WO2017201083A2

WO2017201083A2 - Thermoelectric devices, systems, and methods

Info

Publication number: WO2017201083A2
Application number: PCT/US2017/032959
Authority: WO
Inventors: Tarek Makansi; Alexander DOUMAS; Robert FOGOROS; Kevin Forbes; John Latimer FRANKLIN; Kevin GEISLER; Jonathan KROC; Quincy LEVIEN; Richard Myers; Michael SATO
Original assignee: Tempronics Inc
Current assignee: Tempronics Inc
Priority date: 2016-05-16
Filing date: 2017-05-16
Publication date: 2017-11-23
Anticipated expiration: 2018-11-16
Also published as: WO2017201083A3

Abstract

The present disclosure provides thermoelectric systems and methods for heating and cooling, and methods of forming thermoelectric systems for heating and cooling. A thermoelectric system of the present disclosure may comprise a panel and a plurality of thermoelectric elements connected by individual conductors. The panel may comprise an electrically and/or thermally insulating material. The thermoelectric system may include integrated components. The integrated components may include occupancy and load sensors, massage transducers, thermal protection units, heat exchangers, and foam-molding components for use with or in, for example, wearables or furniture.

Description

THERMOELECTRIC DEVICES, SYSTEMS, AND METHODS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application Nos. 62/337,283, filed May 16, 2016, 62/363,713 filed July 18, 2016, 62/384,048 filed September 6, 2016, 62/401,604 filed September 29, 2016, and 62/433,020 filed December 12, 2016. The contents of all the aforesaid applications are incorporated herein by reference.

BACKGROUND

[0002] The thermoelectric effect describes both the conversion of a temperature gradient to an electric voltage and an electric voltage to a temperature gradient. A thermoelectric device may create a voltage when there is a temperature gradient across the thermoelectric device. An applied temperature gradient may cause charge carriers in the device to diffuse from a hot side to a cold side of the thermoelectric device. Alternatively, when a voltage is applied to the thermoelectric device, it may create a temperature gradient across the thermoelectric device.

[0003] The term "thermoelectric effect" encompasses the Seebeck effect, Peltier effect, and Thomson effect. Solid-state cooling and power generation based on thermoelectric effects typically employ the Seebeck effect or Peltier effect for power generation and heat pumping. The utility of such conventional thermoelectric devices is typically limited by their low coefficient- of-performance (COP) or low efficiency.

[0004] Thermoelectric modules may contain densely packed elements connected in an array. When these modules are deployed, large and heavy heat sinks and powerful fans may be required to dissipate or absorb heat on each side of the module. Small elements with low resistance may allow larger current (I) to flow before the resistive heat (I R) generated destroys the thermoelectric cooling. The use of short elements for maximum cooling capacity results in the hot and cold side of the module being close together. This proximity may result in the high density.

[0005] To achieve low density packing of thermoelectric elements, the elements may be laterally spaced on boards. However, backflow of heat conducted and radiated through the air between the elements limits the overall performance. Another disadvantage to this design is that the high density of heat moved to the hot side may result in a temperature gradient through the heat sink and this temperature change may subtract from the overall cooling and prevent true refrigeration temperatures from being achieved. SUMMARY

[0006] Provided herein are thermoelectric systems and methods of forming thermoelectric systems. A thermoelectric system may include a thermally and/or electrically insulating panel and thermoelectric elements. The thermoelectric element may include alternating p-type and n- type elements. The thermoelectric elements may be connected by conductors. The conductors may be expanded or compacted. The thermoelectric system may include integration components.

[0007] In an aspect, a thermoelectric system for heating or cooling comprises a panel comprising an electrically and/or thermally insulating material, a plurality of thermoelectric elements connected by individual conductors that are (i) compacted in a cross section inside the panel and (ii) expanded in at least one dimension outside the panel, where the plurality of thermoelectric elements comprise alternating p-type and n-type thermoelectric elements, and a load sensor in electrical communication with the plurality of thermoelectric elements, where the load sensor (i) detects applied load on or in proximity to the panel, and (ii) permits flow of electrical current through the plurality of thermoelectric elements upon detecting the applied load.

[0008] In some embodiments, the load sensor is integrated with a control system of a vehicle. In some embodiments, the load sensor enables, disables, or alters a property of the control system of the vehicle. In some embodiments, the load sensor is integrated with a passive restraint system of a vehicle. In some embodiments, the load sensor enables, disables, or alters a property of the passive restraint system. In some embodiments, the load sensor is operatively coupled to a load distributing unit. In some embodiments, the load distributing unit includes a plurality of elongated load elements. In some embodiments, the plurality of thermoelectric elements is arranged in rows. In some embodiments, the elongated load elements are placed between the rows.

[0009] In some embodiments, the thermoelectric system further comprises a heat exchanger adjacent to a side of the panel. In some embodiments, the heat exchanger comprises a thin mat with fluid flowing therein. In some embodiments, the heat exchanger comprises fluid flow channels between one or more support walls. In some embodiments, the load sensor is aligned with the one or more support walls. In some embodiments, the load sensor is disposed adjacent to the one or more support walls. In some embodiments, the load sensor is disposed between the panel and the heat exchanger. In some embodiments, the load sensor converts the applied load to a capacitance reading. In some embodiments, the load sensor converts the applied load to a resistance reading. In some embodiments, the load sensor converts the applied load into a fluid pressure reading. [0010] In some embodiments, the thermoelectric system is incorporated into a seat cushion or a bed. In some embodiments, the seat cushion is a portable seat cushion. In some embodiments, the portable seat cushion comprises bolsters in the sides, rear, or both sides and rear of the portable seat cushion. In some embodiments, the portable seat cushion further comprises a bottom material with a high coefficient of friction. In some embodiments, the portable seat cushion further comprises a porous top material.

[0011] In some embodiments, the thermoelectric system further comprises a battery, switch, intensity control device, thermostatic control device, wireless interface circuit, manifolds, carrying handle, printed circuit board, porous material, or any combination thereof. In some embodiments, the wireless interface circuit is a Bluetooth or Wi-Fi circuit and is controlled by a mobile control device. In some embodiments, the thermoelectric system further comprises a power adapter for charging the battery. In some embodiments, the heat exchanger comprises multiple fluid inlets or multiple fluid outlets. In some embodiments, the one or more fans are disposed adjacent to the multiple fluid inlets or multiple fluid outlets. In some embodiments, the thermoelectric system is integrated into a wearable object. In some embodiments, the thermoelectric system further comprises a microprocessor.

[0012] In an aspect, the thermoelectric system for heating or cooling comprises a panel comprising an electrically and/or thermally insulating material, where in a first portion of the panel comprises a flexible material and a second portion of the panel comprises a less flexible material than the first portion of the panel, a massage transducer adjacent to the second portion of the panel, and a plurality of thermoelectric elements connected by individual conductors that are (i) compacted in a cross section inside the panel and (ii) expanded in at least one dimension outside the panel, where the plurality of thermoelectric elements comprise alternating p-type and n-type thermoelectric elements.

[0013] In some embodiments, the plurality of thermoelectric elements is arranged in rows in the panel. In some embodiments, the thermoelectric system further comprises a heat exchanger adjacent to a side of the panel. In some embodiments, the heat exchanger comprises multiple fluid inlets or multiple fluid outlets. In some embodiments, the one or more fans are disposed adjacent to the multiple fluid inlets or multiple fluid outlets.

[0014] In some embodiments, the thermoelectric system is integrated into a wearable object. In some embodiments, the thermoelectric system is integrated into a seat or bed. In some embodiments, the thermoelectric system further comprises a battery, switch, intensity control device, thermostatic control device, wireless interface circuit, manifolds, carrying handle, printed circuit board, porous material, or any combination thereof. In some embodiments, the wireless interface circuit is a Bluetooth or Wi-Fi circuit and is controlled by a mobile control device. In some embodiments, the thermoelectric system further comprises a power adapter for charging the battery. In some embodiments, the thermoelectric system further comprises a

microprocessor.

[0015] In an aspect, a thermoelectric system for heating or cooling comprises a panel comprising an electrically and/or thermally insulating material, a plurality of thermoelectric elements connected by individual conductors that are (i) compacted in a cross section inside the panel and (ii) expanded in at least one dimension outside the panel, where the plurality of thermoelectric elements comprise alternating p-type and n-type thermoelectric elements, and where flow of electrical current through the plurality of thermoelectric elements heats a first side of the panel and cools a second side of the panel, and a thermal protection unit in electrical communication with the plurality of thermoelectric elements, where upon the first side of the panel reaching a threshold temperature the thermal protection device terminates the flow of electrical current.

[0016] In some embodiments, the thermal protection unit measures a temperature of the first side of the panel. In some embodiments, the thermal protection unit includes or is in electrical communication with a thermocouple that measures the temperature. In some embodiments, the thermal protection unit is connected in series with the plurality of thermoelectric elements. In some embodiments, the thermal protection unit is adjacent to the individual conductors. In some embodiments, the thermal protection unit comprises a resistive material with a positive temperature coefficient. In some embodiments, the thermal protection unit comprises a bimetallic material. In some embodiments, the threshold temperature is from about 40 degrees centigrade to about 50 centigrade.

[0017] In some embodiments, the plurality of thermoelectric elements is arranged in rows in the panel. In some embodiments, the thermoelectric system further comprises a heat exchanger adjacent to a side of the panel. In some embodiments, the heat exchanger comprises multiple fluid inlets or multiple fluid outlets. In some embodiments, the one or more fans are disposed adjacent to the multiple fluid inlets or multiple fluid outlets. In some embodiments, the thermoelectric system is integrated into a wearable object. In some embodiments, the

thermoelectric system is integrated into a seat or bed. In some embodiments, the thermoelectric system further comprises a battery, switch, intensity control device, thermostatic control device, wireless interface circuit, manifolds, carrying handle, printed circuit board, porous material, or any combination thereof. In some embodiments, the wireless interface circuit is a Bluetooth or Wi-Fi circuit and is controlled by a mobile control device. In some embodiments, the thermoelectric system further comprises a power adapter for charging the battery. In some embodiments, the thermoelectric system further comprises a microprocessor.

[0018] In an aspect, a thermoelectric system for heating and cooling comprises a first and a second support, where the first and the second support comprise one or more electrically and/or thermally insulating materials, and where the first and the second support are spaced apart by a gap, and a plurality of thermoelectric elements connected by individual conductors, where the plurality of thermoelectric elements are wrapped around the first and the second support, and where the plurality of thermoelectric elements comprise alternating p-type and n-type

thermoelectric elements.

[0019] In some embodiments, the p-type thermoelectric elements are adjacent to the first support and the n-type thermoelectric elements are adjacent to the second support. In some embodiments, the p-type and the n-type thermoelectric elements are adjacent to the first support and the individual conductors are adjacent to the second support. In some embodiments, the

thermoelectric system further comprises insulation disposed between the first and the second supports. In some embodiments, the insulating material is foam. In some embodiments, the foam is molded to surround portions of the first and the second support and the plurality of

thermoelectric elements. In some embodiments, the individual conductors comprise alternating hot and cold conductors. In some embodiments, the hot and cold conductors are disposed on opposite sides of the first and the second support.

