DE102012009295A1 - Heating device for seat of vehicle e.g. motor car, has electric conductors connected with electrical function layer that is provided with bus bars which are extended around through-holes for surrounding through-holes - Google Patents

Abstract

The heating device (2) has an electrical function layer (10) that is located on a carrier (30). Several electric conductors are connected with the electrical function layer to provide current to a heating portion. Multiple through-holes (32) are provided in the carrier. A heating region is provided between two electrical function paths. The electrical function layer is provided with bus bars having different polarities. The bus bars are extended around the through-holes for surrounding the through-holes. An independent claim is included for a vehicle seat.

Description

Claiming the priority

The present invention claims priority to US Provisional Patent Application Serial No. 61 / 537,361, filed September 21, 2011, and Serial No. 13 / 106,148, filed May 12, 2011; and International Application No. PCT / US2011 / 36202, filed May 12, 2011, the disclosure of which is incorporated herein by reference.

area

The present teachings generally relate to a heater, and more particularly, to a vehicle seat heater that provides heat to areas adjacent to holes in the heater, a plurality of discrete carriers, and / or provides a uniform current density across a heating area.

background

Typically, heaters include a conductive material that provides heat when connected to a power source. Some heaters heat by applying current to a metal wire (ie, copper wires) passing through the heater. Recently, however, heaters have a substrate layer comprising a positive conductor path and a negative conductor path printed on the substrate, and a resistive material is printed between the positive conductor path and the negative conductor path on the substrate layer so that heat is generated when power is applied. Examples of such heaters are in the U.S. Patent Nos. 3,287,684 ; 4,777,351 ; 4,852,228 ; 5,432,322 ; 6,194,692 ; 6,495,809 ; 6,884,965 ; 7,053,344 ; 7,202,444 ; 7,284,748 ; 7,306,283 ; 7,500,536 and 7,741,582 discloses the disclosure of which is hereby incorporated by reference for all purposes.

In some cases, through-holes are created that pass through the substrate so that the heater is flexible and suitable for use in a vehicle seat. However, the attachment of through-holes in the substrate has resulted in heaters that have unheated zones around the cutouts, through-holes, orifices or a combination thereof; Temperature variations along the surface of the heater; a reduced heating capacity; or a combination thereof. Further, in systems having a fan, a blower, or both, these cold spots are increased due to the flow of air through the through-holes. In addition, the through-holes reduce the space available for the electrical function layers, thereby reducing the available heating surface, the efficiency of the heater, the efficiency of the heater, or both. More recently, additional features have been introduced in vehicle seats to enhance the comfort of the seated person, such as variable thigh pads that adjust to the height and / or length of a seated person so that a larger passenger can extend the seat, To support his or her legs, however, it may be that the additional seat part is not heated and this part feels cold to the seated person.

Here, it would be desirable to have a heater that has increased flexibility while maintaining uniform heating performance around the through-holes, cutouts, openings, moving parts of a vehicle seat, or a combination thereof. Further, it would be desirable to have a heater that heats the area directly adjacent to a through hole in the carrier. There is therefore a need for a heater that contributes to the heating of air passing through the through-holes in the carrier. It would be desirable to have a heater portion that would permit movement of the seat so that extended portions of the seat would be heated while maintaining high durability so that the heater would not fail due to repeated movement. Further, it would be desirable to configure the electrical function layers to maximize the heated area while maintaining installation tolerances, manufacturer requirements, or both.

Summary

The present teaching surprisingly addresses one or more of these needs by providing: a heater comprising: at least one carrier comprising: a first electrical functional layer disposed on the carrier; a second electrical functional layer disposed on the support and in contact with the first electrical functional layer; and one or more electrical conductors connected to the first electrical function layer for supplying power to the heater; wherein the heater comprises one or more of the following features: (1) one or more through holes in the heater, the first electrical function layer having a portion having a first polarity and a portion having a second polarity respectively a region of at least one of the one or more through holes, and wherein the second electrically functional layer is arranged so that the the second electric functional layer is electrically connected to the part having the first polarity and the part having the second polarity so that the area around the at least one of the one or more through holes is heated; (2) wherein the first electrically functional layer is a conductive material, the first electrical functional layer comprising: a primary conductor path having a first width; and a secondary conductor path having a second width that is reduced relative to the primary conductor path, the secondary conductor path being adjacent to the primary conductor path, such that the width of the secondary conductor path is approximately proportional to the current conduction requirement for the one or more heating regions; (3) wherein the at least one carrier is a plurality of discrete carriers and each discrete carrier comprises: the first electrical functional layer and the second electrical functional layer, wherein at least one of the plurality of discrete heaters is connected to one or more electrical conductors that supply power to the heater and wherein each of the plurality of discrete heaters is electrically connected such that when current is applied, each of the discrete carriers generates heat; and (4) one or more through holes in the carrier, the first electrically functional layer having a bus bar having a first polarity and having a bus bar having a second polarity, the bus bar having the first polarity, the bus bar having the first polarity second polarity or both are split such that either the first polarity bus bar or the second polarity bus bar extends concurrently about at least one of the one or more vias such that the at least one of the one or more vias substantially from one Busbar that has a first polarity, or a bus bar that has a second polarity is surrounded.

A possible embodiment of the present teachings comprises: a heater comprising: a carrier, the carrier comprising: an electrical function layer made of a conductive material; a second electrical functional layer made of a resistive material and in electrical contact with the first electrical functional layer; one or more electrical conductors connected to a first electrical functional layer for applying power to generate heat; and one or more through holes in the carrier; wherein the first electrical functional layer has a part having a first polarity and a part having a second polarity; wherein the part having the first polarity is adjacent to a part of the one or more through holes in the support, and the part having the second polarity is adjacent to an opposite part of the one or more through holes in the support, so that the part has the first polarity and the second-polarity portion are disposed opposite to each other and the one or more through-holes are interposed therebetween, and wherein the second electrically-functional layer (ie, a resistance layer) is proximate to the one or more through-holes in the support and the portion electrically connects with the first polarity and the part with the second polarity, so that a portion of the carrier, which is close to the one or more through holes (ie a region between the one or more through holes in the carrier and the part with the first polarity and the part with the second polarity) are heated.

A further unique aspect of the teachings disclosed herein is a heater comprising: a plurality of discrete carriers, each discrete carrier having: a first electrical functional layer and a second electrical functional layer disposed on the respective discrete carriers such that upon application of electricity each of the discrete carriers generates heat; wherein at least one of the plurality of discrete heaters is connected to one or more electrical conductors that provide power to the heater; and wherein each of the discrete carriers is electrically connected.

A heater comprising: a carrier having: one or more through holes; a first electrical functional layer; and a second electrical functional layer; wherein the first electrical functional layer comprises: an outer busbar structure and an inner busbar structure; wherein the outer bus bar structure extends around an outer edge of the carrier and the outer bus bar structure forms a gap and extends around the one or more through holes.

A unique aspect of the present teachings contemplates a heated seat comprising: a cushion having one or more trench areas; the heater disclosed herein; and a reference layer covering the heater, an occupancy sensor mat, a pad, or a combination thereof.

Another unique aspect of the present teachings contemplates a method of heating the region surrounding a through-hole, comprising: obtaining a carrier having at least one through-hole in the carrier; Depositing a first electrically conductive layer around at least a portion of the through hole so as to define a region between the first electrical functional layer and the first electrically conductive layer Through hole is that is free of the first electrical functional layer; Depositing a second electrically functional layer around at least a part of the through-hole such that there is a region between the second electrical functional layer and the through-hole which is free from the second electrical functional layer, and so that the first electrical functional layer and the second electrical functional layer are non-contact are; Depositing a resistive layer on the region between the first electrically functional layer and the via and the second electrical functional layer and the via and in contact with both the first electrical functional layer and the second electrically functional layer such that at least a portion of the region between the first electrically functional layer and the through hole and the second electrically functional layer and the through hole, the resistance layer; Applying current to the first electrically functional layer so that the resistance layer generates heat around the through hole.

The teachings disclosed herein surprisingly solve one or more of these problems by providing a heater that has greater flexibility while maintaining uniform heating around the through-holes, cutouts, openings, moving parts of a vehicle seat, or a combination thereof. The teachings disclosed herein provide a heater that heats the area that directly adjoins a through hole in the carrier. The teachings provide a heater that helps to heat air that passes through the through-holes in the carrier. The gauge provides a heating member that allows movement of the seat so that extended portions of the seat are heated while providing high durability such that the heater does not fail due to repeated movement. The heater disclosed herein is configured so that the electrical functional layer maximizes the heating area while maintaining installation tolerances, manufacturer requirements, or both.

