US20070080155A1 - Heating blankets and pads - Google Patents
Heating blankets and pads Download PDFInfo
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- US20070080155A1 US20070080155A1 US11/537,179 US53717906A US2007080155A1 US 20070080155 A1 US20070080155 A1 US 20070080155A1 US 53717906 A US53717906 A US 53717906A US 2007080155 A1 US2007080155 A1 US 2007080155A1
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- Prior art keywords
- heating element
- blanket
- heating
- edge
- extending
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Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
- H05B3/34—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
- H05B3/342—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs heaters used in textiles
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B46/00—Surgical drapes
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B46/00—Surgical drapes
- A61B46/20—Surgical drapes specially adapted for patients
- A61B46/27—Surgical drapes specially adapted for patients tubular, e.g. for arms or legs
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F7/00—Heating or cooling appliances for medical or therapeutic treatment of the human body
- A61F7/007—Heating or cooling appliances for medical or therapeutic treatment of the human body characterised by electric heating
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
- A61B2017/00017—Electrical control of surgical instruments
- A61B2017/00022—Sensing or detecting at the treatment site
- A61B2017/00084—Temperature
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F7/00—Heating or cooling appliances for medical or therapeutic treatment of the human body
- A61F2007/0001—Body part
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F7/00—Heating or cooling appliances for medical or therapeutic treatment of the human body
- A61F7/007—Heating or cooling appliances for medical or therapeutic treatment of the human body characterised by electric heating
- A61F2007/0071—Heating or cooling appliances for medical or therapeutic treatment of the human body characterised by electric heating using a resistor, e.g. near the spot to be heated
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F7/00—Heating or cooling appliances for medical or therapeutic treatment of the human body
- A61F2007/0086—Heating or cooling appliances for medical or therapeutic treatment of the human body with a thermostat
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F7/00—Heating or cooling appliances for medical or therapeutic treatment of the human body
- A61F7/02—Compresses or poultices for effecting heating or cooling
- A61F2007/0244—Compresses or poultices for effecting heating or cooling with layers
- A61F2007/0257—Compresses or poultices for effecting heating or cooling with layers with a fluid impermeable layer
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/011—Heaters using laterally extending conductive material as connecting means
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/016—Heaters using particular connecting means
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/017—Manufacturing methods or apparatus for heaters
Definitions
- the present invention is related to heating or warming blankets or pads and more particularly to those including electrical heating elements.
- FAW forced-air warming
- FAW Fluorescence Activated Air
- FIG. 1A is a plan view of a flexible heating blanket subassembly for a heating blanket, according to some embodiments of the present invention.
- FIGS. 1 B-C are end views of two embodiments of the subassembly shown in FIG. 1A .
- FIG. 1D is a schematic showing a blanket including the subassembly of FIG. 1A draped over a body.
- FIG. 2A is a top plan view of a heating element assembly, according to some embodiments of the present invention, which may be incorporated in the blanket shown in FIG. 3A .
- FIG. 2B is a section view through section line A-A of FIG. 2A .
- FIG. 2C is an enlarged plan view and corresponding end view schematic of a portion of the assembly shown in FIG. 2A , according to some embodiments of the present invention.
- FIG. 2D is an enlarged view of a portion of the assembly shown in FIG. 2A , according to some embodiments of the present invention.
- FIG. 3A is a top plan view, including partial cut-away views, of a lower body heating blanket, according to some embodiments of the present invention.
- FIG. 3B is a schematic side view of the blanket of FIG. 3A draped over a lower body portion of a patient.
- FIG. 3C is a top plan view of a heating element assembly, which may be incorporated in the blanket shown in FIG. 3A .
- FIG. 3D is a cross-section view through section line D-D of FIG. 3C .
- FIG. 4A is a plan view of flexible heating element, according to some alternate embodiments of the present invention.
- FIG. 4B is a top plan view, including a partial cut-away view, of a heating element assembly, according to some embodiments of the present invention, which may be incorporated in the blanket shown in FIG. 4C .
- FIG. 4C is a top plan view, including a partial cut-away view, of an upper body heating blanket, according to some embodiments of the present invention.
- FIG. 4D is a schematic end view of the blanket of FIG. 4B draped over an upper body portion of a patient.