[0020] In some embodiments, the thermoelectric system further comprises a heat exchanger adjacent to a side of the first and the second support. In some embodiments, the thermoelectric system is integrated into a wearable object. In some embodiments, the thermoelectric system is integrated into a seat or bed. In some embodiments, the thermoelectric system further comprises a battery, switch, intensity control device, thermostatic control device, wireless interface circuit, manifolds, carrying handle, printed circuit board, porous material, or any combination thereof. In some embodiments, the wireless interface circuit is a Bluetooth or Wi-Fi circuit and is controlled by a mobile control device. In some embodiments, the thermoelectric system further comprises a power adapter for charging the battery. In some embodiments, the first and the second supports are flexible. In some embodiments, the thermoelectric system further comprises a

microprocessor.

[0021] In an aspect, the thermoelectric system for heating and cooling comprises a panel comprising an electrically and/or thermally insulating material, a plurality of thermoelectric elements connected by individual conductors, where the plurality of thermoelectric elements comprise alternating p-type and n-type thermoelectric elements, and where the individual conductors are alternating expanded conductors and looped conductors, and a heat exchanger in thermal communication with the individual conductors, where the heat exchanger comprises a lattice of flexible tubes, where the lattice of flexible tubes comprises holes, and wherein the looped conductors are disposed in the holes.

[0022] In some embodiments, the lattice of flexible tubes further comprises support bridges. In some embodiments, the expanded conductors are disposed adjacent to the support bridges. In some embodiments, the panel comprises a molded foam. In some embodiments, the molded foam is formed around the heat exchanger. In some embodiments, a fluid flows through the lattice of flexible tubes. In some embodiments, the fluid is at least partially obtained from an air conditioner outlet. In some embodiments, the fluid is recirculated. In some embodiments, the fluid is chilled. In some embodiments, the fluid is chilled in a separate thermoelectric module. In some embodiments, the heat exchanger comprises multiple fluid inlets or multiple fluid outlets. In some embodiments, the one or more fans are disposed adjacent to the multiple fluid inlets or multiple fluid outlets.

[0023] In some embodiments, the thermoelectric system further comprises a battery, switch, intensity control device, thermostatic control device, wireless interface circuit, manifolds, carrying handle, printed circuit board, porous material, or any combination thereof. In some embodiments, the wireless interface circuit is a Bluetooth or Wi-Fi circuit and is controlled by a mobile control device. In some embodiments, the thermoelectric system further comprises a power adapter for charging the battery. In some embodiments, the thermoelectric system is integrated into a wearable object. In some embodiments, the thermoelectric system is integrated into a seat or bed. In some embodiments, the thermoelectric system further comprises a microprocessor.

[0024] In an aspect, a method of forming a thermoelectric system comprises providing a molding frame and foaming material, where the molding frame comprises an array of support features, providing a plurality of thermoelectric elements connected by individual conductors, where the plurality of thermoelectric elements comprises alternating p-type and n-type thermoelectric elements, adding the foaming material to the molding frame to activate an expansion reaction to form a molded foam panel, where during the expansion reaction the array of support features generates slits in the molded foam, and inserting the plurality of

thermoelectric elements into the slits in the molded foam panel to form the thermoelectric system, where the individual conductors are (i) compacted in a cross section inside the molded foam panel and (ii) expanded in at least one dimension outside the molded foam panel. [0025] In some embodiments, the array of support features comprises triangle shaped features that generate the slit. In some embodiments, the slit extends through a width of the molded foam panel. In some embodiments, on a side of the molded foam panel the slit is narrow and on another side of the molded foam panel the slit is wide. In some embodiments, the array of features is positioned so that the slits form an acute angle with a surface of the molded foam panel. In some embodiments, the plurality of thermoelectric elements is substantially parallel to a surface of the molded foam panel. In some embodiments, the thermoelectric system further comprises treating the molding frame or the plurality of thermoelectric elements with a foam release material. In some embodiments, the thermoelectric system further comprises a heat exchanger. In some embodiments, the molded foam panel is formed around the heat exchanger.

[0026] In an aspect, a method of forming a thermoelectric system comprises providing a molding frame and a foaming material, where the molding frame comprises an array of support features, providing a plurality of thermoelectric elements connected by individual conductors, where the plurality of thermoelectric elements comprises alternating p-type and n-type thermoelectric elements, positioning the plurality of thermoelectric elements adjacent to the array of support features, adding the foaming material to the molding frame to activate an expansion reaction, where during the expansion reaction the array of support features holds the plurality of thermoelectric elements in place, and wherein the molded foam panel forms around the plurality of thermoelectric elements to form the thermoelectric system.

[0027] In some embodiments, the method further comprises treating the molding frame or the plurality of thermoelectric elements with a foam release material. In some embodiments, the array of support features comprises a lattice structure. In some embodiments, the lattice structure is incorporated into the molded foam panel. In some embodiments, the lattice comprises a durable material that does not adversely affect appearance or thermal performance. In some embodiments, the thermoelectric system further comprises a heat exchanger. In some

embodiments, the heat exchanger is positioned adjacent to the array of support features. In some embodiments, the molded foam panel forms around the heat exchanger. In some embodiments, the heat exchanger comprises flexible tubes with holes. In some embodiments, a portion of the individual conductors comprise loops of stranded wire. In some embodiments, the loops of stranded wire are inserted into the holes of the flexible tubes. In some embodiments, the array of support features comprises clips and bridging objects. In some embodiments, the clips and bridging objects hold the plurality of thermoelectric elements and the individual conductors in place during formation of the molded foam panel. [0028] Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure.

Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.

INCORPORATION BY REFERENCE

[0029] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference. To the extent publications and patents or patent applications incorporated by reference contradict the disclosure contained in the specification, the specification is intended to supersede and/or take precedence over any such contradictory material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings or figures (also "FIG." and "FIGs." herein), of which:

[0031] FIGs. 1A-1C shows an example thermoelectric system for use in an automotive seat; FIG. 1A shows a top surface view of an example thermoelectric system; FIG. IB shows a bottom surface view of an example thermoelectric system with a heat exchanger layer; FIG. 1C shows the foam side layers of an example thermoelectric system;

[0032] FIGs. 2A-2C shows common load sensors for automotive use; FIG. 2A shows an example capacitive load sensor; FIG. 2B shows and example resistive load sensor; FIG. 2C shows and example fluid pressure load sensor;

[0033] FIG. 3 shows an example thermoelectric system with representative load sensor positioned on the top side of the panel;

[0034] FIG. 4 shows an example thermoelectric system with representative load sensor aligned with heat exchanger air channels;

[0035] FIG. 5 shows an example thermoelectric system with representative load sensor positioned between the panel and a heat exchanger; [0036] FIG. 6 shows an example load sensor positioned in an automotive seat away from the thermoelectric system;

[0037] FIG. 7 shows an example thermoelectric system integrated with a massage transducer in a seat back;

[0038] FIG. 8 shows an example thermoelectric string integrated with a thermal protection unit;

[0039] FIG. 9 shows an example thermal protection unit positioned underneath a conductor loop of the thermoelectric string;

[0040] FIG. 10 shows an example thermoelectric system with an integrated heat exchanger in thermal communication with a heating, ventilation, and air conditioning (HVAC) unit;

[0041] FIGs. 11A and 11B show an example heat exchanger with flexible tubing; FIG. 11A shows multiple views of an example heat exchanger with flexible tubing configured in a lattice arrangement; FIG. 11B shows an example heat exchanger with flexible tubing integrated with a thermoelectric string;

[0042] FIG. 12 shows an example thermoelectric system with a thermoelectric string wrapped around supports;

[0043] FIG. 13 shows an example thermoelectric system formed by cutting slits into the panel and inserting the thermoelectric elements;

[0044] FIG. 14 shows an example molding frame for forming a molded foam panel with slits;

[0045] FIG. 15 shows an example molding frame with sacrificial lattice for supporting the thermoelectric string during foam formation;

[0046] FIG. 16 shows an example ultra-thin thermoelectric system;

[0047] FIG. 17 shows an example thermoelectric system integrated into a headband;

[0048] FIGs. 18A and 18B show an example thermoelectric system with heat exchanger integrated into a waste band; FIG. 18A shows a heat exchanger side of a thermoelectric system with heat exchanger integrated into a waist band; FIG. 18B shows a top surface of a

thermoelectric system with heat exchanger integrated into a waist band;

[0049] FIGs. 19A and 19B show an example thermoelectric system with heat exchanger integrated into an armored vest; FIG. 19A shows a top surface of a thermoelectric system with heat exchanger integrated into an armored vest; FIG. 19B shows a covered heat exchanger of a thermoelectric system with heat exchanger integrated into an armored vest;

[0050] FIGs. 20A - 20F show an example thermoelectric system with heat exchanger integrated into a portable seat; FIG. 20A shows a top surface of a thermoelectric system with heat exchanger integrated into a portable seat; FIG. 20B shows an internal view of a thermoelectric system with heat exchanger integrated into a portable seat; FIG. 20C shows a back bolster of a portable seat; FIG. 20D shows a battery slot of a portable seat; FIG. 20E shows a bottom surface of a thermoelectric system with heat exchanger integrated into a portable seat; FIG. 20F shows a top cover of a thermoelectric system with heat exchanger integrated into a portable seat; and

[0051] FIG. 21 shows a computer control system that is programmed or otherwise configured to control or implement methods and systems of the present disclosure, such as controlling the thermoelectric systems of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0052] While various embodiments of the invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed.

[0053] The terms "adjacent" or "adjacent to," as used herein, includes "next to," "adjoining," "in contact with," and "in proximity to." In some instances, adjacent components are separated from one another by one or more intervening components.

[0054] The present disclosure provides thermoelectric systems and methods of forming thermoelectric systems. The thermoelectric systems may be applied to heating and/or cooling in various applications such as, but not limited to, vehicle climate control, portable seating, comfort and therapeutic devices, and wearable objects. The thermoelectric system may be integrated with additional components such as load sensors, temperature sensors, thermal switches, control units, comfort and therapeutic devices, heat exchangers, batteries, and microprocessors.

[0055] The thermoelectric system may include a thermoelectric string of alternating p-type and n-type thermoelectric elements connected by conductors. The thermoelectric string may be distributed through an insulating layer or panel. The conductors may be stranded or braided wire that is compacted or expanded. The conductors may be positioned adjacent to a surface of the insulating panel and may insert heat to or remove heat from the thermoelectric string via conduction. The thermoelectric system may generate heat upon flow of electrical current through the thermoelectric string. Alternatively, or in addition to, the thermoelectric system may be used to generate an electrical current, thereby generating power, upon the flow of heat through the thermoelectric string.