Brief description of the drawings

1 illustrates an example of a heater of the present teachings;

2 is an enlarged view of a through hole of 1 ;

The 3A FIGS. 1B-B illustrate possible cross-sectional views of a heater discussed herein;

4 Figure 4 illustrates a heater as taught herein, which is mounted on a possible vehicle seat as taught herein;

5 illustrates another possible example of a heater of the teachings herein;

6 illustrates one possible example of electrical function guide paths of the present teachings;

7 illustrates an example of a heater discussed herein having electrical function layers around the vias;

8th Fig. 3 illustrates an example of a heating device having a plurality of discrete support members interconnected by one or more bridges; and

9 is an enlarged view of a bridge connection with a carrier.

Detailed description

The explanations and illustrations presented herein are intended to illustrate to the skilled person the invention, its principles and its practical application. The person skilled in the art can adapt and apply the invention and its numerous manifestations as best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present invention as set forth herein are not intended to be exhaustive or to limit the teachings. The scope of the teaching should, therefore, be determined not with reference to the above description, but instead with reference to the appended claims, along with the full scope of equivalents applicable to those claims. The disclosure of all articles and references, including patent applications and publications, is hereby incorporated by reference for all purposes. Other combinations are also possible, as will be apparent from the following claims, the disclosure of which is also incorporated herein by reference.

The present teaching is directed to providing an improved heater. The heater has at least one carrier. The heater may consist of one or more carriers. Preferably, the heater may consist of a plurality of discrete carriers that are electrically connected together. For example, the heater may include a discrete main carrier member in electrical communication with one or more discrete secondary carrier members exhibit. The discrete main carrier part can fit on a pillow. Preferably, the heater has two discrete secondary carrier parts which oppose each other via the discrete main carrier part. The discrete secondary backing members may be configured such that the discrete secondary backing members fit on a cushion of a seat, extend across a trench, fit over a leg region, connect the seat cushion and backrest, extend across the pleat, or a combination thereof , The discrete main carrier member and the one or more discrete secondary carrier members may be electrically interconnected using any device that electrically connects, physically connects, or both of the discrete main carrier member to the discrete secondary carrier members. Preferably, the discrete main support member and the one or more discrete secondary support members may be in electrical communication with one another using a device and / or method that is free of mechanical attachment (eg, a mechanical fastener) , Preferably, the discrete main carrier part and the discrete secondary carrier part are interconnected by at least one bridge.

The bridge may be any device that physically connects, electrically connects, or both the discrete main carrier member to one or more secondary carrier members. The bridge may be any device which physically connects and electrically connects the discrete secondary carriers to the discrete main carrier and which allows the carriers to be moved relative to one another without the discrete main carrier, the discrete secondary carrier, the bridge or a combination of these will be stretched. For example, the bridge may allow the discrete secondary parts to be moved relative to the discrete main carrier and / or the discrete secondary part without causing the discrete main carrier part and / or the discrete secondary parts to be twisted, stretched, bent out of plane, or one Combination of it will be. In another example, when the heater is in an uninstalled position, the bridge may allow the discrete secondary carriers to hang slackly from the discrete main carrier member. The bridge may be of sufficient size, thickness, width, or a combination thereof so that enough current can be passed through the bridge to a connected carrier and heat generated. The bridge may have a width of about 1 mm or more, about 2 mm or more, or about 3 or more, and the first electrical functional layer may have substantially the same width. The bridge may have a width of about 10 mm or less, about 7 mm or less, or about 5 mm or less, and the first electrical functional layer may have substantially the same width.

The one or more bridges may be made of any material disclosed herein. Preferably, the bridge can be made of the same material as the carrier. It is even better if the bridge has a first electrical functional layer on at least one side. It is even more preferable if the bridge has a first electrical functional layer on one side and the first electrical functional layer of the bridge is in electrical communication with the first electrical functional layer of the discrete main carrier part and the discrete secondary carrier part, so that the bridge makes the discrete main carrier part electrically connects to the discrete secondary support part. Most preferably, the bridge is free of the second electrical functional layer. The bridge may include a sufficient amount of the electrically functional layer so that current may be passed from one discrete carrier to another discrete carrier to generate heat. One or more bridges may form a connection to the discrete main carrier part, the discrete secondary carrier parts or both by any device and / or method providing both physical connection and electrical connection, and the connection is free of a mechanical connection element Connecting element that extends through the carrier, a connecting element that adds additional parts or a combination thereof.

One or more bridges may be connected at any location to the discrete main electrical carrier, the discrete secondary electrical carrier, or both, such that the bridge allows current to flow therebetween. Preferably, the bridge is connected to a bus bar of the discrete main functional carrier, the discrete electrical secondary function carrier, or both, so that current flows between the discrete carriers. It is contemplated that a single bridge may be used to form the connection between two discrete carriers. For example, an electrical functional layer may be printed on a bridge on both sides, and one side may have a positive electrical functional layer and the opposite side may have a negative electrical functional layer. One side may communicate directly with the respective discrete carrier and the opposite side with the discrete carriers using another second one-way bridge, one connection, one indirect Connection or a combination thereof.

The connection can be formed using ultrasonic welding. Ultrasonic welding can be carried out at such a low temperature that the bridge is connected to the carrier and vice versa and the carrier is not further damaged. Ultrasonic welding can be performed without the addition of an external heat source (ie, the only heat that is generated comes from the pressure and vibration of the ultrasonic welder). In this way, the base material may be heated (ie, heated), but not to such a high temperature that the physical properties of the wearer are changed (eg, melted, thrown, damaged, or the like) at a location other than the point of contact ) become. Ultrasonic welding may be directed to a precise location such that the substrate is not damaged and only the bridge and the first electrical functional layer, the second electrical functional layer or both are welded (ie fused, welded, bonded or the like). The depth of the weld can be controlled by adjusting the pressure applied to the bridge and support by the anvil and sonotrode. A pressure of about 6000 N / m ² to about 350,000 N / m ² may be applied. Preferably, a pressure of about 13,000 N / m ² to about 170,000 N / m ^{2 may be} applied. It is more preferable if a pressure of about 20,000 N / m ² to about 35,000 N / m ² can be applied. The sonotrode can be used in a vertical relationship (ie vertical) to the anvil. The sonotrode can be used in a substantially parallel relationship to the anvil. The relationship of the sonotrode to the anvil can control the direction of the ultrasonic vibration and the depth of the weld. For example, if the sonotrode and the anvil are generally parallel to each other, then the ultrasonic vibrations are also along the same plane (ie, a vertical vibration). In another example where the sonotrode and the anvil are perpendicular to each other, the ultrasonic vibrations may be parallel to the sonotrode and perpendicular to the anvil (ie, horizontal vibration).

The depth of the weld can also be controlled by adjusting the frequency. A frequency of about 5 kHz to about 150 kHz may be used to secure the electrical conductor to the carrier. Preferably, a frequency between about 15 kHz to about 70 kHz may be used to secure the electrical conductor to the carrier. Even more, it is preferable to use a frequency between about 20 kHz to about 40 kHz to secure the electrical conductor to the carrier. Preferably, when ultrasonic welding is used, the first electrical functional layer, the carrier, and the bridge are converted so that the carrier and / or the bridge fuse together only at the point of contact, with the first electrically functional layers interlocking with each other both an electrical connection is formed. The heater may be ultrasonically welded to a pouch for use with the air conditioning system or walls discussed herein, which pouch may be welded together by ultrasonic welding, or may be used to ultrasonically weld the heater to another article of manufacture. This can be achieved by using methods described herein to adjust the depth, heat, frequency, pressure, or a combination thereof to connect the heater to the bag, article of manufacture, a bridge, or a combination thereof. The bridge may be secured by a combination of devices and methods that do not require a mechanical fastener.

The bridge may be connected via a conductive adhesive, a conductive adhesive, a conductive bonding agent, a conductive adhesive or the like or a combination thereof (hereinafter referred to as a conductive adhesive). The conductive adhesive may be any adhesive that adheres two materials together and contributes to the formation of an electrically conductive connection therebetween. The conductive adhesive may also bond various materials together. For example, the conductive adhesive may bond a conductive material (eg, copper or silver) to a polymeric material (eg, Mylar, Polyester, Melinex). In another example, in addition to bonding a conductive material to each of the dissimilar polymeric materials, the conductive adhesive may combine with joining together various polymeric materials. The conductive adhesive may be measured after setting ASTM D 732 have a shear strength of about 0.5 MPa or more, about 1.0 MPa or more, or about 1.5 MPa or more. The conductive adhesive may be measured after setting ASTM D 732 have a shear strength of about 10 MPa or less, about 8 MPa or less, about 5 MPa or less, or about 3 MPa or less.