- FIG. 1A is a plan view of a flexible heating blanket subassembly 100 , according to some embodiments of the present invention; and FIGS. 1 B-C are end views of two embodiments of the subassembly shown in FIG. 1A .
- FIG. 1A illustrates a flexible sheet-like heating element 10 of subassembly 100 including a first end 101 , a second end 102 , a first lateral portion 11 extending between ends 101 , 102 , and a second lateral portion 12 , opposite first lateral portion 11 , also extending between ends 101 , 102 .
- heating element 10 comprises a conductive fabric or a fabric incorporating closely spaced conductive elements such that heating element 10 has a substantially uniform watt density output, preferably less than approximately 0.5 watts/sq. inch, and more preferably between approximately 0.2 and approximately 0.4 watts/sq. inch, across a surface area, of one or both sides 13 , 14 (FIGS. 1 B-C), the surface area including and extending between lateral portions 11 , 12 of heating element 10 .
- conductive fabrics which may be employed by embodiments of the present invention include, without limitation, carbon fiber fabrics, fabrics made from carbonized fibers, woven or non-woven non-conductive substrates coated with a conductive material, for example, polypyrrole, carbonized ink, or metalized ink.
- FIG. 1A further illustrates subassembly 100 including two bus bars 15 coupled to heating element 10 for powering element 10 ; each bar 15 is shown extending alongside opposing lateral portions 11 , 12 , between first and second ends 101 , 102 .
- bus bars 15 are coupled to heating element 10 within folds of opposing wrapped perimeter edges 108 of heating element 10 by a stitched coupling 145 , for example, formed with conductive thread such as silver-coated polyester or nylon thread (Marktek Inc., Chesterfield, Mo.), extending through edges 108 of heating element 10 , bars 15 , and again through heating element 10 on opposite side of bars 15 .
- heating element 10 is not folded over bus bars 15 as shown.
- bars 15 are comprised of flattened tubes of braided wires, such as are known to those skilled in the art, for example, a flat braided silver coated copper wire, and may thus accommodate the thread extending therethrough, passing through openings between the braided wires thereof. In addition such bars are flexible to enhance the flexibility of blanket subassembly 100 .
- bus bars 15 can be a conductive foil or wire, flattened braided wires not formed in tubes, an embroidery of conductive thread, or a printing of conductive ink.
- bus bars 15 are each a flat braided silver-coated copper wire material, since a silver coating has shown superior durability with repeated flexion, as compared to tin-coated wire, for example, and may be less susceptible to oxidative interaction with a polypyrrole coating of heating element 10 according to an embodiment described below. Additionally, an oxidative potential, related to dissimilar metals in contact with one another is reduced if a silver-coated thread is used for stitched coupling 145 of a silver-coated bus bar 15 .
- two or more rows of stitches are applied to each bus bar 15 for added safety and stability of the bus bar/heating element interface.
- the two rows of stitches are oriented in a “zigzag” pattern so that each row of stitches captures an edge of bus bar 15 .
- a zigzag pattern of relatively closely positioned stitches stabilizes flexible heating element 10 and holds it in close opposition to bus bar 15 so that the fabric cannot physically pull away from the bus bar during flexing.
- a ribbon of highly conductive material is interposed between bus bar 15 and heating element 10 .
- a conductive fabric comprising heating element 10 comprises a non-woven polyester having a basis weight of approximately 130 g/m 2 and being 100% coated with polypyrrole (available from Eeonyx Inc., Pinole, Calif.); the coated fabric has an average resistance, for example, determined with a four point probe measurement, of approximately 15-20 ohms per square inch at about 48 volts, which is suitable to produce the preferred watt density of 0.2 to 0.4 watts/sq. in. for surface areas of heating element 10 having a width, between bus bars 15 , in the neighborhood of about 20 inches. Such a width is suitable for a lower body heating blanket, some embodiments of which will be described below.
- a resistance of such a conductive fabric may be tailored for different widths between bus bars (wider requiring a lower resistance and narrower requiring a higher resistance) by increasing or decreasing a surface area of the fabric that can receive the conductive coating, for example by increasing or decreasing the basis weight of the fabric.