Thermoelectric systems integrated with load sensors

[0056] In an aspect, the present disclosure provides thermoelectric systems for heating or cooling. The thermoelectric system may include a panel, thermoelectric elements connected by conductors, and a load sensor. The panel may be an electrically insulating material, a thermally insulating material, or a material that is both electrically and thermally insulating. The thermoelectric elements may include alternating p-type and n-type thermoelectric elements. The conductors may be compacted inside the panel and expanded outside the panel. The load sensor may be in electrical communication with the thermoelectric elements. The sensor may detect a load applied to the panel or may detect a load applied in proximity to the panel. Upon detecting an applied load, the load sensor may permit the flow of electrical current through the

thermoelectric elements. The flow of electrical current through the thermoelectric elements may provide heating or cooling.

[0057] The electrical and/or thermally insulating material may include foam, rubber, plastic, silicone, or any other similar material. The panel may include holes or slits for inserting the thermoelectric elements into the panel. The holes or slits may be added to the panel after the panel has been formed. Alternatively, or in addition to, the panel may be pre-formed with the holes or slits. The thermoelectric elements may be woven into or inserted into a pre-formed panel or the panel may be formed around the thermoelectric elements. The holes or slits may extend through the entire thickness of the panel or may extend partially through the panel. The panel may have a thickness of at least about 0.5 centimeters (cm), at least about 1 cm, at least about 2 cm, at least about 4 cm, at least about 6 cm, at least about 8 cm, at least about 10 cm, at least about 25 cm, or more. The panel may have a thickness of less than about 25 cm, less than about 10 cm, less than about 8 cm, less than about 6 cm, less than about 4 cm, less than about 2 cm, less than about 1 cm, less than about 0.5 centimeters, or less.

[0058] The alternating p-type and n-type thermoelectric elements may be inserted into different holes or slits in the panel. Alternately, or in addition to, the alternating p-type and n-type thermoelectric elements may be paired and inserted into the same hole or slit in the panel. The thermoelectric elements may be positioned substantially perpendicular or substantially parallel to a surface of the panel. Alternately, or in addition to, the thermoelectric elements may be positioned at an acute angle to a surface of the panel. The thermoelectric system may have at least about 5, at least about 10, at least about 15, at least about 20, at least about 30, at least about 40, at least about 50, at least about 75, at least about 100, at least about 200, at least about 300, at least about 400, at least about 500, or more thermoelectric elements. The conductors may be directly connected to the thermoelectric elements. Alternatively, or in addition to, the conductors may be connected to the thermoelectric element via a strain relief. The strain relief may be a rigid or a flexible strain relief. The strain relief may prevent breakage of the thermoelectric elements and conductors when a load is applied to the panel. Rigid strain relief elements may comprise glass and/or epoxy. The thermoelectric elements and conductors may be soldered to the strain relief elements.

[0059] The conductors may include stranded wires, braided wires, mesh, screen, or tinsel. The conductors may be loose, roped, or grouped axially. The conductors may be compacted or expanded. The conductors may be compacted inside the panel and expanded outside the panel. The conductors may be elongated outside of the panel or the conductors may be looped outside of the panel. Looped and elongated conductors may alternate. The thermoelectric elements and conductors may be distributed in the panel in rows or grids. Alternatively, or in addition to, the thermoelectric elements and conductors may be randomly distributed in the panel.

[0060] The thermoelectric system may include a heat exchanger. The heat exchanger may be positioned adjacent to a side of the panel. Alternately, or in addition to, a portion of the panel may be a heat exchanger. The heat exchanger may be added to the panel after the panel has been fabricated. Alternately, or in addition to, the heat exchanger may be added to the panel during fabrication of the panel. The heat exchanger may be a thin mat. The thin mat may have a flowing fluid within. The heat exchanger may include fluid flow channels between support walls. The heat exchanger may include multiple fluid inlets and multiple fluid outlets. Some of the fluid inlets and fluid outlets may be blocked. One or more fans may be positioned adjacent to the fluid inlets, the fluid outlets, or both the fluid inlets and fluid outlets. The fans may increase the rate of heat exchange to or from the conductors. The fluid may include a gas or a liquid. The fluid may be a heated fluid or a chilled fluid.

[0061] FIGs. 1A - 1C show an example thermoelectric system for use in an automotive seat. FIG. 1A shows a top surface view of the example thermoelectric system. The thermoelectric system 101 has a top foam panel 602 with a thermoelectric string 102 woven through the panel 602. The top foam panel may comprise seat foam and may insulate the warm side of the thermoelectric system from the and cool side of the thermoelectric system. The thermoelectric string 102 comprises thermoelectric elements connected via conductors. The conductors may be alternating elongated conductors 103 and looped conductors 104. The elongated conductors may be positioned adjacent to the topside of the panel 602. FIG. IB shows a bottom surface view of an example thermoelectric system with a heat exchanger layer 106. The heat exchanger layer 106 may be molded or machined to contain air channels. The looped conductors 104 may be positioned in the air channels. Air may flow through the air channels and across the looped conductors 104 to remove heat from the thermoelectric string 102. FIG. 1C shows the foam side layers of the example thermoelectric system. The panel 602 and heat exchanger layer 106 may be bonded by an adhesive. [0062] The load sensor may permit or prevent the flow of electrical current to the thermoelectric elements. Without the flow of electrical current the thermoelectric system may not provide heating or cooling. In one example, the presence of an applied load detected by the load sensor may permit the flow of electrical current to the thermoelectric elements and enable heating or cooling. In one example, the presence of an applied load detected by the load sensor may prevent the flow of electrical current to the elements and disable heating or cooling. The load sensor may be integrated with the control system of a vehicle. The load sensor may enable, disable, or alter the properties of a control system of a vehicle. In one example, an applied load that is sensed by the load sensor in the driver's seat of a vehicle may indicate the presence of a driver and enable the control system of a vehicle. The load sensor may be integrated with a passive restraint system of a vehicle. The load sensor may enable, disable, or alter a property of the passive restraint system of a vehicle. In one example, an applied load detected by a load sensor in a passenger seat of a vehicle may enable a passenger air bag system. Conversely, lack of a detectable load in a passenger seat of a vehicle may disable a passenger air bag system.

[0063] The load sensor may be a capacitance, resistance, or pressure load sensor. The load sensor may convert an applied load to a capacitance, resistance, or fluid pressure reading. The load sensor may include a load distributing unit elongated load elements. The elongated load elements may detect an applied load. The elongated load elements may be positioned between rows of thermoelectric elements. The elongated load elements may be aligned with the support walls of a heat exchanger. The load sensor may be positioned adjacent to a top surface of the heat exchanger. The load sensor may be positioned between the heat exchanger and the panel. Alternatively, or in addition to, the load sensor may be positioned away from the panel in the thermoelectric system.

[0064] FIGs. 2A-2C shows common load sensors 201 for automotive use. Load sensors may be used to sense the presence of a driver and/or to sense the weight of a passenger to deploy the air bag appropriately or not in the event of an accident. FIG. 2A shows an example capacitive load sensor 202. The capacitive load sensor 202 may contain two conducing layers separated by a dielectric. The capacitance of the sensor may change as a function of applied load or occupant weight. FIG. 2B shows and example resistive load sensor 203. The resistive load sensor 203 may include several resistive load cells located on or in a thin mat. The resistance of the load cells may change as a function of applied load or occupant weight. FIG. 2C shows and example pressure load sensor 204. The pressure load sensor 204 may include a mat-shaped bag containing a compressible fluid. When a load is applied to the pressure load sensor 204 the fluid may compress and interact with a pressure sensor. The sensed pressure may change as a function of applied load or occupant weight. The load sensor may be thin and have elongated load elements extending from a common distribution unit. The elongated load elements may enable the load sensor to detect a load applied at various locations across the thermoelectric system. The elongated load elements may also enable the load sensor to avoid contact with other system elements, such as heaters, ventilation ducts, or massage transducers.

[0065] FIG. 3 shows an example thermoelectric system 101 with representative load sensor 201 positioned on the top side of the panel 602. The load sensor 201 may be positioned to avoid the conductors present on the surface of the panel 602. In this configuration, the conductors of the thermoelectric string along the surface may not contact or covered by the elongated load elements and are able to provide maximum heat transfer to the occupant. Without limitation, the representative load sensor 201 may represent a capacitive load sensor, resistive load sensor, or fluid pressure load sensor. Additionally, the representative load sensor 201 may represent any flat load sensor that is shaped with elongations to avoid other seat components.

[0066] FIG. 4 shows an example thermoelectric system 101 with representative load sensor 201 aligned with heat exchanger air channels. The load sensor may be positioned on top of the air channel walls of the heat exchanger layer 106 with the elongations of the load sensor oriented along the walls. In this configuration, the weight of the occupant is presented to the sensor in the seating area, and the linear nature of the channel walls and the linear nature of the sensor's fingers are exploited for physical compatibility.

[0067] FIG. 5 shows an example thermoelectric system 101 with representative load sensor 201 positioned between the panel 602 and a heat exchanger layer 106. The load sensor may be aligned with the channel walls of the heat exchanger layer 106.

[0068] FIG. 6 shows an example load sensor positioned in an automotive seat away from the thermoelectric system. The load sensor may be placed deeper within the seat and below the thermoelectric system 101. In this configuration, the elongations of the load sensor may or may not be oriented with respect to the air channels or with respect to the thermoelectric string.

[0069] The thermoelectric system may be integrated with a variety of components. In one example, the thermoelectric system may include a battery to enable the portability of the thermoelectric system. The battery may be replaceable, rechargeable, or both replaceable and rechargeable. The thermoelectric system may include a power adapter. The power adapter may allow the thermoelectric system to be plugged into an outlet and the battery to be charged. The thermoelectric system may be in electrical communication with an external power unit. The external power unit may include an electrical outlet, a vehicle battery or vehicle electrical system, or any other external power unit. The thermoelectric system may include one or more switches, intensity control devices, and/or thermostatic control devices. The switches and control devices may enable, disable, or regulate the flow of electrical current to the thermoelectric elements. The thermoelectric system may include a wireless interface circuit. The wireless interface circuit may be a Bluetooth or Wi-Fi circuit. The wireless interface circuit may be controlled by a mobile control device. The mobile control device may be a cellular phone, tablet, or laptop computer. The thermoelectric system may also include manifolds, one or more carrying handles, printed circuit boards, porous materials, and/or one or more microprocessors.

[0070] The thermoelectric system may be incorporated into a wearable object, a bed, or a seat cushion. The wearable object may include, but is not limited to, a head band, an armored vest, or an article of clothing. The seat cushion may be a vehicle seat cushion or a portable seat cushion. The seat cushion may include bolsters in the side, rear, or both side and rear. The bolsters may provide support of the user of the seat cushion. The bolster may additionally house a battery, switches, control devices, wireless interface circuits, manifolds, printed circuit boards, fans, or other thermoelectric system components. The top material and bottom material of the portable seat cushion may be the same material or different materials. The bottom material may be a material with a high coefficient of friction, such as a rubber, silicon, or plastic based material. The top material may be a porous material. The porous material may enhance the heat transfer of the thermoelectric system.