The conductive adhesive may be any adhesive that retains some flexibility after setting so that the adhesive will not crack or break when subjected to repeated bending. The conductive adhesive may after the Setting measured according to ASTM D 790 have a bending strength of about 10 MPa or more, about 14 MPa or more, or about 17 MPa or more. The conductive adhesive may be measured after setting ASTM D 790 have a flexural strength of about 40 MPa or less, about 30 MPa or less, about 20 MPa or less, or about 18 MPa or less.

The conductive adhesive may have some resilience after setting so that the adhesive can conform to irregularly shaped surfaces. The conductive adhesive may be stretchable after setting. The set conductive adhesive can be measured after ASTM D 638 be about 10 percent or more, about 20 percent or more, or about 25 percent or more stretchy. The set conductive adhesive can be measured after ASTM D 638 be about 100 percent or less, about 80 percent or less, or about 60 percent or less extensible. The conductive adhesive has measured after setting after ASTM D 638 a tensile strength of about 1 MPa or more, about 3 MPa or more, about 5 MPa or more, or about 6.5 MPa or more. The conductive adhesive has measured after setting after ASTM D 638 a tensile strength of about 20 MPa or less, about 15 MPa or less, or about 10 MPa or less.

Preferably, the conductive adhesive is not brittle after setting. The set conductive adhesive may have a hardness of about 20 Å or more, about 40 Å or more, or about 60 Å or more, as measured by the Shore A hardness. The set conductive adhesive may have a hardness of about 100 D or less, about 90 D or less, about 80 D or less, or preferably about 75 D or less (ie, between about 70 D and about 75 D) as measured by the Shore D hardness , The conductive adhesive may set at room temperature so that the carrier is not heated and / or damaged to bind the conductive adhesive. The conductive adhesive may contribute to forming an electrical contact between two opposing electrically conductive layers. The conductive adhesive can help protect against the formation of corrosion on the electrical functional layers. The conductive adhesive can enhance the electrical conductivity of the electrical functional layers.

The conductive adhesive has a conductivity. The conductive adhesive may have such high conductivity that the adhesive may contribute to the formation of an electrical connection between two surfaces and bond the surfaces together. The conductive adhesive may be conductive so that the conductive adhesive has a low volume resistance and is useful for promoting electrical connection between two opposing surfaces. The conductive adhesive, as measured using Method 5011.5 in MIL-STD-883H, has a bulk resistivity of approximately 1.0 Ω · m or greater, approximately 1.0 × 10 ^-1 Ω · m or greater, preferably approximately 1.0 × 10 ^-2 Ω · m or more, more preferably about 1.0 × 10 ^-3 Ω · m or more, or even more preferably about 1.0 × 10 ^-4 Ω · m or more (ie, between about 1.74 × 10 ^-4 Ω · m and about 2.5 × 10 ^-4 Ω · m). The conductive adhesive measured using Method 5011.5 in MIL-STD-883H has a bulk resistivity of approximately 1.0 x 10 ^-8 Ω • m or less, approximately 1.0 x 10 ^-7 Ω • m or less, approximately 1 , 0 × 10 ^-6 Ω · m or less, or about 1.0 × 10 ^-5 Ω · m or less.

The conductive adhesive may include a conductive additive. The conductive additive may be any additive that contributes to forming an electrical connection. The conductive additive may be any conductive material discussed herein. Preferably, the conductive additive is copper, silver, nickel, gold or a combination thereof. The conductive additive may be added in such a large amount that an electrical connection can be made between two opposing surfaces. The conductive additive may be added in such a large amount that the conductive additive contributes to forming an electrical connection. The conductive adhesive may contain about 10% by weight or more, about 20% by weight or more, preferably about 30% by weight or more, more preferably about 40% or more, even more preferably about 45% or more by weight of the conductive additive (ie, between about 45% and 50% by weight) 50 weight percent conductive additive). The conductive adhesive may contain about 90 weight percent or less, about 75 weight percent or less, about 60 weight percent or less, or about 45 weight percent or less conductive additive. Some examples of conductive adhesives which can be used herein are Ekecikut 414, commercially available from Panacol; Eccobond CA 3556HF, available from Hysol; and 8331, available from MG Chemicals, the disclosure of which is hereby incorporated by reference for all purposes.

The heating device has a carrier, a first electrical functional layer and a second electrical functional layer. The carrier may be made of any material, such that a first electrical functional layer, a second electrical functional layer or both the carrier can be printed. The carrier may be made of any material suitable as a heater. The carrier may have an insulating property. The carrier can be fire resistant. For example, the carrier can withstand temperatures of 50 ° C or more, about 75 ° C or more, about 100 ° C or more, or even about 125 ° C or more, without the carrier melting, catching fire, smoking, or a combination hereof. The backing may be made of a polymeric material (eg, thermoset or thermoplastic) and, in particular, may be a thermoplastic polymeric material. The polymeric material may be selected from homopolymers, copolymers, composites, or other combination of materials containing one or more polyesters, a polyimide, polyolefin (e.g., polypropylene, polyethylene, or a combination thereof), or polyetherimide. Examples of commercially available materials are Mylar ^®, Melinex ^®, Tyvek ^®, Cetus ^® or Ultem ^® or more thereof. The support may be made of any material disclosed herein, including the teachings of US Patent Application Serial No. 13 / 106,140 filed on May 12, 2011, paragraph No. 0042, the disclosure of which is hereby incorporated by reference.

The carrier has an outer edge. The outer edge includes an upper edge, a lower edge, a first side edge and a second side edge. The carrier may include one or more of the following: slits, cuts, through holes, cutouts, tabs, features, or a combination thereof. Preferably, the cutouts are arranged on an outer edge of the carrier. The slots, cuts, through holes, cutouts, tabs, features, or a combination thereof may be disposed at any location on the carrier. The slots, cuts, through holes, cutouts, tabs, features or a combination thereof may be of any shape and size such that they reduce stresses on the wearer. Additional disclosure regarding the slots, cuts, through holes, cutouts, tabs, and features are included in the present teaching, which is the teachings of US Patent Application No. 13 / 106,140, filed May 12, 2011, paragraph 0096, 0099, 0100, 0103, 0112 and 0113, the disclosure of which is hereby incorporated by reference. The through holes may be any absence of material in a surface (i.e., part of the carrier with the largest surface area) of the carrier. For example, the surface of the carrier consists of the parts of the heater which are arranged on the seat under the seat occupant, are in contact with an occupancy sensor, are in contact with a reference layer, or a combination thereof. The through holes may be the area where material has been removed from the carrier. An inner slot may be considered as a through hole. An outer slot and / or a cutout is not a through hole. The through-holes may be of any size and shape in the carrier so that the through-holes provide relaxation to the wearer so that the wearer can flex and stretch due to settling, knee loading, indentation, pockets, boxes, heavy Objects or a combination thereof provides a relaxation. For example, the through-holes may be round, oval, rectangular, cross-shaped, T-shaped, S-shaped, diamond-shaped or a combination of holes of different shapes. The carrier may include a through hole. The carrier may include a plurality of through holes. The carrier may have 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 15, 18 or even 20 through holes in the carrier. The carrier may have about 5 through holes or more, about 8 through holes or more, about 15 through holes, or more or about 20 through holes or more. The carrier may have about 50 through holes or less, about 40 through holes, or about 30 through holes or less. Preferably, the carrier has between about 10 and about 30 through holes in the carrier. The through holes can all be the same size and shape. Preferably, the through holes vary in size, shape, or both. The through holes may be arranged symmetrically in the carrier. For example, the through-holes may be arranged symmetrically on opposite sides of a centerline of the carrier in a coordinated manner. The through holes may also be arranged asymmetrically in the carrier (i.e., on opposite sides of a centerline in an uncoordinated manner).