- Resistance over the surface area of the conductive fabrics is generally uniform in many embodiments of the present invention. However, the resistance over different portions of the surface area of conductive fabrics such as these may vary, for example, due to variation in a thickness of a conductive coating, variation within the conductive coating itself, variation in effective surface area of the substrate which is available to receive the conductive coating, or variation in the density of the substrate itself.
- Local surface resistance across a heating element for example element 10
- Q (Joules) I 2 (Amps) ⁇ R (Ohms)
- Variability in resistance thus translates into variability in heat generation, which is measured as a temperature.
- precise temperature control is desirable. Means for determining heating element temperatures, which average out temperature variability caused by resistance variability across a surface of the heating element, are described below in conjunction with FIGS. 2 A-B.
- a flexibility of blanket subassembly 100 allows blanket subassembly 100 to conform to the contours of a body, for example, all or a portion of a patient undergoing surgery, rather than simply bridging across high spots of the body; such conformance may optimize a conductive heat transfer from element 10 to a surface of the body.
- heating element 10 may be draped over a body 16 such that lateral portions 11 , 12 do not contact side surfaces of body 16 ; the mechanism of heat transfer between portions 11 , 12 and body 16 , as illustrated in FIG. 1D , is primarily radiant with some convection.
- the uniform watt-density output across the surface areas of preferred embodiments of heating element 10 translates into generally uniform heating of the surface areas, but not necessarily a uniform temperature.
- the heat is efficiently drawn away from heating element 10 and into the body, for example by blood flow, while at those locations where element 10 does not come into conductive contact with the body, for example lateral portions 11 , 12 as illustrated in FIG. 1D , an insulating air gap exists between the body and those portions, so that the heat is not drawn off those portions as easily.
- heating element 10 not in conductive contact with the body will gain in temperature, since heat is not transferred as efficiently from these portions as from those in conductive contact with the body.
- the ‘non-contacting’ portions will reach a higher equilibrium temperature than that of the ‘contacting’ portions, when the radiant and convective heat loss equal the constant heat production through heating element 10 .
- radiant and convective heat transfer are more efficient at higher heater temperatures, the laws of thermodynamics dictate that as long as there is a uniform watt-density of heat production, even at the higher temperature, the radiant and convective heat transfer from a blanket of this construction will result in a lower heat flux to the skin than the heat flux caused by the conductive heat transfer at the ‘contacting’ portions at the lower temperature.
- the ‘non-contacting’ portions must have a lower heat flux. Therefore, by controlling the ‘contacting’ portions to a safe temperature, for example, via a temperature sensor 121 coupled to heating element 10 in a location where element 10 will be in conductive contact with the body, as illustrated in FIG. 1D , the ‘non-contacting’ portions, for example, lateral portions 11 , 12 , will also be operating at a safe temperature because of the less efficient radiant and convective heat transfer.
- heating element 10 comprises a conductive fabric having a relatively small thermal mass so that when a portion of the heater that is operating at the higher temperature is touched, suddenly converting a ‘non-contacting’ portion into a ‘contacting’ portion, that portion will cool almost instantly to the lower operating temperature.
- zones of heating element 10 may be differentiated according to whether or not portions of element 10 are in conductive contact with a body, for example, a patient undergoing surgery.
- gentle external pressure may be applied to a heating blanket including heating element 10 , which pressure forces heating element 10 into better conductive contact with the patient to improve heat transfer.
- the blood flow to that skin may be reduced at the same time that the heat transfer is improved and this combination of heat and pressure to the skin can be dangerous. It is well known that patients with poor perfusion should not have prolonged contact with conductive heat in excess of approximately 42° C. 42° C.
- the portion of heating element 10 that is in conductive contact with the patient is controlled to approximately 43° C. in order to achieve a temperature of about 41-42° C.
- flaps 125 are shown extending laterally from either side of heating element 10 in order to enclose the sides of body 16 thereby preventing heat loss; according to preferred embodiments of the present invention, flaps 125 are not heated and thus provide no thermal injury risk to body if they were to be tucked beneath sides of body 16 .
- FIG. 1C illustrates subassembly 100 wherein insulating members 18 , for example, fiberglass material strips having an optional PTFE coating and a thickness of approximately 0.003 inch, extend between bus bars 15 and heating element 10 at each stitched coupling 145 , so that electrical contact points between bars 15 and heating element 10 are solely defined by the conductive thread of stitched couplings 145 .