Thermoelectric systems integrated with massage transducers

[0071] In an aspect, the present disclosure provides thermoelectric systems for heating or cooling. The thermoelectric system may include a panel, thermoelectric elements connected by conductors, and a massage transducer. The panel may be an electrically insulating material, a thermally insulating material, or a material that is both electrically and thermally insulating. The panel may include a first portion, layer, or section that includes a first material. The panel may include a second portion, layer, or section that includes a second material. The second material may be a less flexible than the first material. The thermoelectric elements may include alternating p-type and n-type thermoelectric elements. The conductors may be compacted inside the panel and expanded outside the panel. The massage transducer may be adjacent to the second portion of the panel.

[0072] The first material may be a flexible material selected for comfort. The Young's modulus of the first material may be less than about 250 KiloPascal (KPa), less than about 200 KPa, less than about 150 KPa, less than about 100 KPa, less than about 80 KPa, less than about 60 KPa, less than about 40 KPa, less than about 20 KPa, less than about 10 KPa, or less. The second material may be flexible or firm. The second material may be less flexible than the first material. The second material may be selected to increase the effectiveness of the massage transducer. The Young's modulus of the second material may be greater than about 100 KPa, greater than about 150 KPa, greater than about 200 KPa, greater than about 250 KPa, greater than about 300 KPa, greater than about 400 KPa, greater than about 500 KPa, or greater. The Young's modulus of the second material may be greater than that of the first material.

[0073] The thermoelectric elements may be arranged in a row, grid, or random configuration. The thermoelectric elements may be distributed through the first material, the second material, and bot the first and second material. The panel may be positioned adjacent to a heat exchanger. The heat exchanger may have multiple fluid inlets and multiple fluid outlets. Some of the fluid inlets and fluid outlets may be blocked. One or more fans may be positioned adjacent to the fluid inlets, the fluid outlets, or both the fluid inlets and fluid outlets. The fans may increase the rate of heat exchange to or from the conductors. The fluid may include a gas or a liquid. The fluid may be a heated fluid or a chilled fluid.

[0074] The massage transducer may be an individual massage transducer or multiple massage transducers. The massage transducer may include an actuator that vibrates, translates linearly, or translates in a rotational pattern. The second material of the panel may efficiently transfer motion from the massage transducer to the user. The thermoelectric system may include a battery to enable the portability of the system. The battery may be replaceable, rechargeable, or both replaceable and rechargeable. The thermoelectric system may include a power adapter. The power adapter may allow the thermoelectric system to be plugged into an outlet and the battery to be charged. The thermoelectric system may include one or more switches, intensity control devices, and/or thermostatic control devices. The switches and control devices may enable, disable, or regulate the flow of electrical current to the thermoelectric elements. The switches and control devices may enable, disable, or regulate the massage transducer. The control devices may control the motion, intensity, or pattern of massage. The thermoelectric system may include one or more microprocessors. The microprocessor may be programmed to control the thermoelectric elements and the massage transducer. The thermoelectric system may include a wireless interface circuit. The wireless interface circuit may be a Bluetooth or Wi-Fi circuit. The wireless interface circuit may be controlled by a mobile control device. The mobile control device may be a cellular phone, tablet, or laptop computer. The thermoelectric system may be incorporated into a wearable object, a bed, or a seat cushion. The wearable object may include, but is not limited to, a head band, an armored vest, or an article of clothing.

[0075] FIG. 7 shows an example thermoelectric system 101 integrated with a massage transducer 302 in a seat back. The panel may include a foam area of standard firmness 303 and more firm foam 301 in the area over the massage transducer 302. The firmer foam 301 is placed adjacent to the massage transducer to increase its effectiveness. The massage transducer provides additional force to the body by having firmer foam 301 between the transducer and the occupant. Without limitation, the firmer foam 301 may be larger or smaller in area and shaped differently than the transducer's actuator.

Thermoelectric systems integrated with thermal protection units

[0076] In an aspect, the present disclosure provides thermoelectric systems for heating or cooling. The thermoelectric system may include a panel, thermoelectric elements connected by conductors, and a thermal protection unit. The panel may be an electrically insulating material, a thermally insulating material, or a material that is both electrically and thermally insulating. The thermoelectric elements may include alternating p-type and n-type thermoelectric elements. The thermoelectric elements may heat a first side of the panel and cool a second side of the panel when an electrical current flows through the thermoelectric elements. The conductors may be compacted inside the panel and expanded outside the panel. The thermal protection unit may be in electrical communication with the thermoelectric elements. The thermal protection unit may terminate the flow of electrical current through the thermoelectric elements when a side panel reaches a threshold temperature. Terminating the flow of electrical current may prevent the thermoelectric elements from heating a side of the panel and cooling the other side of the panel.

[0077] The thermoelectric elements may be arranged in a row, grid, or random configuration. The panel may be positioned adjacent to a heat exchanger. The heat exchanger may have multiple fluid inlets and multiple fluid outlets. Some of the fluid inlets and fluid outlets may be blocked. One or more fans may be positioned adjacent to the fluid inlets, the fluid outlets, or both the fluid inlets and fluid outlets. The fans may increase the rate of heat exchange to or from the conductors. The fluid may include a gas or a liquid. The fluid may be a heated fluid or a chilled fluid.

[0078] The thermal protection unit may protect the thermoelectric system from overheating or prevent a user from experiencing uncomfortably high temperatures. The thermal protection unit may measure the temperature of a side of the panel. The thermal protection unit may include or be in electrical communication with a thermocouple that measures the temperature of a side of the panel. The thermal protection unit may be a thermal cutoff or a thermal switch. The thermal protection unit may include a resistive material with a positive temperature coefficient. The resistance of the thermal protection unit may increase as a function of temperature. At the threshold temperature, the resistance of the thermal protection unit may be sufficiently high to reduce or terminate the flow of electrical current. The thermal protection unit may include a bimetallic material. The bimetallic material may undergo thermal expansion or contraction to break the circuit and terminate the flow of electrical current at the threshold temperature. At the threshold temperature, the flow of current may be terminated or limited. The threshold temperature may be greater than about 30 °C, greater than about 40 °C, greater than about 50 °C, greater than about 60 °C, or greater. The threshold temperature may be between about 30 °C and 40 °C, between about 30 °C and 50 °C, between about 30 °C and 60 °C, or more.

[0079] The thermal protection unit may be connected in series with the plurality of

thermoelectric elements. The thermoelectric system may include at least about 1, at least about 2, at least about 4, at least about 6, at least about 8, at least about 10, at least about 15, at least about 20, at least about 30, at least about 50, at least about 100, or more thermal protection units.

[0080] The thermal protection unit may be positioned adjacent to the conductors. The conductors may be compacted or expanded. The conductors may be compacted inside the panel and expanded outside the panel. The conductors may be elongated outside of the panel or the conductors may be looped outside of the panel. Looped and elongated conductors may alternate. The thermal protection unit may be positioned adjacent to an elongated conductor or adjacent to a looped conductor. In one example, the thermal protection unit is positioned in the loop of the conductor. The thermal protection unit may be placed electrically in series with the

thermoelectric string in any location, including adjacent to the conductors, the strain reliefs, the heat exchanger, on the top surface of the panel, between the panel and the air flow layer, below the air flow layer, or outside of the panel.

[0081] The thermoelectric system may include a battery to enable the portability of the system. The battery may be replaceable, rechargeable, or both replaceable and rechargeable. The thermoelectric system may include a power adapter. The power adapter may allow the thermoelectric system to be plugged into an outlet and the battery to be charged. The

thermoelectric system may include one or more switches, intensity control devices, and/or thermostatic control devices. The switches and control devices may enable, disable, or regulate the flow of electrical current to the thermoelectric elements. The thermoelectric system may include one or more microprocessors. The thermoelectric system may include a wireless interface circuit. The wireless interface circuit may be a Bluetooth or Wi-Fi circuit. The wireless interface circuit may be controlled by a mobile control device. The mobile control device may be a cellular phone, tablet, or laptop computer. The thermoelectric system may be incorporated into a wearable object, a bed, or a seat cushion. The wearable object may include, but is not limited to, a head band, an armored vest, or an article of clothing. [0082] FIG. 8 shows an example thermoelectric string 102 integrated with a thermal protection unit 401. The thermal protection unit 401 may prevent the user from experiencing excessively high temperatures in the event that the temperature control system fails or air flow system is no longer functional. A positive temperature coefficient (PTC) circuit protection device may be added in series the thermoelectric string 102 in place of or integrated into one of the conductors 103. The PCT device 401 opens the circuit above a certain temperature, preventing the thermoelectric string 102 from exceeding a threshold temperature.

[0083] FIG. 9 shows an example thermal protection unit positioned underneath a conductor loop of the thermoelectric string 102. The thermal protection unit is a bimetal mechanical thermostat circuit protection device 402 and is added in series with the thermoelectric string 102. The thermal protection unit is position under a nearby conductor 103. The threshold temperature of the device may be selected based on the temperature tolerance of the thermoelectric system or the user. The factors that may affect the selected threshold temperature include type and thickness of covers over the thermoelectric system, thermal conduction environment of the thermal protection unit, the maximum power supply voltage in a failed state, or other factors. Without limitation, the thermal protection device may be of the PTC type, the bimetal mechanical type, or other mechanism.

Thermoelectric system integrated with heat exchangers

[0084] In an aspect, the present disclosure provides thermoelectric systems for heating or cooling. The thermoelectric system may include a panel, thermoelectric elements connected by conductors, and a heat exchanger. The panel may be an electrically insulating material, a thermally insulating material, or a material that is both electrically and thermally insulating. The thermoelectric elements may include alternating p-type and n-type thermoelectric elements. The conductors may be alternating expanded conductors and looped conductors. The heat exchanger may be in thermal communication with the individual conductors. The heat exchanger may be a lattice of flexible tubes. The flexible tubes may comprise holes and the looped conductors may be inserted into the holes of the flexible tubes.

[0085] The heat exchanger may be positioned adjacent to a side of the panel. Alternately, or in addition to, the heat exchanger may be incorporated into the panel. The heat exchanger may be added to the panel after the panel has been fabricated. Alternately, or in addition to, the heat exchanger may be added to the panel during fabrication of the panel. The panel may be molded foam and the foam may be formed around the heat exchanger. The heat exchanger may include fluid flow channels. The flexible tubes may be the fluid flow channels. The heat exchanger may include multiple fluid inlets and multiple fluid outlets. Some of the fluid inlets and fluid outlets may be blocked. One or more fans may be positioned adjacent to the fluid inlets, the fluid outlets, or both the fluid inlets and fluid outlets. The fans may increase the rate of heat exchange to or from the conductors. The fluid may include a gas or a liquid. The fluid may be a heated fluid or a chilled fluid. The fluid may be chilled in a separate thermoelectric module. The fluid may be from an air conditioner outlet. The fluid may be recirculated.