The carrier has two electrical functional layers. Preferably, the first electrical functional layer is made of a conductive material and the second electrical functional layer is made of a resistive material. The electrically functional layers may be applied by any known method disclosed herein, including that in paragraph No. 0046 of U.S. Patent Application No. 13 / 106,140, filed May 12, 2011, the disclosure of which is hereby incorporated by reference. Preferably, the electrically conductive layers are applied by screen printing or by the use of a printer (eg, an ink jet printer, a bubble jet, a laser printer, a piezo printer, or the like, or a combination thereof). A piezo printhead that can be used for this purpose is any piezo printhead that is capable of producing high viscosity inks such as for example, to print the inks disclosed herein. The electrical functional layers may have any shape and thickness, so that the electrical functional layers can conduct electricity and generate heat. The electrical function layers may have a thickness as taught herein, including a thickness of paragraph No. 0046 of U.S. Patent Application No. 13 / 106,140, filed May 12, 2011, the disclosure of which is hereby incorporated by reference.

The first electrical functional layer is conductive (i.e., a conductive electrical functional layer). The conductive electrical functional layer may be made of any material or combination of materials that conducts electricity. The conductive electric layer may be made of a nano-ink. The electrically conductive layer can be made of copper. Preferably, the conductive electrical functional layer may be made of silver or nano-silver. The conductive electrical functional layer may be made of any material taught herein and / or any material having the material properties as taught herein, including those of paragraphs 0050 to 0061 of U.S. Patent Application No. 13 / 106,140, filed on Apr. 12, 1985 May 12, 2011, the disclosure of which is hereby incorporated by reference. Examples of commercially available copper inks that may be used herein are CB200 Copper Conductor and CB230 Copper Conductor available from DuPont. An example of a commercially available silver ink that can be used herein is the DuPont 5000 Series ink. In particular, a 5064H silver ink available from DuPont.

The second electrical functional layer is a resistance layer (i.e., an electrical resistance functional layer). The resistive layer may be made of any material that generates heat as it passes electricity through the material. In this case, the material preferably has the properties of a positive temperature coefficient. It may consist of a copolymer binder mixed with carbon particles (e.g., natural carbon, petroleum carbon, carbon flakes, graphite or the like), additives (e.g., antifoaming agents, adhesives, fire retardants or the like), fillers (e.g. Clay, titanium dioxide or the like), solvents (eg based on alcohol, based on ethanol or the like) or a combination thereof. Additional aspects of the electrically functional resistive layer, such as material properties, may be derived from the teachings herein, including those of paragraphs 0014, 0015, 0050, 0061, 0062, and 0090 of U.S. Patent Application No. 13 / 106,140, filed on 12th May 2011, the disclosure of which is hereby incorporated by reference. Preferably, the electrically resistive functional layer may be PTC ink, for example DuPont's 7282 ink series.

The electrical functional layers can be applied to the substrate in virtually any pattern. The first electrical functional layer has at least one positive electrical functional layer part and one negative electrical functional layer part. The first electrical functional layer is preferably applied to the carrier such that the carrier has a positive conductive electrical functional layer and a negative electrical functional layer. The positive and negative electrical functional layers each have at least one electrode and a comb-like intermeshing member (i.e., finger). The positive electrical functional layer and the negative electrical functional layer may have one or more electrical functional paths. The electrical function paths may have any shape, size, configuration or combination thereof, so that when applying a second electrical functional layer to the first electrical functional layer, heat is generated. Preferably, the size, shape, configuration or combination thereof of the first electrical functional layer is such that the power distribution across the heater is substantially constant over a surface of the heater such that heating is applied to the first electrical functional layer upon application of a second electrical functional layer is substantially the same over an area of the heater. Even more, it is preferable that the size, shape, configuration or combination thereof of the first electric functional layer is such that the power distribution and the heating are substantially equal in a region adjacent to a through hole in a heater and near the edge of the heater Heat is generated (ie, heat is generated within about 1.0 mm or less, about 0.5 mm or less, or even about 0.1 mm or less away from the edge of the through-hole).

The electrical functional layers have one or more main electrical function paths (ie, a bus bar, an electrode, or both). The electrical functional layers preferably have at least two main electrical functional paths. One or more of the main electrical function paths may be split along its length. Preferably, one or more of the main electrical function paths may be cleaved along the length and substantially defined by an opening, cavity, through-hole, feature, or the like Be surrounded by this combination. More preferably, the split substantially surrounds or surrounds an opening, cavity, through-hole, feature, or combination thereof that allows air to pass through the support, as discussed herein. The cleavage in the main electrical function layer may include one or more openings, cavities, vias, features, or a combination thereof between the two or more portions of the main electrical function layers. The one or more main electrical function paths may have gaps in rows. For example, gaps may occur in rows along the length of the main electrical function layers. The one or more main electrical function paths may have about one or more columns, about two columns or more, about three columns or more, about four columns or more, about six columns or more, or even about eight columns or more columns in series. The one or more main electrical function paths may have about 20 columns or less, about 15 columns or less, or about 12 columns or fewer columns in series. Preferably, the one or more main electrical function paths have approximately four columns and ten columns in series. For example, the main electrical function layer may be cleaved four times such that at least four through holes in the carrier are substantially surrounded. The main electrical function paths may surround and / or substantially surround one or more, two or more, three or more, or even four or more cavities, openings, vias, features or a combination thereof at the same time. The main electrical function paths may surround and / or substantially surround about ten or less, about eight or fewer, or about six or fewer cavities, openings, vias, features, or a combination thereof at the same time. The main electrical function paths may also have gaps in parallel. For example, the main electrical function path may be split into three parts so that two adjacent through holes are separated from a split bus bar passing between them, with one bus bar passing around the corresponding through hole each.

The main electrical function path can have two columns in parallel or more, three columns in parallel, or more or even four columns in parallel or more. The gaps that exist in parallel in the main electrical functional paths together have a combined width. Preferably, a combined width of the parallel column in the main electrical function paths remains substantially constant with the non-split portions of the main electrical function paths. For example, the combined width of the two or more parallel gaps in the main electrical function path is equal to or less than the width of the main electrical functional path before cleavage, after cleavage, or both. Preferably, the width of the main electrical function paths narrows gradually as the main electrical function paths departs from the power source, and any parallel gaps in the main electrical functional paths have a combined width substantially equal to the width before cleavage, after cleavage, or both. The combined parallel width of the main electrical function paths may be less than the width before cleavage, after cleavage, or both. The combined parallel width of the main electrical function paths may be any width such that sufficient power can be supplied to the heating area, can be supplied if an electrical function path is damaged, or both. The current carrying capacity of the combined width of the main electrical function layer may be substantially equal to a single width of a main electrical function layer, the main electrical function layer before cleavage, the main electrical function layer after cleavage, or a combination thereof. The amount of current flowing through the combined width of the cleavage in the main electrical function path is substantially equal to the amount of current flowing through the main electrical function path before and after cleavage. The amount of current supplied to the heating regions may be the same as before cleavage, after cleavage and during cleavage, so that the amount of current supplied to the heating regions remains constant. The parallel width of the electrical function paths may be any width, so that the electrical function path maximizes the heating area. The electrical function path may be between a cavity, a through-hole, an opening, a feature, or a combination thereof and an edge of the carrier (eg, an inner slot, an outer slot, a cut-out, a through-hole, a feature, a peripheral edge or a combination thereof) or both, so that the number of conductor paths in the heating areas can be maximized so that the heater heats up.

The main electrical function paths may be in a high stress area (eg, under a seated person), near a cavity, opening, through-hole, feature, or combination thereof that forms a high stress area, or both. The gaps in the main electrical function path may provide an electrical path in the event of a gap in the main electrical path of operation, so that power continues to flow through the main electrical function paths becomes. The main electrical function path may be spaced a distance from a peripheral edge of the carrier (ie, the outer edge of the carrier). The distance may be any distance such that the flow of current through the main electrical function paths does not disturb the surrounding components (eg occupancy sensor, air mover, or both). The distance may be any distance such that the main electrical function path extends between an edge of the carrier and an edge of a cavity, aperture, through-hole, feature, or a combination thereof. The main electrical function paths may have an average distance from the edge of about 1 mm or more, about 2 mm or more, or about 3 mm or more. The main electrical function path may have an average distance from the edge of about 10 mm or less, about 8 mm or less, or about 6 mm or less.

The electrical functional paths may include one or more conductive paths that are directly and / or indirectly connected to the main electrical functional paths. For example, the electrical function layers may include a primary electrical conductor path, a secondary electrical conductor path, a tertiary electrical conductor path, etc., or a combination thereof, and the primary electrical function path connects directly to the main electrical function path on one side / one end and provides the secondary electrical conductor path connects on an opposite side and / or at an opposite end. The tertiary electrical function path may connect to one side and / or one end of the secondary electrical function path opposite the primary electrical function path, and so on as more paths are added. The electrical functional layers may have one or more widths. The width of the electrical function paths can remain constant while the paths lead away from the main electrical function paths. The width of the electrical function paths may become smaller while the electrical function paths lead away from the main electrical function path. The width of the electrical function paths may be incrementally reduced incrementally while the electrical function paths lead away from the main electrical function path. For example, a primary electrical function path may have a first width, a second electrical function path may have a second width, and the third electrical function path may have a third width.