- the electrical insulation material layer could be made of polymeric film, rubber sheeting, polymeric or rubber coated fabric or woven materials or any other suitable electrically insulating material.
- Each of the conductive thread stitches of coupling 145 maintains a stable and constant contact with bus bar 15 on one side and heating element 10 on the other side of insulator 18 .
- the stitches produce a stable contact in the face of any degree of flexion, so that the potential problem of intermittent contact between bus bar 15 and heating element 10 (that could arise for the embodiment shown in FIG. 1B , where bus bar 15 is in physical contact with heating element 10 ) can be avoided.
- the stitches are the only electrical connection between bus bar 15 and heating element 10 , but, since the conductive thread has a much lower electrical resistance than the conductive fabric of heating element 10 , the thread does not heat under normal conditions.
- such a design for providing for a uniform and stable conductive interface between a bus bar and a conductive fabric heater material can be used to improve the conductive interface between a bus bar or electrode and a conductive fabric in non-flexible heaters, in electronic shielding, in radar shielding and other applications of conductive fabrics.
- coupling 145 includes two or more rows of stitches for added security and stability.
- the thread of stitched couplings 145 may undergo stresses that, over time and with multiple uses of a blanket containing subassembly 100 , could lead to one or more fractures along the length of stitching 145 .
- Such a fracture if it occurred in the embodiment of FIG. 1B , could also result in intermittent contact points, between bus bar 15 and heating element 10 , that could lead to a melt down of element 10 along bus bar.
- insulating member 18 may prevent a meltdown of element 10 , so that only the conductive thread of stitching 145 melts down along bus bar 15 .
- bus bars 15 are shown extending past ends 101 and 102 of heating element 10 , according to preferred embodiments. If bus bars did not extend at least to ends 101 and 102 , increased current would flow from ends of bus bars 15 and into the fabric of heating element 10 . Normally the current flows approximately perpendicularly between bus bars 15 , therefore, each point on one of bus bars 15 supplies a narrow line of current to the other of bus bars 15 . If either bus bar 15 terminates before reaching the end of the heater fabric, current will flow out the end of that bus bar. The excess current flow can result in excessive heating of the fabric of heating element 10 , adjacent the end of that bus bar, which can cause degradation of the fabric leading to a catastrophic failure of heating element 10 by spreading along the entire bus bar.
- both ends of bus bars 15 are extended beyond ends 101 , 102 of heating element 10 , preferably over a length of at least approximately 1 ⁇ 2 cm.
- the conductive thread stitches previously described, also extend past ends 101 , 102 being terminated on the bus bar extensions. This design advantageously creates an easy manufacturing process, which assures a dependable and repeatedly manufacturable bus bar termination which avoids the creation of hot spots at the ends of bus bars 15 .
- FIG. 2A is a top plan view of a heating element assembly 250 , according to some embodiments of the present invention, which may be incorporated by blanket 200 , which is shown in FIG. 3A and further described below.
- FIG. 2B is a section view through section line A-A of FIG. 2A .
- FIGS. 2 A-B illustrate a temperature sensor assembly 421 assembled on side 14 of heating element and heating element 10 overlaid on both sides 13 , 14 with an electrically insulating layer 210 , preferably formed of a flexible non-woven high loft fibrous material, for example, 1.5 OSY (ounces per square yard) nylon, which is preferably laminated to sides 13 , 14 with a hotmelt laminating adhesive.
- OSY ounces per square yard
- the adhesive is applied over the entire interfaces between layer 210 and heating element 10 .
- suitable materials for layer 210 include, without limitation, polymeric foam, a woven fabric, such as cotton or fiberglass, and a relatively thin plastic film, cotton, and a non-flammable material, such as fiberglass or treated cotton.
- overlaid layers 210 prevent electrical shorting of one portion of heating element 10 with another portion of heating element 10 if heating element 10 is folded over onto itself.
- Heating element assembly 250 may be enclosed within a relatively durable and waterproof shell, for example shell 20 shown with dashed lines in FIG. 2B , and will be powered by a relatively low voltage (approximately 48V). Layers 210 may even be porous in nature to further maintain the desired flexibility of assembly 250 .