[0086] The lattice of flexible tubes may include support bridges and/or clips that connect the flexible tubes. The support bridges and/or clips may be positioned adjacent to the holes in the flexible tubes. The internal diameter of the flexible tube may be greater than about 0. 25 cm, greater than about 0.5 cm, greater than about 0.75 cm, greater than about 1 cm, greater than about 1.5 cm, greater than about 2 cm, greater than about 4 cm, or more. The expanded conductors may be elongated conductors. The expanded or elongated conductors may be positioned adjacent to the top of the support bridges. The expanded or elongated conductors may span the width of the support brides. The expanded conductors may be adjacent to a surface of the panel. The looped conductors may be inserted into the holes of the flexible tube. The looped conductors may be inserted into the holes of the flexible tube before formation of the molded foam panel or after formation of the molded foam panel. The holes in the flexible tube may be sealed around the looped conductors.

[0087] The thermoelectric system may include a battery to enable the portability of the system. The battery may be replaceable, rechargeable, or both replaceable and rechargeable. The thermoelectric system may include a power adapter. The power adapter may allow the thermoelectric system to be plugged into an outlet and the battery to be charged. The

thermoelectric system may include one or more switches, intensity control devices, and/or thermostatic control devices. The switches and control devices may enable, disable, or regulate the flow of electrical current to the thermoelectric elements. The switches and control devices may enable, disable, or regulate the flow of fluid through the heat exchanger. The thermoelectric system may include one or more microprocessors. The thermoelectric system may include a wireless interface circuit. The wireless interface circuit may be a Bluetooth or Wi-Fi circuit. The wireless interface circuit may be controlled by a mobile control device. The mobile control device may be a cellular phone, tablet, or laptop computer. The thermoelectric system may be incorporated into a wearable object, a bed, or a seat cushion. The wearable object may include, but is not limited to, a head band, an armored vest, or an article of clothing.

[0088] FIG. 10 shows an example thermoelectric system 101 with an integrated heat exchanger in thermal communication with a heating, ventilation, and air conditioning (HVAC) unit. The thermoelectric system may be integrated with a heat exchanger positioned on the warm side of the panel. The heat exchange panel may be in thermal communication with a HVAC vent and may provide air flow from the HVAC vent to the conductors. The HVAC vent may be located below a vehicle seat and may cool the conductors of a thermoelectric system in the seat above the vent. The HVAC vent may provide air to the heat exchanger via the air inlet 1002 in the foam vehicle seat. The air may be provided through ducting, manifolds, accelerating fans, or other air handling methods. The waste heat may be removed by conducting it to a water flow system inside a series of sealed pipes. In one example, thermoelectric system incorporated into a bed may include a bed topper with water circulation to cool the surface of the bed 502. The conductors may be in contact with the bed topper or similar liquid flow layer. The tubes of the heat exchanger may be threaded through the looped conductors. A bonding compound may be provided between the looped conductors and the heat exchange tubes to promote thermal conduction and heat transfer. The tubes may be thin-walled and built from materials with high thermal conductivity such as a high-density polyethylene. The liquid may we water or another liquid. The liquid may be thermoelectrically chilled or chilled further inside a re-circulator 503.

[0089] FIGs. 11A and 11B show an example heat exchanger 901 with tubing. FIG. 11A shows multiple views of an example heat exchanger with tubing configured in a lattice arrangement. The tubing may be flexible or rigid. The lattice arrangement may be flexible or rigid. The lattice arrangement may be designed to hold the thermoelectric string 102 in place inside a foam mold. Holes 903 in the tubes 902 allow for insertion of a looped conductor. The tubing may be connected by a series of support bridges 904. The support bridges may be flexible or rigid. FIG. 11B shows the looped conductors 104 inserted into the heat exchanger tubing. The support bridges 904 may be adjacent to the holes 903 and run between tubes. The support bridges may provide for support and positioning of the expanded conductors between the thermoelectric elements 105. The expanded conductors may be positioned adjacent to the surface of the panel. The lattice structure 901 may be made of molded foam, polyurethane, vinyl, or any other flexible material that provides strength and ensures consistent fluid flow. The looped conductors 104 of the thermoelectric string 102 may be positioned inside the tubes. The tubes may function as heat exchange channels. The thermoelectric devices may be fixed in the holes of the tubes. The holes of the tubes may be sealed around the thermoelectric devices. The thermoelectric string may be mounted on the flexible lattice 901 or on the support bridges 904 that connect the heat exchange channels. The angle between a horizontal plane drawn between the tubes and the support bridge may be greater than about 10 degrees, greater than about 20 degrees, greater than about 30 degrees, greater than about 40 degrees, greater than about 50 degrees, greater than about 60 degrees, or greater. The angle between the horizontal plane and the support bridge 903 may enable the bridge to bend and flex under the application of a load or downward force. The support bridges 903 may include flanges 905 that extrude from the side of the support bridge. The flanges 905 may create a channel for the expanded conductor to be routed. The heat exchanger and thermoelectric string may be positioned prior to forming the molded foam panel. The molded foam panel may be formed around the heat exchanger and thermoelectric string. The expanded conductors may be partially exposed during formation of the molded foam panel. The thermoelectric string may be treated with a foam release material prior to formation of the foam panel. The foam release material may enable foam removal and increase the flexibility within the panel.

Thermoelectric system with support elements

[0090] In an aspect, the present disclosure provides thermoelectric systems for heating or cooling. The thermoelectric system may include a first support, a second support, and thermoelectric elements connected by conductors. The first and second supports may be an electrically insulating material, a thermally insulating material, or a material that is both electrically and thermally insulating. The supports may be spaced apart by a gap. The thermoelectric elements may include alternating p-type and n-type thermoelectric elements. The thermoelectric elements and conductors may be wrapped around the first and second supports.

[0091] The first and the second supports may comprise the same material or different materials. The supports may be rigid or the supports may be flexible. The supports may be shaped like a rod or dowel. A cross sectional area of the supports may be a circle, square, triangle, hexagon, or any other shape. The cross sectional area of the supports may be less than about 50 cm squared

(cm 2 ), less than about 40 cm 2 , less than about 30 cm 2 , less than about 20 cm 2 , less than about 10 cm 2 , less than about 5 cm 2 , less than about 1 cm 2 , or less. The supports may be spaced apart by a distance less than about 50 cm, less than about 40 cm, less than about 30 cm, less than about 20 cm, less than about 10 cm, less than about 8 cm, less than about 6 cm, less than about 4 cm, less than about 2 cm, less than about 1 cm, less than about 0.5 cm, or less.

[0092] The thermoelectric string may be wrapped around the supports. The thermoelectric elements may be positioned such that all the thermoelectric elements are adjacent to one of the support. Alternatively, or in addition to, the thermoelectric elements may be positioned such that the p-type thermoelectric elements are adjacent to one support and all the n-type thermoelectric elements are adjacent to the other support. The conductors may be stranded, braided, or woven wire. The conductors may be expanded, contracted, or alternating expanded and contracted conductors. The conductors may include hot and cold conductors. The hot and cold conductors may be positioned so that all the hot conductors are on one side of the supports and all the cold conductors are on the other side of the supports. The gap between the supports may include an insulating material that separates the hot conductors from the cold conductors. The insulating material may be foam or a molded foam. The molded foam may be formed to surround portions the supports, the thermoelectric elements, and the conductors. The thermoelectric system may be fabricated on a continuous-roll type of manufacturing line.

[0093] The thermoelectric system may include a heat exchanger. The heat exchanger may be positioned adjacent to a side of the supports. The thermoelectric system may include a battery to enable the portability of the system. The battery may be replaceable, rechargeable, or both replaceable and rechargeable. The thermoelectric system may include a power adapter. The power adapter may allow the thermoelectric system to be plugged into an outlet and the battery to be charged. The thermoelectric system may include one or more switches, intensity control devices, and/or thermostatic control devices. The switches and control devices may enable, disable, or regulate the flow of electrical current to the thermoelectric elements. The

thermoelectric system may include one or more microprocessors. The thermoelectric system may include a wireless interface circuit. The wireless interface circuit may be a Bluetooth or Wi-Fi circuit. The wireless interface circuit may be controlled by a mobile control device. The mobile control device may be a cellular phone, tablet, or laptop computer. The thermoelectric system may be incorporated into a wearable object, a bed, or a seat cushion. The wearable object may include, but is not limited to, a head band, an armored vest, or an article of clothing. The thermoelectric system may be wrapped around a wearable object to provide heating or cooling to the object.

[0094] FIG. 12 shows an example thermoelectric system with a thermoelectric string wrapped around supports. The thermoelectric system may be configured into panels 101 of any length or thickness. The panel 101 may enable the thermoelectric system to be wrapped around an object. The object may be a part of a body. The thermoelectric system may be integrated into wearable clothing and sports gear such as vests, headbands, wrist guards, helmets, wet suits, or similar. The thermoelectric system may be incorporated into clothing by sewing, bonding, or adhering the panel into the clothing. The thermoelectric elements 105 may be split between n-type and p- type elements with each type on separate and opposite sides of the panel. When electrical current flows in the thermoelectric string 102, the front conductors 103 will evolve to a different temperature than the rear conductors 103. The front or rear conductors may be positioned near a body. The other conductors may be in thermal communication with a heat exchanger. The thermoelectric system may be placed against any surface requiring or desiring heating and cooling. Alternatively, or in addition to, the thermoelectric system may be position near to a heat source for electricity generation. The thermoelectric system may provide cooling or heating to manage and optimize the thermal load on the body during sports activity. In other industries such as, without limitation, mining and construction, workers and other personnel may benefit from use of the thermoelectric system for thermal comfort. The space between the conductors may be filled with foam or other material. The material may be added by physically inserting the material into the space or by forming a molded foam in the space. The conductors 103 on the warm and cool sides of the panel may be compacted or expanded. The conductors may be made from woven or nonwoven strands. The thermoelectric system may include a heat exchanger or heat exchange may take place by natural airflow generated by a user's movement, such as by running, swimming, biking, or similar activity. T

Methods of fabricating thermoelectric systems

[0095] In an aspect, the present disclosure provides methods for fabricating thermoelectric systems for heating or cooling. The method may include providing a molding frame, foaming materials, and a thermoelectric string. The foaming materials may be added to the molding frame to activate an expansion reaction and form a molded foam panel. The thermoelectric string may be inserted into the molded foam panel.

[0096] The molding frame may include an array of support features. The array of support features may generate slits in the molded foam panel during formation of the foam panel. The slits may extend through the width of the panel. The features may be any shape including, but not limited to, cones, cylinders, triangular prisms, or cuboids. The features may generate a slit that is wider on one side of the panel than on the other side of the panel. The features may be positioned such that the generated slit is at an acute angle with the surface of the panel. The features may be positioned such that the generated slit is substantially parallel with the surface of the panel. The angle between the surface and the long dimension of the slit may be less than about 45 degrees, less than about 30 degrees, less than about 20 degrees, less than about 10 degrees, less than about 5 degrees, or less.