The primary electrical function path may have a width X. The secondary electrical function path may have a width of between about 1.0X and about 0.7X, and preferably between about 1.0X and about 0.8X. The tertiary electrical function path may have a width of between about 0.8X and about 0.3X, preferably between about 0.7X and about 0.4X (i.e., between about 0.65X and about 0.45X). The primary electrical function path may have a width of about 3.0 mm or less, about 2.5 mm or less, or about 2.2 mm or less. The primary electrical function path may have a width of about 1.0 mm or more, about 1.2 mm or more, or about 1.4 mm or more. Preferably, the primary electrical function path may have a width between about 3.0 mm and about 1.2 mm and more preferably between about 2.5 mm and about 1.4 mm (i.e., about 2.0 mm). The secondary electrical function path may have a width of about 3.0 mm or less, about 2.5 mm or less, or about 2.2 mm or less. The secondary electrical function path may have a width of about 0.8 mm or more, about 1.0 mm or more, or about 1.1 mm or more. Preferably, the secondary electrical function path may have a width between about 2.5 mm and about 0.8 mm and more preferably between about 2.2 mm and about 1.3 mm (i.e., about 2.0 mm). The tertiary electrical function path may have a width of about 1.5 mm or less, about 1.2 mm or less, or about 1.1 mm or less. The tertiary electrical functional path may have a width between about 0.5 mm or more, about 0.7 mm or more, or about 0.9 mm or more. Preferably, the tertiary electrical function path has a width between about 1.4 mm and about 0.8 mm and more preferably between about 1.2 mm and about 0.9 mm (i.e., about 1.0 mm). The primary electrical function path, the secondary electrical function path, the tertiary electrical function path, or a combination thereof may have a width that varies along the length of the respective path. For example, a path may begin with a width of about 2.0 mm and end with a width of about 1.8 mm.

The width of the Primary electrical functional path, secondary electrical functional pathway, tertiary electrical functional pathway or a combination thereof may vary by about 10% or more, about 20% or more, about 30% or more along the length of the corresponding pathway. The width of the primary electrical function path, the secondary electrical function path, the tertiary electrical function path, or a combination thereof may vary by about 100% or less, about 80% or less, or about 60% or less along the length of the corresponding path. The width of the primary electrical functional path, the secondary electrical functional path, the tertiary electrical functional path, or a combination thereof may be varied so that the current density delivered to the heating regions remains substantially constant along the length of the respective path. For example, the amount of current per millimeter width of the respective path may be relatively the same amount of current along the length of the respective path (eg, the current varies about 20% or less, preferably about 15% or less, or more preferably about 10%. or less, when measured along the length) so that the current density remains substantially constant along the length of the electrical functional layer. The current carrying capacity of the primary electrical functional path, the secondary electrical functional path, the tertiary electrical functional path or a combination thereof may be substantially proportional to the width of the respective path. For example, a 10 mm wide path may have a current carrying capacity of about one ampere and a path having a width of about 5 mm may have a current carrying capacity of about 0.5 ampere. The current carrying capacity of the respective path may be varied based on the width of the respective path, the current required to heat a particular heating area to a specific temperature, or both, and the width of the path may be substantially proportional to the amount of current that is required for a particular one required heating area is required so that the required power can be supplied to the heating area. As discussed herein above, substantially proportional to varying the width and / or area with the required current, width and / or area is about 30% or less, preferably about 20% or less, more preferably about 10 % or less of the current load requirements, the ampacity, or both. For example, if a given path is 20 mm long and 4 mm wide and the current carrying capacity and the current applied at the beginning of the path is one ampere and the current applied at the end of the 20 mm is 0.9 amperes, the current load requirements will remain over the length the path is substantially proportional (ie, the currents deviate at most 10% from each other). In other words, as the path from the power source is further removed, the available amount of power becomes smaller and the width of the corresponding path smaller by a proportional amount so that the heating range is maximized, the path widths remain as small as necessary to accommodate a heating target reach, or both.

The electrical functional parts (eg, alternating fingers or comb-like intermeshing parts) are at least partially covered by a second electrical functional layer so that when voltage is applied to the first electrical functional layer, electrons flow through the resistive layer and generate heat. The fingers may include a primary electrical function path, a second electrical function path, a tertiary electrical function path or the like, or a combination thereof. Preferably, the fingers are a combination of positive electrical functional paths and negative electrical functional paths that substantially mesh with each other (ie, form an alternating pattern so that heat can be generated). The first and second electrical functional layers may have any shape, pattern, arrangement, or combination thereof relative to each other. The first electrical functional layer may generally consist of straight lines. The first electrical functional layer may contain curves. The first electrically functional layer may include parts that are adjacent to through holes and / or openings formed in the carrier so that the holes and / or openings may be heated. Additional aspects of the patterns of the electrically functional layers can be deduced from the teachings herein, including those of paragraphs Nos. 0011, 0014, 0015, 0061, and 0102, and U.S. Pat 1 - 13 U.S. Patent Application No. 13 / 106,140, filed May 12, 2011, the disclosure of which is hereby incorporated by reference. The first electrical functional layer and the second electrical functional layer generally adjoin a through-hole.

The through holes may be heated or unheated. The unheated through holes may not have a positive electrical functional layer, a negative electrical functional layer, an electrically resistive functional layer, or a combination thereof. The unheated through holes may be free of the positive conductive layer, the negative conductive layer or the resistance layer.

The heated through holes have at least one conductive electrical functional layer and an electrical resistance functional layer. The electrically conductive layers may adjoin the through holes. The conductive electrical functional layer has a positive electrical functional layer part and a negative electrical functional layer part. For example, an electrical functional layer of a first polarity may be substantially adjacent to one side of the through-hole and an electrically conductive layer of a second other polarity may be substantially adjacent to the opposite side of the through-hole such that the through-hole between the electrical functional layers having a first polarity and have a second polarity, is arranged. In combination, the two conductive electrical functional layers do not completely surround the through-holes. For example, the two conductive electrical functional layers do not touch and also do not form a layer 100% around the through-hole (ie, closing the circle). The two conductive electrical functional layers may each be at about 10% or more, at about 20% or more, preferably at about 30% or more, more preferably at about 45% or more, or even more preferably at about 47% or more of the through-hole adjoin. The two conductive electrical functional layers each adjoin less than about 50% of the respective through-hole and preferably about 48% or less of the respective through-hole. The positive and negative conductive electrical functional layers may be adjacent to the via holes at different amounts. For example, the positive conductive electrically functional layer may be adjacent to about 20% of a via and the negative electrical functional layer may be adjacent to about 75% of the same via or vice versa. In this way, the two conductive electrical functional layers in combination generally abut the respective through-hole so as to surround less than 100% of its circumference, preferably surround about 99% or less, and more preferably surround about 95% or less. The total amount of the two conductive electric functional layers is less than 100% in total, preferably about 99% or less, more preferably about 95% or less. The total amount of the two conductive electric functional layers is about 50% or more in total, about 60% or more, about 70% or more, preferably about 80%, or more preferably about 85% or more of the circumference of the respective through-hole.

The electrical functional layer having a first polarity, a second polarity or both may be about 10% or more, about 20% or more, about 30% or more, about 40% or more, about 50% or more, about 60 % or more, about 70% or more, about 80% or more, or even about 85% or more of the respective through hole. The percentage of abutment with the respective through-hole through the conductive electrical functional layer may vary from through-hole to through-hole. For example, one through hole may be adjacent to about 20% of the conductive electrical functional layer and about 70% adjacent to an adjacent via hole in the conductive electrical functional layer. The conductive electrical functional layer having a first polarity and the conductive electrical functional layer having a second polarity in combination with the electrical resistance functional layer may substantially surround the through-hole.

Preferably, the combination of the conductive electrical functional layer and the electrically resistive functional layer surrounds 100% of the through-hole. It is more preferable that the conductive electric functional layers (i.e., conductive layers of opposite polarity) are electrically connected to each other via the second electrically functional layer (i.e., the resistive layer) so that heat is generated in a region near a through hole in the substrate. In this configuration, electricity and / or current flows at least partially around the via hole via the second electrically functional layer so that heat is generated. The heating device may have a third layer, which covers the first electrical functional layer, the second electrical functional layer or both.