- FIG. 2C is an enlarged plan view and a corresponding end view schematic showing some details of the corner of assembly 250 that is circled in FIG. 2A , according to some embodiments.
- FIG. 2C is representative of each corner of assembly 250 .
- FIG. 2C illustrates insulating layer 210 disposed over side 14 of heating element and extending beneath bus bar 15 , optional electrical insulating member 18 , and layer 210 disposed over side 13 of heating element 10 and terminated adjacent bus bar 15 within lateral portion 12 so that threads of conductive stitching 145 securing bus bars 15 to heating element 10 electrically contact heating element 10 along side 13 of heating element 10 .
- 2C further illustrates two rows of conductive stitching 145 coupling bus bar 15 to heating element 10 , and bus bar 15 and insulating member 18 extending past end 102 ; a backtack securing stitching 145 may be approximately 0.375 inches long and also extends beyond end 102 .
- FIG. 2A further illustrates junctions 50 coupling leads 205 to each bus bar 15 , and another lead 221 coupled to and extending from temperature sensor assembly 421 ; each of leads 205 , 221 extend over insulating layer 210 and into an electrical connector housing 225 containing a connector 23 , which will be described in greater detail below, in conjunction with FIGS. 3 A-C.
- FIG. 2D is an enlarged view of junction 50 , which is circled in FIG. 2A , according to some embodiments of the present invention.
- junction 50 including a conductive insert 55 which has been secured to bus bar 15 , for example, by inserting insert 55 through a side wall of bus bar 15 and into an inner diameter thereof, the bus bar 15 of the illustrated embodiment being formed by a braided wire tube so that an opening between the wires may be formed for access to the inner diameter.
- FIG. 2B illustrates assembly 421 including a substrate 211 , for example, of polyimide (Kapton), on which a temperature sensor 21 , for example, a surface mount chip thermistor (such as a Panasonic ERT-J1VG103FA: 10K, 1% chip thermistor), is mounted; a heat spreader 212 , for example, a copper or aluminum foil, is mounted to an opposite side of substrate 211 , for example, being bonded with a pressure sensitive adhesive; substrate 211 is relatively thin, for example about 0.0005 inch thick, so that heat transfer between heat spreader 212 and sensor is not significantly impeded.
- a substrate 211 for example, of polyimide (Kapton)
- a temperature sensor 21 for example, a surface mount chip thermistor (such as a Panasonic ERT-J1VG103FA: 10K, 1% chip thermistor)
- a heat spreader 212 for example, a copper or aluminum foil
- Temperature sensor assembly 421 may be bonded to layer 210 with an adhesive layer 213 , for example, hotmelt EVA. Although not shown, it should be noted that sensor assembly 421 may be potted with a flexible electrically insulating material, such as silicon or polyurethane. Heat spreader 212 is a desirable component of a temperature sensor assembly, according to some embodiments of the present invention, since conductive fabrics employed by heating element 10 , such as those previously described, may not exhibit uniform resistance across surface areas thereof.
- Some alternate embodiments of the present invention address a non-uniform resistance across a surface area of element 10 by employing a distributed temperature sensor, for example, a resistance temperature detector (RTD) laid out in flat plane across a surface of heating element 10 , or by employing an infrared temperature measurement device positioned to receive thermal radiation from a given area of heating element 10 .
- a distributed temperature sensor for example, a resistance temperature detector (RTD) laid out in flat plane across a surface of heating element 10 , or by employing an infrared temperature measurement device positioned to receive thermal radiation from a given area of heating element 10 .
- RTD resistance temperature detector
- an infrared temperature measurement device positioned to receive thermal radiation from a given area of heating element 10 .
- An additional alternate embodiment is contemplated in which an array of temperature sensors are positioned over the surface of heating element 10 , being spaced apart so as to collect temperature readings which may be averaged to account for resistance variance.
- super over-temperature sensors 41 are incorporated to detect overheating of areas of assembly 250 susceptible to rucking, that is areas, for example, lateral portions 11 , 12 , where assembly 250 is most likely to be folded over on itself, either inadvertently or on purpose to gain access to a portion of a patient disposed beneath a blanket including assembly 250 .
