 10) in a carrier 22 mold. At step 106, the carrier 22 is overmolded onto the fabric 10 with a block copolymer or other suitable polymeric material. Preferably, the carrier overmold material is chemically similar to a textile monofilament (e.g., weft fibers 16) such that chemical bonding as well as mechanical bonding occurs during the injection molding process.

In one method, carrier 22 overmolding is performed as a two shot or two coat process. In the first shot, the overmolding material is an electrically conductive thermoplastic material 36. Next, the fabric 10 with the heating element fibers 18 is laid onto the conductive thermoplastic material 36, and a second shot of the non-conductive thermoplastic material 38 is laid over the fabric 10 and the conductive thermoplastic material 36.

In another approach, carrier 22 overmolding is also performed as a two shot or two coat process. In the first shot, the overmolding material is a non-conductive thermoplastic material 38. The powdered metal 40 is applied to the fabric 10 and powdered metal 40 are laid onto the non-conductive thermoplastic material 38. The second shot of nonconductive thermoplastic material 38 is laid over the fabric 10 and metal 40 and the first shot of nonconductive thermoplastic material 38.

In yet another method, carrier 22 overmolding is performed in a single shot or coating process. An electrically conductive element 42, such as a metal foil or tape, is positioned in the overmolding tool, and the fabric 10 with the heating element fibers 18 is laid onto the element 42. The non-conductive thermoplastic material 28 is laid over the fabric 10 and the elements 42.

In yet another method, the carrier 22 is overmolded in a two-shot or two-coat process, wherein the fabric 10 is sandwiched between two coats of the nonconductive thermoplastic material 38 to form the carrier 22. The ends of the heating element fibers 18 are exposed beyond the carrier periphery 50. A conductive adhesive 44 is applied to the outer surface of the carrier 22 or the bottom of the frame channels 28 to make contact with the exposed ends of the thermal element fibers 18.

Once the fabric or seating surface/carrier assembly 48 is formed, any insulating coating is removed from the heating element fibers 18 outside the overmolded fabric/carrier assembly 48 in a post-processing step of step 108. The insulative coating (if present) may be removed by sanding, heating, or other suitable methods to expose the conductive core of the heating element fibers 18. If desired, the carrier 22 and fabric 10 may be trimmed to remove excess polymer beyond the carrier perimeter 50 for higher quality and fit into the frame 26. In some methods, a small amount of the fabric 10 with exposed ends of the heating element fibers 18 remains beyond the carrier perimeter 50.

The frame 26 is molded to receive the seating surface/carrier assembly 48. In embodiments, the frame 26 has a channel 28, and depending on which configuration of fabric/carrier assembly 48 is used, the conductors 24 may be coated or mounted in the channel 28, preferably in the bottom of the channel 28, or the fabric/carrier assembly 48 incorporating the conductors 24 is mounted directly into the channel 28, as in step 110.

In one method, the sanded ends of the heating element fibers 18 are folded over the carrier 22 to expose the conductive fibers to the conductors 24 as needed, and the fabric/carrier assembly 48 is installed into the frame.

In another method for manufacturing a suspended fabric seat heating system, the fabric 10 is woven (with the heating element fibers 18 in the fabric 10) such that the heating element fibers 18 do not extend to the edges of the fabric 10. The heating element fibers 18 may be woven into the fabric 10 with some slack. The heating element fibers 18 are captured between conductive strips 19 and strip receivers 21 (such as the strip receptacles shown) on both sides of the fabric 10. Carrier 22 is overmolded onto fabric 10 outside of conductive strips 19 and strip receivers 21, for example with a block copolymer or other suitable polymeric material. Preferably, the carrier overmold material is chemically similar to a textile monofilament (e.g., weft fibers 16) such that chemical bonding as well as mechanical bonding occurs during the injection molding process.

The carrier 22 and conductive strip 19 and the strip receiver 21 with the captured heating element fibers 18 are then installed in the channel 28 in the frame 26. The conductive strips 19/strip receivers 21/captured heating element fibers 18 and carrier 22 may be mounted in a common channel 28, or the conductive strips 19/strip receivers 21/captured heating element fibers 18 may be mounted in one channel 28' and the carrier mounted in another channel 28.

Because the channel 28 or 28' runs around the perimeter of the frame 26 and terminates at a connector 30, preferably at a location that is not visible to the occupant and near the vehicle wiring harness and wiring harness terminal connectors, there are hardly any visible parts that detract from the aesthetics of the seat. Furthermore, in configurations where the conductive strips 19/strip receivers 21/captured heating element fibers 18 do not extend into the carrier and into the carrier, the channels 28 or 28' may act as a protective zone for the seat, without occupant-induced stress, and improve the robustness of the circuit and the lifetime of the electronics.

The molded electrical connector 30 ensures easy access to electrical power for the circuitry and maintains a discrete appearance hidden from view within the seat frame assembly. The present arrangement is robust enough to withstand repeated loading by an occupant of the vehicle seat.

In this disclosure, the words "a" and "an" are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. It will be appreciated by those of ordinary skill in the art that directional terms, such as upper, lower, rearward, forward and the like are used for explanatory purposes only and are not intended to limit the scope of the present disclosure.

All patents or patent applications mentioned herein are hereby incorporated by reference, whether or not specifically done so within the text of this disclosure.

From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.