The third layer may be a protective layer. The third layer may cover the heater in whole or in part. The heater may be free of a third layer. The third layer may have an adhesive on both sides so that the third layer may be used to place and / or secure adjacent layers of the heater. The third layer may have an adhesive on one side only. Preferably, the third layer has adhesive on at least one side. The third layer may protect the first electrical functional layer and the second electrical functional layer from environmental conditions (eg, dirt, liquids, or other things commonly found in a vehicle). Preferably, the protective third layer may be selected to be resistant to moisture and moisture. In this way, the third layer can be moisture impermeable. The protective third layer can also be well adapted to the curved surfaces so that the curved surfaces can be protected. The third layer may be a film, a film, a textile, a coating, a web, or any combination thereof. The third layer may be at least partially transparent, at least partially opaque, it may be completely opaque or a combination thereof. The third layer may be made from a polymeric film (eg polyester or polyurethane) or may be coated on one side or both sides with an acrylic adhesive or uncoated. The third layer may be glued, laminated or taped (ie heat laminated) onto the backing. A preferred third layer may be ARClad 8350 manufactured by Adhesive Research. Additional aspects of the third layer doctrine can be found here existing paragraphs 0064, 0065, 0066, 0067, 0081, 0096, 00114, 00116 and 00117 and the 2A - 2 B of US Patent Application No. 13 / 106,140 filed May 12, 2011, the disclosure of which is hereby incorporated by reference.

The heater may have a fourth layer. The fourth layer may be an adhesive film. The fourth layer can be used to bond one of the further layers to the carrier. The fourth layer can be used to glue the carrier to a seat. The fourth layer may be an adhesive layer (eg, an adhesive, a paste, a spray adhesive, an adhesive film, a protective-layer adhesive tape, a hook-and-loop fastener, or the like). Preferably, the fourth layer may be an adhesive film having a protective layer. The heater may also be free of a fourth layer. The fourth layer may completely or partially cover the carrier. Additional aspects of the fourth layer teaching may be deduced from the teachings herein which include those of paragraphs 0064, 0065, 0066, 0067, 0081, 0096, 00114, and 00116, and of 2A - 2 B US Patent Application No. 13 / 106,140, filed May 12, 2011, the disclosure of which is hereby incorporated by reference.

The heater may have a fifth layer. The fifth layer may be a protective layer. The fifth layer may be on a top of the carrier. The fifth layer can be on a bottom of the vehicle. The fifth layer may be of a woven or non-woven material, such as polyester, nonwoven, polypropylene, rayon, nylon, wool, linen, cotton, any combination thereof, or the like. The fifth layer may be breathable or non-breathable. The fifth layer may have through-holes corresponding to the heater through-holes. Preferably, the fifth layer is of a breathable polyester. The size, shape and configuration of the fifth layer may substantially reflect the size, shape and configuration of the heater. The fifth layer may be present on both sides of the carrier. The fifth layer can be held by the fourth layer on the carrier. Preferably, the fifth layer is arranged and / or fixed over the printed side of the carrier. The fifth layer may have a bulk density that is about 0.6 g / cm ³ or less, about 0.4 g / cm ³ or less, about 0.2 g / cm ³ or less, or even about 0.10 g / cm is ³ or less (ie, about 0.15 g / cm ³ to about 0.04 g / cm ^3). The heater may be free of a fifth layer. The fifth layer may be connected to one or more of the bridges. The fifth layer may be associated with each discrete carrier and be free of connection to the bridges. The fifth layer can connect all the discrete carriers and bridges together to form a large piece connected by the fifth layer. The fifth layer may be attached to the bridges, backings, discrete backings, or a combination thereof, by the third layer, the fourth layer, a proprietary adhesive, a proprietary adhesive tape, a proprietary bonding agent, or a combination thereof. The fifth layer may interconnect the discrete carriers such that when the discrete carriers are pulled in opposite directions, a majority of the voltages are applied to the fifth layer so that the bridge connections remain intact. Additional aspects of the fifth-layer teaching may be understood from the teachings herein, including paragraphs 0064, 0065, 0066, 0067, 0081, 0096, 00114, and 00116, and U.S. Patent Nos. 5,196,074; 2A - 2 B US Patent Application No. 13 / 106,140, filed May 12, 2011, the disclosure of which is incorporated herein by reference.

The heater has an electrical conductor which is connected to each pole of the first electrical functional layer. The electrical conductor may consist of copper wires, silver wires, wires, tracks or a combination thereof. The electrical conductor may be connected to the heating device via a mechanical fastening element. The electrical conductor may be connected to the carrier using a low pressure molding. The electrical conductor may be connected to the heater by welding, soldering, conductive adhesive, or a combination thereof. Preferably, the electrical conductor is connected via a mechanical fastener to the heater, which engages the electrical conductor and is connected to the carrier via holes in the carrier. Additional aspects of the attachment methods for attaching electrical conductors to the carrier can be understood from the teachings herein, including paragraphs 0070, 0077, 0081 and 00124, and FIGS 4A - 4B and 12A - 12B US Patent Application No. 13 / 106,140, filed May 12, 2011, the disclosure of which is incorporated herein by reference.

The present teaching is directed to providing an improved heater suitable for incorporation into a variety of articles of manufacture. For example, the heater in supports (eg, elements, structures, panels, floors, walls, or the like) of various articles of manufacture, such as buildings, furniture, transport vehicles (eg, boats, trains, aircraft, motorcycles, all-terrain Vehicles, buses, snowmobiles or others) or the like integrated or attached to these become. Alternatively, the heater may be incorporated into various components of transport vehicles such as seats, benches, mirrors or mirror assemblies (eg, rearview mirrors, exterior mirrors or the like), gear levers, panels, footrests, floor mats, trunk liners, windows, batteries, or other components attached to them. The heater of the present teachings may be disposed at any location in a vehicle, and most advantageously on components that generally contact a passenger of the vehicle, such as armrests, rearview mirrors, user control interfaces, seats, steering wheels, or others. The heater may also be used for other off-vehicle heating applications (eg, bedding, clothing, helmets, shoes, tool handles, plant growth, medical use, pharmaceutical use, or others).

The heater is particularly suitable for installation in a seat of a motor vehicle. In particular, the heater is suitable for installation in the seat part with or without upholstery, the backrest with or without upholstery, the headrest or a combination thereof. The heater may include discrete parts that heat the upholstery of a vehicle seat. Preferably, the heater has a discrete part suitable for heating the upholstery of a seat. The heater may include a discrete part that heats a leg rest of a vehicle seat. The heater may include a discrete part that moves with a movable leg rest of the vehicle seat. The bridges may tie discrete girders that heat one or more pads, one or more leg portions, a headrest, a seat and a backrest, or a combination thereof. The bridges may extend between the areas mentioned herein, a trench, a crease or a combination thereof, and through one or more of these areas so that the discrete heating parts are electrically connected together and generate heat.

The heater may be disposed under a fabric layer (eg, cloth, leather, faux leather, or the like) and on top of a cushion, a backrest, a cushion, a thigh support, or a combination thereof (eg, a foam support for the user) , In one aspect, the present teaching utilizes a structure that makes it particularly suitable for use under a perforated leather seat cover or a braided imitation leather seat cover. In this way, the present heaters are particularly desirable for use in combination with a conditioned seat (eg, a ventilated, actively cooled, and / or actively heated seat (eg, through the use of a thermoelectric device or a thermoelectric module)). ,

The seat of the vehicle may include one or more fans or fans that move air for the comfort of the passenger. For example, the fan may bleed air from the user or the fan may push air toward the user. The fan and / or the fan may have their own conditioning device, such as a thermoelectric device or pelleting device. The conditioning device can be used to provide heat. The conditioning device can be used to provide cool air. The heater discussed here can be used to provide heated air. The fan and / or fan may move air to the passenger, and the heater may heat the air as the air exits through the heater through holes. Preferably, the vicinity of the through holes of the heater is heated so that the through holes do not constitute a cold spot while the air leaks through the through holes during a heating application. For example, when air passes through the through holes, heat is peeled off around the through holes, and when the through holes are surrounded only by a conductive electric functional layer, the through hole temperature by the resistance material can not be maintained. However, in the configuration taught herein, the resistance material abuts against the through holes and supplies heat to the area directly adjacent to the through holes, so that the temperature difference between the area adjacent to the through hole and the area of the heater having no through holes is substantially canceled becomes. The region directly adjacent to the through-holes preferably heats the fluid as it passes through the through-holes. The temperature difference between the region directly adjacent to a through hole and a region having no through hole is then substantially canceled (ie, about 1 ° C to about 5 ° C) when no air passes through the through hole. The temperature difference between a region directly adjacent to a through hole that is heated and a region that does not have a through hole is then about 8 ° C or less, about 5 ° C or less, about 3 ° C or less, about 2 ° C or less and / or about 1 ° C or less when fluid passes through the through hole. The temperature difference between a region directly adjacent to a through hole that is not heated and a region that does not have a through hole is then about 1 ° C or more, about 2 ° C or more, about 3 ° C or more, or even about 5 ° C or more when fluid passes through the through hole.