- An area of assembly 250 which is beneath the folded-over portion of assembly 250 , and not in close proximity to sensor assembly 421 can become significantly warmer due to the additional thermal insulation provided by the folded-over portion that goes undetected by sensor 21 .
- sensors 41 are wired in series, as illustrated in FIG. 2A .
- Super over-temperature sensors 41 may be set to open, or significantly increase resistance in, a circuit, for example, the over-temperature circuit, thereby activating an alarm and/or cutting power to heating element 10 , at prescribed temperatures that are significantly above the normal operating range, for example, temperatures between approximately 45° C. and approximately 60° C.
- sensors 41 may be part of the bus bar power circuit, in which case sensors 41 directly shut down power to heating element 10 when in an open condition or add sufficient resistance when in a high resistance condition to substantially reduce heating of element 10 .
- FIG. 3A is a top plan view, including partial cut-away views, of a lower body heating blanket 200 , according to some embodiments of the present invention, which may be used to keep a patient warm during surgery.
- FIG. 3A illustrates blanket 200 including heating element assembly 250 covered by flexible shell 20 ; shell 20 protects and isolates assembly 250 from an external environment of blanket 200 and may further protect a patient disposed beneath blanket 200 from electrical shock hazards.
- shell 20 is waterproof to prevent fluids, for example, bodily fluids, IV fluids, or cleaning fluids, from contacting assembly 250 , and may further include an anti-microbial element, for example, being a SILVERionTM antimicrobial fabric available from Domestic Fabrics Corporation.
- blanket 200 further includes a layer of thermal insulation 201 extending over a top side (corresponding to side 14 of heating element 10 ) of assembly 250 ; layer 201 may or may not be bonded to a surface of assembly 250 . Layer 201 may serve to prevent heat loss away from a body disposed on the opposite side of blanket 200 , particularly if a heat sink comes into contact with the top side of blanket 200 .
- FIG. 3C illustrates insulation 201 extending over an entire surface of side 14 of heating element 10 and over sensor assembly 421 . According to the illustrated embodiment, layer 201 is secured to heating element assembly 250 to form an assembly 250 ′, as will be described in greater detail below.
- insulating layer 201 comprises a polymer foam, for example, a 1 pound density 30 ILD urethane foam, which has a thickness between approximately 1 ⁇ 8 th inch and approximately 3 ⁇ 4 th inch.
- insulating layer 201 could be a non-woven, high-loft fibrous, polymeric material or fiberglass insulation material.
- FIG. 3A further illustrates shell 20 forming flaps 25 extending laterally from either side of assembly 250 and a foot flap or drape 26 extending longitudinally from assembly 250 .
- a length of assembly 250 is either approximately 28 inches or approximately 48 inches, the shorter length providing adequate coverage for smaller patients or a smaller portion of an average adult patient.
- FIG. 3B is a schematic side view of blanket 200 draped over a lower body portion of a patient. With reference to FIG. 3B it may be appreciated that flaps 25 , extending down on either side of the patient, and foot drape 26 , being folded under and secured by reversible fasteners 29 ( FIG.
- Fasteners 29 may be any suitable type, for example, hook-and-loop or snap.
- FIG. 3B it may also be appreciated that neither shell 20 nor insulation layer 201 add appreciable stiffness to heating element 10 so that blanket 200 conforms nicely to the contour of the patient's lower body.
- temperature sensor assembly 421 is located on assembly 250 so that, when blanket 200 including assembly 250 is draped over the lower body of the patient, the area of heating element 10 surrounding sensor assembly 421 will be in conductive contact with one of the legs of the patient in order to maintain a safe temperature distribution across element 10 .
- shell 20 includes top and bottom sheets extending over either side of assembly 250 ; the two sheets of shell 20 are coupled together along a seal zone 22 (shown with cross-hatching in the cut-away portion of FIG. 3A ) that extends about a perimeter edge 2000 of blanket 200 , and within perimeter edge 2000 to form zones, or pockets, where a gap exists between the two sheets.
- shell 20 comprises a nylon fabric having an overlay of polyurethane coating to provide waterproofing; the coating is on at least an inner surface of each of the two sheets, further facilitating a heat seal between the two sheets, for example, along seal zone 22 , according to preferred embodiments.