[0097] The thermoelectric string may include alternating p-type and n-type thermoelectric element connected via conductors. The thermoelectric string may be inserted into the slits of the molded foam panel. The conductors may be compacted in a cross section inside the panel and expanded in at least one dimension outside of the molded foam panel. The conductors may include alternating hot and cold conductors. The hot conductors may be positioned on one side of the panel and the cold conductors may be positioned on the other side of the panel. [0098] The molding frame may be treated with a foam release material prior to formation of the foam panel. The foam release material may allow for the foam panel to be easily removed from the molding frame.

[0099] The thermoelectric system may further comprise a heat exchanger. The heat exchanger may be integrated into the thermoelectric system after formation of the foam panel.

Alternatively, or in addition to, the molded foam panel may be formed around the heat exchanger. The heat exchanger may be treated with the foam release material prior to formation of the molded foam panel.

[0100] FIG. 13 shows an example thermoelectric system 101 formed by manually cutting slits into the panel and inserting the thermoelectric string 102. The slits are cut into the panel 602 at an acute angle. The acute angle of the thermoelectric elements may increase the durability of the thermoelectric system over many ingress/egress cycles. The acute angle of the thermoelectric elements 105 permits the conductors to rotate instead of bend during each ingress or egress. Rotation of conductors may increase the number of stress cycles the conductors can endure as compared to conductors that bend under an applied load or stress. The slits may be punctured or cut into the panel using a tapered blade 601. The slits may be added individually or the slits may be added in multiples using a translating row of blades or array of blades to make the angular puncture. The slits may be tapered in width and may be wider near one surface of the panel and narrower near the other surface of the panel. The wider width at the top surface allows for separation of adjacent conductors, preventing electrical shorts across the thermoelectric elements. The narrower width at the bottom minimizes leakage of air flowing across the cooled conductors 103, improving the cooling power available to the user. The panel may comprise a two-layer foam stack with slits. The bottom side of the lower layer 603 may contain air channels for a fan to remove the waste heat.

[0101] FIG. 14 shows an example molding frame 701 for forming a molded foam panel with slits. The molding frame 701 may include an array of features. The features may be support features or blades. Using a molding frame to form the panel with slits may be more efficient than puncturing and may reduce tears that generate during the puncturing process. The tears may propagate when a load is applied to the thermoelectric system. Molding the foam panel may be a batch operation, which may be more efficient than puncturing individual slits or rows of slits. Molded foam may also have a skin on all surfaces of the foam. The skin may strengthen the physical interface between the foam and the thermoelectric string and increase the durability of the thermoelectric system. The foaming material may be placed into the molding frame and an expansion reaction may occur. The foam may form and mold around an array of blades 702. The array of blades 702 may generate slits in the molded foam panel. The slits may be available as cavities for angled insertion of the thermoelectric string. A foam release material may be applied to the molding frame 701 and array of blades 702 to facilitate removal of the molded panel from the molding frame. The array of blades 701 may be permanently attached to the molding frame and stationary. Alternatively, the array of blades may be temporarily attached to the molding frame and mobile. The distribution and density of the blade array may be modified to produce molded foam panels with a variety of thermoelectric string configurations and densities.

[0102] In an aspect, the present disclosure provides methods for fabricating thermoelectric systems for heating or cooling. The method may include providing a molding frame, foaming materials, and a thermoelectric string. The thermoelectric string may be positioned in the molding frame. The foaming materials may be added to the molding frame to activate an expansion reaction and form a molded foam panel around the thermoelectric string.

[0103] The molding frame may include an array of support features. The array of support features may include a lattice structure. The lattice structure may be a sacrificial lattice structure that is incorporated into the molded foam panel. The lattice structure may comprise a durable material that does not adversely affect the appearance or thermal performance of the

thermoelectric system. The lattice structure may hold the thermoelectric string in place during the formation of the foam panel. The molding frame, array of support features, and

thermoelectric stream may be treated with a foam release material prior to formation of the foam panel.

[0104] The thermoelectric system may include a heat exchanger. The heat exchanger may be positioned adjacent to the array of support features. The molded foam panel may form around the heat exchanger. The heat exchanger may be treated with the foam release material. The heat exchanger may include an array of flexible tubes with holes. The thermoelectric string may comprise thermoelectric elements and alternating expanded and looped conductors. The looped conductors may be inserted into the holes of the flexible tubes. The array of flexible tubes may further include support bridges and clips. The support bridges and clips may position and hold the thermoelectric string in place during formation of the molded foam panel.

[0105] FIG. 15 shows an example molding frame with sacrificial lattice for supporting the thermoelectric string during foam formation. The thermoelectric string 102 may be pre-molded into the molded foam panel. A foam release material may be used on the thermoelectric string 102. Manually inserting the thermoelectric string 102 into the molded panel may create and propagate tears in the foam. Pre-molding the foam panel with the thermoelectric string may generate a more durable thermoelectric system without tears. The process of pre-molding the foam panel with the thermoelectric string may also reduce gaps between thermoelectric elements and the panel and increase the heating and cooling efficiency. A molded foam may have a skin on all surfaces that may strengthen the physical interface between the thermoelectric string and the panel. The skin may also create a more airflow resistant barrier and prevent leaks that may reduce the efficacy of the thermoelectric system. Without limitation, mold release material can be applied to any portion or all of the thermoelectric string 102 to retain flexibility between the foam and the thermoelectric string and to avoid tearing that may result from wear. Other benefits of treating the thermoelectric string with mold release material may include allowing the thermoelectric string to slide easily in the foam, which may help to prevent bending and breaking of conductors, and easy removal of excess foam that may form on the conductors. The thermoelectric string 102 may be placed in the lattice 801 either before or after the

thermoelectric string has been treated with the foam release material. The lattice may comprise Styrofoam, aerogel, hard foam, or other sacrificial material that is crushed, dissolves or otherwise does not adversely affect the physical properties of the thermoelectric system. The lattice and thermoelectric string may be placed into the mold 701 prior to foaming materials being added. Without limitation, the molded panel may include two or more foaming materials that generate molded foams of differing densities. Using foaming materials of differing densities may allow for a panel layer and an airflow layer to be molded simultaneously.

Thermoelectric systems integrated into wearables and furniture

[0106] The thermoelectric systems disclosed herein may be incorporated or integrated with a variety of wearable or usable objects or devices. In some examples, the thermoelectric systems are incorporated into seats, cushions, beds, or mats that may provide a user thermal comfort or therapeutic benefit. In some example, the thermoelectric systems are incorporated into wearable objects and devices that may provide a user thermal comfort or therapeutic benefit.

[0107] FIG. 16 shows a thermoelectric string 102 inserted into a very thin insulating panel 602. This assembly may be created using a molding or puncturing processes as previously described. The thickness of the insulating panel may be only slightly greater than the height of the slanted thermoelectric element 105. The slanted thermoelectric element may be comprised of n-type and p-type thermoelectric elements mounted on a strain relief. The expanded conductors 103 and looped conductors 104 on both the warm and cool sides may be spread out in a flat

configuration, further reducing the overall thickness. The assembly of FIG. 16 may be used as a wearable device, or any other thermoelectric application such as heated and cooled seat, beds, or medical surface. The thermoelectric system 101 may be covered with a sheet of Teflon, polyurethane, Tyvek, nylon, polyimide, Mylar or other material to electrically isolate the user from the wires. Further, this insulating layer may be covered with an electrically conducting layer to protect the user from leakage current should the insulating sheet be compromised. The electrically conducting layer may flow the leakage current rather than the leakage current flowing through the body of a user.

[0108] FIG. 17 shows a design for a thermoelectric system 101 that can be worn as a headband or wrapped around another part of the body. This design may be used independently or integrated into wearable clothing or sports gear such as helmets, protective padding, arm bands, or similar. The thermal load on the human body may limit athletic performance and this type of wearable thermoelectric system can provide cooling or heating to manage and optimize the thermal load of the body during physical activity. Additionally, this wearable thermoelectric system may provide thermal comfort to a user. The side of the headband may be comprised of fabric 1004 and exposed thermoelectric string 102 may contact the user. Without limitation, the heat exchanger layer may be comprise a single channel or multiple channels with a row or rows of thermoelectric string cooled by two fans 1001 on either end of the channel. The fans 1001 may pull air from a mesh-covered inlet 1002 located in the center of the channel midway between the fans. The heat exchanger layer may be separated from the top surface that contacts the user by an airtight barrier layer. The wire leads 1003 from the thermoelectric string 102 and the fans 1001 may be connected to a battery or other power source to power the device portably or tethered.

[0109] FIGs. 18A and 18B show the front and back, respectively, of a design for a

thermoelectric system integrated into and worn as a waist strap that can be combined with a backpack, fanny pack, or similar. The wearable thermoelectric system can provide similar physiological benefits to those addressed in the previous section. FIG. 18A shows the uncovered heat exchange layer which, without limitation, can be comprised of four rows of channels 1101 separated from the user-contacting top surface by an airtight barrier layer. Without limitation, each fan 1001 pulls air through two channels from a respective inlet 1002 as indicated. FIG. 18B shows the top surface of the waist band that contacts the user with a grid indicating the locations of thermoelectric devices that make up the thermoelectric string to be inserted (not shown). Wire leads 1003 from the thermoelectric string and fans may be connected to a battery or other power source to power the waist strap portably or tethered.

[0110] FIGs. 19A and 19B show the top and bottom of a design for a thermoelectric system 101 that may be integrated into an armored vest 1201 or other wearable item. The wearable thermoelectric system may have similar physiological benefits to those addressed in previous sections. FIG. 19A shows the top surface of the thermoelectric panel which, without limitation, may comprise of one or multiple columns of thermoelectric string 102 running vertically with an air inlet 1002 in the center, while the air channels 1101 of the heat exchange layer run horizontally, as shown in FIG. 19B. Without limitation, the thermoelectric panel can be mounted to the armored vest 1201 in the location shown in FIG. 19A, or anywhere else on the inside of the front or back portions of this vest or other wearable item that contacts the front or back of a user's torso. Wire leads from the thermoelectric string and fans may be connected to a battery or other power source to power the integrated thermoelectric system portably or tethered.

[0111] FIGs. 20A and 20B show a design for a thermoelectric system 101 integrated into a portable seat topper 1301 that can be placed on top of a seating surface to provide the user with temperature control for increased comfort. In this example, air is pulled through the heat- exchanger layer by the two fans 1001 located in a manifold container in the back bolster of the topper. The air may first enter through an inlet area 1002 that runs across the front and sides of the topper and flow into the front air channels 1101 to the panel. A cavity underneath the back bolster may allow for airflow from the outlets 1304 of the channels to the manifold of the fans 1001 of FIG. 20B. Inlet air can enter from the front or sides and outlet air can exit the top, sides, or back. The multiple airflow pathways may help maintain consistent airflow in the event that one or more pathways are blocked during use. Axial fans 1001 may be mounted horizontally, vertically, or in another orientation to enable the back bolster to be thinner or shaped differently. Without limitation, the cushion can be powered by rechargeable batteries 1302 concealed in slots on the bottom surface as shown in FIG. 20D or in a single central slot. Alternatively, or in addition to, the cushion may be powered by other methods such as a power cord to a wall outlet through an AC adapter. In one example, the cushion consumes about 12.5 watts of power and is powered by a USB power standard of 5.1 volts and 2.4 amps. Standard adapters and

rechargeable batteries used for USB compatible devices can be used for this seat topper. A load sensor or switch 1305 may be included so the topper does not use power when not in use.