The vehicle seat may include a cushion, and the cushion may include one or more trench areas and one or more pads. Preferably, the heater may be used with any trench discussed herein. Additional aspects of trenches may be understood from the teachings contained herein including paragraphs 0089, 0098, 0112 and 0118 and 3 US Patent Application No. 13 / 106,140, filed May 12, 2011, the disclosure of which is incorporated herein by reference. The pad and / or an occupancy sensor mat may have one or more through holes. The one or more through holes may be substantially aligned with the through holes of the heater. The seat cover layer may include one or more through holes substantially aligned with the through holes in the heater. The reference layer may have a plurality of through holes each aligned with the through holes of the heater. Preferably, the through-holes in the cushion, heater, and cover layer are substantially aligned so that fluid (eg, air) can pass through the through-holes to or from the passenger and / or person sitting in the vehicle. When the heater has a third layer, a fourth layer, a fifth layer, or a combination thereof, then each respective layer may include one or more vias substantially aligned with the one or more vias in the carrier and / or permeable, so that fluids (eg air) can pass through the through-holes.

It is further contemplated that the vehicle seat may include an occupancy sensor. Additional aspects of the occupancy sensor can be learned from the teachings herein, including paragraphs 099 and 126 of US Patent Application No. 13 / 106,140, filed May 12, 2011, the disclosures of which are hereby incorporated by reference. Additional occupancy sensors that can be used with the teachings herein are those of U.S. Patents No. 5,986,221 ; 6,494,284 ; 6,906,293 ; 7,202,444 ; 7,306,283 ; 7,500,536 and 7,708,101 ; U.S. Patent Application Publication No. 2002/000742; 2006/162983; 2007/0215601 and 2007/0290532; and European Patent No. EP 1 209 026 , the disclosure of which is hereby incorporated by reference.

The heaters discussed herein may be manufactured using a method described herein. In particular, the method can be used to heat the area surrounding a through-hole, to produce a heater having a plurality of discrete carriers, and / or to produce a heater having an improved current density. These methods include one or more of the following steps. Obtaining a carrier having a through hole. Obtaining a carrier and then making through holes in the carrier. Depositing a first electrically conductive layer around at least a portion of a via so that a portion of the region directly adjacent to the via is free of the first electrically functional layer. Applying the first electrical functional layer, so that the first electrical functional layer has a part with a first polarity and a part with a second polarity. Applying a second electrical functional layer between the first electrical functional layer and the through hole. Applying the second electrical functional layer in the region directly adjacent to the through hole. Applying the second electrical functional layer, so that the second electrical functional layer connects the electrical functional layer with a first polarity and the electrical functional layer with a second polarity. Connecting electrical conductors to the conductive electrical functional layers. Attaching a bridge to one or more discreet straps. Ultrasonically welding the bridge to one or more discrete carriers as discussed herein. Conductive bonding of one or more bridges to one or more discrete carriers. Applying current to the electrical conductor and / or the heater so that heat is generated.

1 illustrates a heater 2 , The heating device has a first electrical functional layer 10 and a second electrical functional layer 20 on. The second electrical functional layer 20 shown here is shown around the holes for illustrative purposes only. The second electrical functional layer 20 runs over the entire heating ranges of the heater. The first electrical functional layer 10 includes an electrical functional part 12 with a first polarity and a second electrical functional layer 14 with a second polarity. The first electrical functional layer has a first busbar 16A of the electrical functional part 12 the first polarity and a second busbar 16B of the electrical functional part 14 the second polarity. The electrical functional part 12 the first polarity has fingers 18A and the electrical functional part 14 with the second polarity has fingers 18B on. The heater has a carrier 30 on and the carrier has through holes 32 , an inner slot 34A and cutouts 36 on.

2 is an enlarged view of a through hole 32 the in 1 shown heater 2 , The through hole has an electrical functional part 12 a first polarity, to the through hole 32 adjacent to one side, and an electrical functional part 14 a second polarity, on a the electrical functional part 12 the first polarity opposite side of the through hole 32 to the through hole 32 borders. A second electrical functional layer 20 adjoins the through hole and is in a region between the through hole 32 and both the electrical functional layer 12 the first polarity as well as the electrical functional layer 14 the second polarity on the carrier 30 arranged. The second electrical functional layer 20 touches the electrical functional layer 12 the first polarity and the electrical functional layer 14 the second polarity and thereby forms an electrical bridge 38 between these.

The 3A and 3B illustrate possible sectional views of the heater taught here 2 , The heater has a carrier 30 on. The carrier 30 has a first electrical functional layer 10 and a second electrical functional layer 20 on. The carrier has electrical connections 4 on, attached to the first electrical functional layer 10 and the second electrical functional layer 20 Supply electricity. The heater 2 has a fifth layer 60 on top of the first electrical functional layer 10 and the second electrical functional layer 20 over the third layer 40 mounted on the carrier. 3A has a fourth layer 50 on that between the third layer 40 and the fifth layer 60 is inserted. 3A further illustrates a reference layer 70 that spread over the entire heater 2 extends. The heater 2 can be placed over an article of manufacture (not shown).

4 illustrates the heater 2 (from the examples in the 1 and 5 shown), which are about an article of manufacture 80 is laid. The object of manufacture 80 has trenches 82 on. The heater 2 is using a fastening device 84 connected to the anchoring device 86 Located in the trench, connects to the article of manufacture 80 connected. The cutouts 36 are aligned with the trench, leaving a thinner part between the cutouts 36 in the ditch 82 is pulled, leaving the heater 2 on the article of manufacture 80 is attached. The heater 2 also has an external slot 34B on.

5 illustrates another enlarged view of a through-hole 32 which is discussed here. The through hole 32 has a first electrical functional layer 10 on, which is an electrical functional part 12 a first polarity and an electrical functional part 14 having a second polarity. As shown, current flows from the electrical functional part 12 the first polarity by a second electrical functional layer 20 (not shown for clarity, so that the paths are clearly illustrated) to the electrical functional part 14 the second polarity. The second electrical functional layer 20 generates heat while current flows through the second electrical functional layer.

6 illustrates a possible configuration of the conductive electrical functional layers 10 , The conductive electrical functional layer 10 has an electrical functional part 12 first polarity and an electrical functional part 14 second polarity. Both the electrical functional part 12 first polarity as well as the electrical functional part 14 second polarity contain a main electrical function part 16A respectively. 16B , The electrical functional part 12 first polarity and the electrical function part second polarity further have a primary path 100 , a secondary path 102 and a tertiary path 104 which extend from those. The primary path 100 , the secondary path 102 and the tertiary path 104 extend within a heating area 150 ; the heating area, as shown here, does not have the second electrical functional layer just for the sake of illustration. As shown, have the first busbar 16A and the second busbar 16B a width (W), the primary path has a width (W _P ), the secondary path has a width (W _S ) and the tertiary path has a width (W _T ). The first electrical functional part and the second electrical functional part are adjacent to a through hole 32 in the carrier 30 arranged, and the electrical functional part 12 first polarity is the electrical function part 14 second polarity opposite. In 6 is merely a second electrical functional layer for purposes of illustration 20 Not shown.

7 illustrates another possible configuration of a heater taught here. The heater has a carrier having a plurality of through holes extending therethrough 32 on. The through holes are of a first electrical functional layer 10 surround. As shown, a first busbar 16A split and extends through the respective through hole 32 such that the through-hole is essentially from a single busbar 16A is surrounded. The carrier 30 also has an inner cutout 36 on, with outer cutouts 36 on both sides a neck area 120 in the carrier 30 form. The first electrical functional layer 10 has an electrical functional part 12 first polarity and an electrical functional part 14 second polarity with opposite polarity. The electrical functional part 12 first polarity and the electrical functional parts 14 second polarity are via an electrical functional part 20 second polarity connected.