- a covering for heating assemblies such as heating assembly 250
- FIG. 3A further illustrates flaps 25 including zones where there are gaps between the sheets to enclose weighting members, which are shown as relatively flat plastic slabs 255 .
- flaps 25 can be weighted by attaching weighting members to exterior surfaces thereof. Examples of other suitable weighting members include but are not limited to a metal chain, a metal spring, lead shot, plastic rods and sand. The weighting of flaps 25 causes flaps 25 to hang down in order to provide a more secure air seal about the patient.
- the weighting members may further discourage a clinician from tucking flaps 25 under the patient as a safety feature to help to prevent a portion of the blanket containing heating element 10 from coming into relatively high pressure contact with the patient, where it could cause serious burns; as such, the weighting members are relatively stiff and/or form a lump at the outer edge of flaps 25 .
- Relatively stiff flap weighting members 255 for example, batten-like flat plastic slabs 255 by extending along the length of assembly 250 , may further prevent inadvertent rucking of blanket 200 , that is, the folding of blanket 200 over on itself which could lead to over-heating of a portion of heating element 10 , as previously described.
- seal zone 22 extending between members 255 along each flap 25 can predetermine a folding location; the predetermined folding location can prevent overheating (due to the location of sensor assembly 421 ) or can dictate the placement of super over-temperature sensors 41 , as previously described.
- FIG. 3C is a top plan view, including partial cut-away views, of heating element assembly 250 ′, which may be incorporated in blanket 200 ; and FIG. 3D is a cross-section view through section line D-D of FIG. 3C .
- FIGS. 3 C-D illustrates heating element assembly 250 ′ including heating element 10 overlaid with electrical insulation 210 on both sides 13 , 14 and thermal insulation layer 201 extending over the top side 14 thereof (dashed lines show leads and sensor assembly beneath layer 201 ).
- layer 201 is inserted beneath a portion of each insulating member 18 , each which has been folded over the respective bus bar 15 , for example as illustrated by arrow B in FIG.
- layer 201 may further extend over bus bars 15 .
- layer 210 is shown extending beneath layer 201 on side 14 of heating element, according to alternate embodiments, layer 201 independently performs as a thermal and electrical insulation so that layer 210 is not required on side 14 of heating element 10 .
- housing 225 is an injection molded thermoplastic, for example, PVC, and may be coupled to assembly 250 by being stitched into place, over insulating layer 210 .
- housing 225 is an injection molded thermoplastic, for example, PVC, and may be coupled to assembly 250 by being stitched into place, over insulating layer 210 .
- connector 23 protrudes from shell 20 of blanket 200 so that an extension cable 330 may couple bus bars 15 to a power source 234 , and temperature sensor assembly 421 to a temperature controller 232 , both shown incorporated into a console 333 .
- power source 234 supplies a pulse-width-modulated voltage to bus bars 15 .
- the controller 232 may function to interrupt such power supply (e.g., in an over-temperature condition) or to modify the duty cycle to control the heating element temperature.
- FIGS. 3 C-D further illustrate a pair of securing strips 217 , each extending laterally from and alongside respective lateral portions 11 , 12 of heating element 10 and each coupled to side 13 of heating element 10 by the respective row of stitching 345 .
- Another pair of securing strips 271 is shown in FIG. 3C , each strip 271 extending longitudinally from and alongside respective ends 101 , 102 of heating element 10 and being coupled thereto by a respective row of non-conductive stitching 354 .
- Strips 271 may extend over layer 201 or beneath heating element 10 .
- Strips 217 preferably extend over conductive stitching 145 on side 13 of heating element 10 , as shown, to provide a layer of insulation that can prevent shorting between portions of side 13 of heating element 10 if element 10 were to fold over on itself along rows of conductive stitching 145 that couple bus bars 15 to heating element 10 ; however, strips 217 may alternately extend over insulating member 18 on the opposite side of heating element 10 .
- securing strips 217 and 271 are made of a polymer material, for example polyurethane, so that they may be heat sealed between the sheets of shell 20 in corresponding areas of heat seal zone 22 in order to secure heating element assembly 250 ′ within the corresponding gap between the two sheets of shell 20 ( FIG. 3A ).