[0112] FIG. 20C shows the back bolster of the climate cushion and a switch 1303 that allows the user to toggle between full heating, full cooling, and off settings. Without limitation, this switch can be a double-pole double-throw switch to reverse current in the thermoelectric ribbon. Alternatively, or in addition to, a controller and user interface can be added to provide greater adjustability using pulse width modulation (PWM) or other voltage step-down techniques. A Bluetooth or Wi-Fi remote controller may also be used, like a remote-controlled LED light dimmer. FIGs. 20D and 20E show the bottom of the topper, including access to the battery 1302 compartment in the back bolster. FIG. 20F shows a breathable fabric cover over the seat topper to allow airflow into the heat-exchanger layer while concealing the mechanical features. Without limitation, the top of the seat topper cover can be made up of a breathable, minimally- insulating material; while the bottom of the cover can be made out of a more resilient material designed to withstand abrasion from various seating surfaces. Combinations of materials in various parts of the cover can be used to optimize function and appearance. The sides and front and back bolster may have breathable material that allows air to flow in and out. The top cover material may have strong thermal conduction and have a pleasant feel to the user. The bottom cover material may have some friction to prevent sliding in the seat.

[0113] Without limitation, all of the heating and cooling products described herein may be controlled by a microprocessor, computer, or mobile device. Many beneficial functions may be implemented in the software or firmware, including recognizing the user, remembering and applying the user's preferences, active managing the heating and cooling intensity to maintain a preferred or set temperature, maximize battery life, minimize power consumption, prevent over or under temperature conditions, or manage temperature over time to a given profile.

[0114] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.

Computer control systems

[0115] The present disclosure provides computer control systems that are programmed to implement methods of the disclosure. FIG. 21 shows a computer system 2101 that is

programmed or otherwise configured to implement methods of fabricating thermoelectric systems and use thermoelectric systems. The computer system 2101 can regulate various aspects of the thermoelectric systems of the present disclosure, such as, for example, controlling and modulating the flow of electrical current and heat generation, storing and running user profiles on the thermoelectric system, or recording user date from the thermoelectric system. The computer system 2101 can be an electronic device integrated into the thermoelectric system that controls programming and function of the thermoelectric system. The computer system 2101 may also be an electronic device of a user or a computer system that is remotely located with respect to the thermoelectric system and is used to wirelessly program or control the

thermoelectric system. The electronic device can be a mobile electronic device. [0116] The computer system 2101 includes a central processing unit (CPU, also "processor" and "computer processor" herein) 2105, which can be a single core or multi core processor, or a plurality of processors for parallel processing. The computer system 2101 also includes memory or memory location 2110 (e.g., random-access memory, read-only memory, flash memory), electronic storage unit 2115 (e.g., hard disk), communication interface 2120 (e.g., network adapter) for communicating with one or more other systems, and peripheral devices 2125, such as cache, other memory, data storage and/or electronic display adapters. The memory 2110, storage unit 2115, interface 2120 and peripheral devices 2125 are in communication with the CPU 2105 through a communication bus (solid lines), such as a motherboard. The storage unit 2115 can be a data storage unit (or data repository) for storing data. The computer system 2101 can be operatively coupled to a computer network ("network") 2130 with the aid of the communication interface 2120. The network 2130 can be the Internet, an internet and/or extranet, or an intranet and/or extranet that is in communication with the Internet. The network 2130 in some cases is a telecommunication and/or data network. The network 2130 can include one or more computer servers, which can enable distributed computing, such as cloud

computing. The network 2130, in some cases with the aid of the computer system 2101, can implement a peer-to-peer network, which may enable devices coupled to the computer system 2101 to behave as a client or a server.

[0117] The CPU 2105 can execute a sequence of machine-readable instructions, which can be embodied in a program or software. The instructions may be stored in a memory location, such as the memory 2110. The instructions can be directed to the CPU 2105, which can subsequently program or otherwise configure the CPU 2105 to implement methods of the present disclosure. Examples of operations performed by the CPU 2105 can include fetch, decode, execute, and writeback.

[0118] The CPU 2105 can be part of a circuit, such as an integrated circuit. One or more other components of the system 2101 can be included in the circuit. In some cases, the circuit is an application specific integrated circuit (ASIC).

[0119] The storage unit 2115 can store files, such as drivers, libraries and saved programs. The storage unit 2115 can store user data, e.g., user preferences and user programs. The computer system 2101 in some cases can include one or more additional data storage units that are external to the computer system 2101, such as located on a remote server that is in communication with the computer system 2101 through an intranet or the Internet.

[0120] The computer system 2101 can communicate with one or more remote computer systems through the network 2130. For instance, the computer system 2101 can communicate with a remote computer system of a user (e.g., a mobile controller). Examples of remote computer systems include personal computers (e.g., portable PC), slate or tablet PC's (e.g., Apple® iPad, Samsung® Galaxy Tab), telephones, Smart phones (e.g., Apple® iPhone, Android-enabled device, Blackberry®), or personal digital assistants. The user can access the computer system 2101 via the network 2130.

[0121] Methods as described herein can be implemented by way of machine (e.g., computer processor) executable code stored on an electronic storage location of the computer system 2101, such as, for example, on the memory 2110 or electronic storage unit 2115. The machine executable or machine readable code can be provided in the form of software. During use, the code can be executed by the processor 2105. In some cases, the code can be retrieved from the storage unit 2115 and stored on the memory 2110 for ready access by the processor 2105. In some situations, the electronic storage unit 2115 can be precluded, and machine-executable instructions are stored on memory 2110.

[0122] The code can be pre-compiled and configured for use with a machine having a processer adapted to execute the code, or can be compiled during runtime. The code can be supplied in a programming language that can be selected to enable the code to execute in a pre-compiled or as-compiled fashion.

[0123] Aspects of the systems and methods provided herein, such as the computer system 2101, can be embodied in programming. Various aspects of the technology may be thought of as "products" or "articles of manufacture" typically in the form of machine (or processor) executable code and/or associated data that is carried on or embodied in a type of machine readable medium. Machine-executable code can be stored on an electronic storage unit, such as memory (e.g., read-only memory, random-access memory, flash memory) or a hard disk.

"Storage" type media can include any or all of the tangible memory of the computers, processors or the like, or associated modules thereof, such as various semiconductor memories, tape drives, disk drives and the like, which may provide non-transitory storage at any time for the software programming. All or portions of the software may at times be communicated through the Internet or various other telecommunication networks. Such communications, for example, may enable loading of the software from one computer or processor into another, for example, from a management server or host computer into the computer platform of an application server. Thus, another type of media that may bear the software elements includes optical, electrical and electromagnetic waves, such as used across physical interfaces between local devices, through wired and optical landline networks and over various air-links. The physical elements that carry such waves, such as wired or wireless links, optical links or the like, also may be considered as media bearing the software. As used herein, unless restricted to non-transitory, tangible

"storage" media, terms such as computer or machine "readable medium" refer to any medium that participates in providing instructions to a processor for execution.

[0124] Hence, a machine readable medium, such as computer-executable code, may take many forms, including but not limited to, a tangible storage medium, a carrier wave medium or physical transmission medium. Non-volatile storage media include, for example, optical or magnetic disks, such as any of the storage devices in any computer(s) or the like, such as may be used to implement the databases, etc. shown in the drawings. Volatile storage media include dynamic memory, such as main memory of such a computer platform. Tangible transmission media include coaxial cables; copper wire and fiber optics, including the wires that comprise a bus within a computer system. Carrier-wave transmission media may take the form of electric or electromagnetic signals, or acoustic or light waves such as those generated during radio frequency (RF) and infrared (IR) data communications. Common forms of computer-readable media therefore include for example: a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD or DVD-ROM, any other optical medium, punch cards paper tape, any other physical storage medium with patterns of holes, a RAM, a ROM, a PROM and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave transporting data or instructions, cables or links transporting such a carrier wave, or any other medium from which a computer may read programming code and/or data. Many of these forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to a processor for execution.

[0125] The computer system 2101 can include or be in communication with an electronic display 2135 that comprises a user interface (UI) 2140 for providing, for example, a method for programming and controlling the thermoelectric system. Examples of UI's include, without limitation, a graphical user interface (GUI) and web-based user interface.

[0126] Methods and systems of the present disclosure can be implemented by way of one or more algorithms. An algorithm can be implemented by way of software upon execution by the central processing unit 2105. The algorithm can, for example, enable a user to generate user profiles, collect system and user data, and generate use programs.

[0127] While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. It is not intended that the invention be limited by the specific examples provided within the specification. While the invention has been described with reference to the aforementioned specification, the descriptions and illustrations of the embodiments herein are not meant to be construed in a limiting sense. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Furthermore, it shall be understood that all aspects of the invention are not limited to the specific depictions, configurations or relative proportions set forth herein which depend upon a variety of conditions and variables. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is therefore contemplated that the invention shall also cover any such alternatives, modifications, variations or equivalents. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby

Claims

CLAIMS WHAT IS CLAIMED IS:

1. A thermoelectric system for heating or cooling, comprising:

a panel comprising an electrically and/or thermally insulating material;

a plurality of thermoelectric elements connected by individual conductors that are (i) compacted in a cross section inside said panel and (ii) expanded in at least one dimension outside said panel, wherein said plurality of thermoelectric elements comprise alternating p-type and n- type thermoelectric elements; and

a load sensor in electrical communication with said plurality of thermoelectric elements, wherein said load sensor (i) detects applied load on or in proximity to said panel, and (ii) permits flow of electrical current through said plurality of thermoelectric elements upon detecting said applied load.

2. The thermoelectric system of claim 1, wherein said load sensor is integrated with a control system or passive restraint system of a vehicle.

3. The thermoelectric system of claim 2, wherein said load sensor enables, disables, or alters a property of said control system or said passive restraint system of said vehicle.

4. The thermoelectric system of claim 1, wherein said load sensor is operatively coupled to a load distributing unit.

5. The thermoelectric system of claim 4, wherein said load distributing unit includes a plurality of elongated load elements.

6. The thermoelectric system of claim 5, wherein said plurality of thermoelectric elements is arranged in rows.

7. The thermoelectric system of claim 6, wherein said elongated load elements are placed between said rows.

8. The thermoelectric system of claim 1, wherein said thermoelectric system further comprises a heat exchanger adjacent to a side of said panel.

9. The thermoelectric system of claim 8, wherein said heat exchanger comprises fluid flow channels between one or more support walls.

10. The thermoelectric system of claim 9, wherein said load sensor is aligned with said one or more support walls.

11. The thermoelectric system of claim 10, wherein said load sensor is disposed adjacent to said one or more support walls.