8th illustrates a heater 2 that have multiple carriers 30 includes. The heater has a discrete main carrier 200 , two discrete secondary carriers 220 and bridges 250 on which the discrete secondary carriers 220 electrically with the discrete main carrier 200 connect. The discrete secondary carriers 220 as shown here heat upholstery parts of a vehicle seat (not shown). The secondary electrical functional layer 20 is on the two discrete secondary vehicles 220 for illustrative purposes not shown, so the bridges 250 and their connection areas are clearly shown.

9 illustrates an enlarged view of the connection areas 240 the bridges 250 with the discrete main carrier 200 and the discrete secondary carrier 220 ,

All numerical values given here contain all values from the low value to the higher value in unit increments, provided there is a distance of at least two units between a lower value and a higher value. For example, when indicating that the amount of a component or value of a process variable, such as temperature, pressure, time, and the like, for example, from 1-90, preferably from 20-80, is more preferable from 30-70 ranges, it should be indicated that values such as 15-85, 22-68, 43-51, 30-32, etc. are expressly listed in this description. For values less than 1, a unit should be 0.0001, 0.001, 0.01 or 0.1, whichever is appropriate. These are merely examples of what is intended in particular, and all possible combinations of numerical values between the lowest value and the highest value quoted are to be construed as expressly in the present description in a similar manner.

Unless otherwise stated, all ranges include both endpoints and all numbers between endpoints. The use of "about" or "approximately" in connection with an area refers to both ends of the range. Thus, "about 20-30" should also include "about 20-about 30" including at least the specified endpoints.

The disclosure of all articles and references, including patent applications and publications, is incorporated by reference for all purposes. The phrase "consisting essentially of" to describe a combination is intended to include all of the elements, ingredients, components or steps set forth and such other elements, ingredients, components or steps that do not materially affect the novel characteristics of the combination. The use of the phrase "comprising" or "comprising" to describe combinations of elements, ingredients, components or steps also contemplates embodiments consisting essentially of the elements, ingredients, components or steps. By using the phrase "may", it is intended that attributes described thereby that "may" be included are intended to be optional.

Elements, ingredients, components or steps in the plural may also be provided by a single integrated element, a single integrated ingredient, a single integrated component or a single integrated step. Alternatively, a single integrated element, single integrated ingredient, single integrated component or single integrated step may be split into separate elements, ingredients, components or steps in the plural. The disclosure of the term "a" or "one" to describe an element, ingredient, component or step is not intended to exclude additional elements, ingredients, components or steps.

The disclosure of all articles and references, including patent applications and publications, is hereby incorporated by reference for all purposes. The omission of an aspect of the subject matter disclosed herein in the claims is not intended to be a waiver of such subject matter, nor is it intended to imply that the inventors have considered this subject to be part of the disclosed subject matter.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

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Cited non-patent literature

• ASTM D 732 [0029]
• ASTM D 732 [0029]
• ASTM D 790 [0030]
• ASTM D 790 [0030]
• ASTM D 638 [0031]
• ASTM D 638 [0031]
• ASTM D 638 [0031]
• ASTM D 638 [0031]

Claims (15)

Heating device, comprising: a. at least one carrier, comprising: 1. a first electrical functional layer disposed on the carrier; 2. a second electrical functional layer disposed on the carrier and in contact with the first electrical functional layer; and 3. one or more electrical conductors connected to the first electrical functional layer for supplying power to the heater; wherein the heater has one or more of the following features: 1) one or more through holes in the carrier, the first electrically functional layer having a portion having a first polarity and a portion having a second polarity respectively adjacent to opposing portions of at least one of the one or more through holes and the second electrical functional layer is disposed so that the second electrical functional layer electrically connects the first polarity part and the second polarity part between the opposing regions, such that an area around the at least one of the one or more ones Through holes is heated around; 2) one or more heating regions, wherein the first electrically functional layer is a conductive material, and wherein the one or more heating regions are defined between two main electrical function paths, the main electrical function paths each comprising: a) a primary conductive path having a first width; and b) a secondary conductive path connecting to the primary conductive path, the secondary conductive path having a second width that is smaller relative to the primary conductive path such that the width of the secondary conductive path is approximately proportional to the current loading requirements for the one or the plurality of heating areas; 3) wherein the at least one carrier is comprised of a plurality of discrete carriers and only one of the plurality of discrete carriers is connected to the one or more electrical conductors and each discrete carrier comprises: the first electrical functional layer, and the second electrical functional layer, and wherein each the plurality of discrete heaters is electrically connected such that when current is applied, each of the discrete carriers generates heat; and 4) one or more through holes in the carrier, the first electrical functional layer having a bus bar having a first polarity and a bus bar having a second polarity, the bus bar having the first polarity, the bus bar having the second polarity both are split such that the bus bar with the first polarity or the bus bar with the second polarity simultaneously extend around at least one of the one or more through holes, such that the at least one of the one or more through holes substantially from the bus bar the first polarity, the busbar is surrounded with the second polarity or both. The heater of claim 1, wherein the carrier has at least two through holes, and the first polarity portion adjoins approximately 30% of the one or more through holes and more, and the second polarity portion adjoins approximately 30% of the one or more through holes More, wherein the second electrical functional layer between the part with the first polarity and the part with the second polarity extends, so that the area around the through hole is heated. A heater according to any one of the preceding claims, wherein the first electrically functional layer is adjacent to less than about 99% of the one or more via holes. The heater of claim 1, wherein the heating region further comprises a tertiary conductive path having a width that is reduced relative to both the primary conductive path and the secondary conductive path such that the width of the tertiary conductive path is approximately proportional to the width of the tertiary conductive path Current load requirements for the one or more heating areas. The heater of claim 4, wherein the width of the primary conductive path is X, the width of the secondary conductive path is between about 1.0X and about 0.8X, and the width of the tertiary conductive path is between 0.65X and about 0.45X. A heater according to any one of claims 4 to 5, wherein the width of the primary conductive path is between about 3.0 mm and about 1.0 mm (ie 2.0 mm), the width of the secondary conductive path is between about 2.5 mm and about 0.8 mm (ie 2.0 mm) and the width of the tertiary conductive path is between about 1.2 mm and about 0.6 mm (ie 1.0 mm). A heater according to any one of the preceding claims, wherein the heater comprises two or more discrete carriers, wherein a discrete carrier is a discrete main carrier which heats a major portion of a vehicle seat, and one or more discrete carriers is a discrete secondary carrier having one or more Padded parts, one or more leg portions or both of the vehicle seat heated. The heater of claim 7, wherein the discrete main carrier is electrically connected to the one or more discrete secondary carriers via at least one bridge made of the same material as the two or more discrete carriers, and wherein the bridge has the first electrical functional layer mounted on at least one side. A heater according to any one of claims 7 to 8, wherein the at least one bridge is free of mechanical attachment to secure the discrete main carrier and the one or more discrete secondary carriers. A heater according to any one of claims 7 to 9, wherein the at least one bridge is attached to the discrete main carrier and the one or more discrete secondary carriers using ultrasonic welding, a conductive adhesive, or both. A heater according to any one of the preceding claims, wherein the first polarity bus bar, the second polarity bus bar, or both have a pre-split width, and wherein a combined width of the split into the first polarity bus bar, the second polarity bus bar, or both is less than or equal to the width before splitting, such that the current carrying capacity of the combined width around the one or more through holes of the first polarity bus bar, the second polarity bus bar, or both is substantially equal to the current carrying capacity prior to splitting. Vehicle seat comprising: a. a pad having one or more through holes; b. a reference layer having one or more through holes; and c. the heater according to one of the preceding claims, which is arranged between the pad and the cover layer; wherein the one or more through holes in the pad correspond to the one or more through holes in the heater and the cover layer such that fluid moves through the pad, the cover layer, and the heater to and / or away from a seat occupant can be. The vehicle seat of claim 12, wherein the vehicle seat includes one or more air mover means for moving air to a person engaging the seat, and the area around the one or more through holes in the carrier is heated while the fluid is passing through the one or more Through holes in the cushion is moved, so that the fluid is heated when the fluid passes to the seat occupant. The vehicle seat of claim 12, wherein the at least one support is attached to a third layer covering the first electrical functional layer and the second electrical functional layer, and the third layer is one of one or more through-holes corresponding to the one or more through-holes corresponding to the carrier, or the third layer is breathable, so that the fluid passes through the third layer. Vehicle seat according to one of claims 12 to 14, wherein the seat has an occupancy sensor, which is arranged adjacent to the heating device.

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