12. The thermoelectric system of claim 8, wherein said load sensor is disposed between said panel and said heat exchanger.

13. The thermoelectric system of claim 1, wherein said load sensor converts the applied load to a resistance reading.

14. The thermoelectric system of claim 1, wherein said load sensor converts the applied load to a capacitance reading.

15. The thermoelectric system of claim 1, wherein said load sensor converts the applied load into a fluid pressure reading.

16. The thermoelectric system of claim 1, wherein said thermoelectric system is incorporated into a seat cushion or a bed.

17. The thermoelectric system of claim 16, wherein said seat cushion is a portable seat cushion.

18. The thermoelectric system of claim 17, wherein said portable seat cushion comprises bolsters in the sides, rear, or both sides and rear of said portable seat cushion.

19. The thermoelectric system of claim 17, wherein said portable seat cushion further comprises a bottom material with a high coefficient of friction.

20. The thermoelectric system of claim 17, wherein said portable seat cushion further comprises a porous top material.

21. The thermoelectric system of claim 1, wherein said thermoelectric system further comprises a battery, switch, intensity control device, thermostatic control device, wireless interface circuit, manifolds, carrying handle, printed circuit board, one or more microprocessors, porous material, or any combination thereof.

22. The thermoelectric system of claim 21, wherein said wireless interface circuit is a Bluetooth or Wi-Fi circuit and is controlled by a mobile control device.

23. The thermoelectric system of claim 21, wherein said thermoelectric system further comprises a power adapter for charging said battery.

24. The thermoelectric system of claim 8, wherein said heat exchanger comprises multiple fluid inlets or multiple fluid outlets.

25. The thermoelectric system of claim 24, wherein one or more fans are disposed adjacent to said multiple fluid inlets or multiple fluid outlets.

26. The thermoelectric system of claim 1, wherein said thermoelectric system is integrated into a wearable object.

27. A thermoelectric system for heating or cooling, comprising:

a panel comprising an electrically and/or thermally insulating material, wherein a first portion of said panel comprises a flexible material and a second portion of said panel comprises a less flexible material than said first portion of said panel; a massage transducer adjacent to said second portion of said panel; and

a plurality of thermoelectric elements connected by individual conductors that are (i) compacted in a cross section inside said panel and (ii) expanded in at least one dimension outside said panel, wherein said plurality of thermoelectric elements comprise alternating p-type and n- type thermoelectric elements.

28. The thermoelectric system of claim 27, wherein said thermoelectric system further comprises a heat exchanger adjacent to a side of said panel.

29. The thermoelectric system of claim 27, wherein said thermoelectric system is integrated into a wearable object, seat, or bed.

30. The thermoelectric system of claim 27, further comprising a battery, switch, intensity control device, thermostatic control device, wireless interface circuit, manifolds, carrying handle, printed circuit board, one or more microprocessors, one or more fans, a power adapter, porous material, or any combination thereof.

31. A thermoelectric system for heating or cooling, comprising:

a panel comprising an electrically and/or thermally insulating material;

a plurality of thermoelectric elements connected by individual conductors that are (i) compacted in a cross section inside said panel and (ii) expanded in at least one dimension outside said panel, wherein said plurality of thermoelectric elements comprise alternating p-type and n- type thermoelectric elements, and wherein flow of electrical current through said plurality of thermoelectric elements heats a first side of said panel and cools a second side of said panel; and a thermal protection unit in electrical communication with said plurality of thermoelectric elements, wherein upon said first side of said panel reaching a threshold temperature said thermal protection device terminates said flow of electrical current.

32. The thermoelectric system of claim 31, wherein said thermal protection unit measures a temperature of said first side of said panel.

33. The thermoelectric system of claim 32, wherein said thermal protection unit includes or is in electrical communication with a thermocouple that measures said temperature.

34. The thermoelectric system of claim 31, wherein said thermal protection unit is connected in series with said plurality of thermoelectric elements.

35. The thermoelectric system of claim 31, wherein said thermal protection unit is adjacent to said individual conductors.

36. The thermoelectric system of claim 31, wherein said thermal protection unit comprises a resistive material with a positive temperature coefficient.

37. The thermoelectric system of claim 31, wherein said thermal protection unit comprises a bimetallic material.

38. The thermoelectric system of claim 31, wherein said threshold temperature is from about 40 degrees centigrade to about 50 degrees centigrade.

39. The thermoelectric system of claim 31, wherein said thermoelectric system further comprises a heat exchanger adjacent to a side of said panel.

40. The thermoelectric system of claim 31, wherein said thermoelectric system is integrated into a wearable object, seat, or bed.

41. The thermoelectric system of claim 31, further comprising a battery, switch, intensity control device, thermostatic control device, wireless interface circuit, manifolds, carrying handle, printed circuit board, one or more microprocessors, one or more fans, a power adapter, porous material, or any combination thereof.

42. A thermoelectric system for heating or cooling, comprising:

a first and a second support, wherein said first and said second support comprise one or more electrically and/or thermally insulating materials, and wherein said first and said second support are spaced apart by a gap; and

a plurality of thermoelectric elements connected by individual conductors, wherein said plurality of thermoelectric elements are wrapped around said first and said second support, and wherein said plurality of thermoelectric elements comprise alternating p-type and n-type thermoelectric elements.

43. The thermoelectric system of claim 42, wherein said p-type thermoelectric elements are adjacent to said first support and said n-type thermoelectric elements are adjacent to said second support.

44. The thermoelectric system of claim 42, wherein said p-type and said n-type

thermoelectric elements are adjacent to said first support and said individual conductors are adjacent to said second support.

45. The thermoelectric system of claim 42, further comprising insulation disposed between said first and said second supports.

46. The thermoelectric system of claim 45, wherein said insulating material is foam.

47. The thermoelectric system of claim 46, wherein said foam is molded to surround portions of said first and said second support and said plurality of thermoelectric elements.

48. The thermoelectric system of claim 42, wherein said individual conductors comprise alternating hot and cold conductors.

49. The thermoelectric system of claim 48, wherein said hot and cold conductors are disposed on opposite sides of said first and said second support.

50. The thermoelectric system of claim 42, wherein said thermoelectric system further comprises a heat exchanger adjacent to a side of said first and said second support.

51. The thermoelectric system of claim 42, wherein said thermoelectric system is integrated into a wearable object, seat, or bed.

52. The thermoelectric system of claim 42, further comprising a battery, switch, intensity control device, thermostatic control device, wireless interface circuit, manifolds, carrying handle, printed circuit board, one or more microprocessors, one or more fans, a power adapter, porous material, or any combination thereof.

53. The thermoelectric system of claim 42, wherein said first and said second supports are flexible.

54. A thermoelectric system for heating or cooling, comprising:

a panel comprising an electrically and/or thermally insulating material;

a plurality of thermoelectric elements connected by individual conductors, wherein said plurality of thermoelectric elements comprise alternating p-type and n-type thermoelectric elements, and wherein said individual conductors comprise alternating expanded conductors and looped conductors; and

a heat exchanger in thermal communication with said individual conductors, wherein said heat exchanger comprises a lattice of flexible tubes, wherein said lattice of flexible tubes comprises holes, and wherein said looped conductors are disposed in said holes.

55. The thermoelectric system of claim 54, wherein said lattice of flexible tubes further comprises support bridges.

56. The thermoelectric system of claim 55, wherein said expanded conductors are disposed adjacent to said support bridges.

57. The thermoelectric system of claim 54, wherein said panel comprises a molded foam.

58. The thermoelectric system of claim 57, wherein said molded foam is formed around said heat exchanger.

59. The thermoelectric system of claim 54, wherein a fluid flows through said lattice of flexible tubes.

60. The thermoelectric system of claim 59, wherein said fluid is at least partially obtained from an air conditioner outlet.

61. The thermoelectric system of claim 59, wherein said fluid is recirculated.

62. The thermoelectric system of claim 59, wherein said fluid is chilled.

63. The thermoelectric system of claim 62, wherein said fluid is chilled in a separate thermoelectric module.

64. The thermoelectric system of claim 54, further comprising a battery, switch, intensity control device, thermostatic control device, wireless interface circuit, manifolds, carrying handle, printed circuit board, porous material, one or more microprocessors, one or more fans, a power adapter, or any combination thereof.

65. The thermoelectric system of claim 54, wherein said thermoelectric system is integrated into a wearable object, seat, or bed.

66. A method of forming a thermoelectric system, comprising:

(a) providing a molding frame and foaming material, wherein said molding frame comprises an array of support features;

(b) providing a plurality of thermoelectric elements connected by individual conductors, wherein said plurality of thermoelectric elements comprises alternating p-type and n-type thermoelectric elements;

(c) adding said foaming material to said molding frame to activate an expansion reaction to form a molded foam panel, wherein during said expansion reaction said array of support features generates slits in said molded foam; and

(d) inserting said plurality of thermoelectric elements into said slits in said molded foam panel to form said thermoelectric system, wherein said individual conductors are (i) compacted in a cross section inside said molded foam panel and (ii) expanded in at least one dimension outside said molded foam panel.

67. The method of claim 66, wherein said array of support features comprises triangle shaped features that generate said slit.

68. The method of claim 67, wherein said slit extends through a width of said molded foam panel.

69. The method of claim 68, wherein on a side of said molded foam panel said slit is narrow and on another side of said molded foam panel said slit is wide.

70. The method of claim 66, wherein said array of features is positioned so that said slits form an acute angle with a surface of said molded foam panel.

71. The method of claim 66, wherein said plurality of thermoelectric elements are

substantially parallel to a surface of said molded foam panel.

72. The method of claim 66, further comprising treating said molding frame or said plurality of thermoelectric elements with a foam release material.

73. The method of claim 66, wherein said thermoelectric system further comprises a heat exchanger.

74. The method of claim 73, wherein said molded foam panel is formed around said heat exchanger.

75. A method of forming a thermoelectric system, comprising:

(c) positioning said plurality of thermoelectric elements adjacent to said array of support features;

(d) adding said foaming material to said molding frame to activate an expansion reaction, wherein during said expansion reaction said array of support features holds said plurality of thermoelectric elements in place, and wherein said molded foam panel forms around said plurality of thermoelectric elements to form said thermoelectric system.

76. The method of claim 75, further comprising treating said molding frame or said plurality of thermoelectric elements with a foam release material.

77. The method of claim 75, wherein said array of support features comprises a lattice structure.

78. The method of claim 77, wherein said lattice structure is incorporated into the molded foam panel.

79. The method of claim 77, wherein the lattice comprises a durable material that does not adversely affect appearance or thermal performance.

80. The method of claim 75, wherein said thermoelectric system further comprises a heat exchanger.

81. The method of claim 80, wherein said molded foam panel forms around said heat exchanger.

82. The method of claim 75, wherein said array of support features comprises clips and bridging objects.

83. The method of claim 82, wherein said clips and bridging objects hold said plurality of thermoelectric elements and said individual conductors in place during formation of said molded foam panel.