- heating element 10 extends laterally out from each bus bar 15 to a securing edge 27 , which may include one or more slots or holes 207 extending therethrough so that inner surfaces of sheets of shell 20 can contact one another to be sealed together and thereby hold edges 27 .
- FIG. 4A is a plan view of flexible heating element 30 , according to some alternate embodiments of the present invention.
- Heating element 30 is similar in nature to previously described embodiments of heating element 10 , being comprised of a conductive fabric, or a fabric incorporating closely spaced conductive elements, for a substantially uniform watt density output, preferably less than approximately 0.5 watts/sq. inch. While a shape of the surface area of heating element 10 is suited for a lower body blanket, such as blanket 200 , that would cover a lower abdomen and legs of a patient ( FIG. 3B ) undergoing upper body surgery, the shape of a surface area of heating element 30 is suited for an upper body heating blanket, for example, blanket 300 shown in FIG.
- a distance between a first end 301 of element 30 and a second end 302 of element 30 is between about 70 and 80 inches, while a distance between a first lateral edge 311 and a second lateral edge 312 is about 7 to 10 inches.
- FIG. 4B which shows heating element 30 incorporated into a heating element assembly 450 , it can be seen that bus bars 15 are coupled to element 30 alongside respective lateral edges 311 , 312 ( FIG. 4A ).
- element 30 in order to have the desired watt density output, should be comprised of a conductive fabric having a higher resistance than the examples previously recited for heating element 10 , for example, on the order of 100 ohms per square, measured with a four point probe.
- a conductive fabric meeting this resistance requirement is a woven silk-like polyester, for example, known as Pongee, being 100% coated with polypyrrole.
- FIG. 4B is a top plan view, including partial cut-away views, of heating element assembly 450 , according to some embodiments of the present invention, which may be incorporated in blanket 300 shown in FIG. 4C .
- FIG. 4B illustrates assembly 450 having a configuration similar to that of assembly 250 ′, which is illustrated in FIGS. 3 C-D.
- temperature sensor assembly 421 is coupled to heating element 30 at a location where element 30 , when incorporated in an upper body heating blanket, for example, blanket 300 , would come into conductive contact with the chest of a patient, for example as illustrated in FIG.
- bus bar junctions 50 and connector housing 225 are located in proximity to sensor assembly 421 in order to keep a length of leads 205 and 221 to a minimum.
- an electrical insulating layer 310 of assembly 450 corresponds to insulating layers 210 of assembly 250 ′
- a thermal insulating layer 301 of assembly 450 corresponds to layer 201 of assembly 250 ′
- securing strips 317 and 371 of assembly 450 generally correspond to strips 217 and 271 , respectively, of assembly 250 ′.
- FIG. 4C is a top plan view, including partial cut-away views, of upper body heating blanket 300 , according to some embodiments of the present invention.
- FIG. 4C illustrates blanket 300 including heating element assembly 450 covered by a flexible shell 40 ; shell 40 protects and isolates assembly 450 from an external environment of blanket 300 and may further protect a patient disposed beneath blanket 300 from electrical shock hazards.
- shell 40 is similar to shell 20 of blanket 200 in that shell 40 is relatively durable and waterproof and may further include an antimicrobial element or layer extending over an exterior surface thereof.
- shell 40 like shell 20 , includes top and bottom sheets; the sheets extend over either side of assembly 450 and are coupled together along a seal zone 32 that extends around a perimeter edge 4000 and within edge 4000 to form various zones, or pockets, where gaps exist between the two sheets.
- the sheets of shell 40 may be heat sealed together along zone 32 , as previously described for the sheets of shell 20 .
- securing strips 317 may be heat sealed between the sheets of shell 40 in corresponding areas of seal zone 32 , on either side of a central narrowed portion 39 of blanket 300 , in order to secure heating element assembly 450 within the corresponding gap between the two sheets of shell 40 .
- an alternate embodiment for example, as shown with dashed lines in FIG.
- lateral edges 311 , 312 of heating element 30 extend out to form securing edges 27 that each include slots or holes 207 extending therethrough so that inner surfaces of sheets of shell 40 can contact one another to be sealed together and thereby hold edges 27 .
- either of blankets 200 , 300 may include more than one heating element 10 , 30 and more than one assembly 250 / 250 ′, 450 .
- blanket 300 is symmetrical about a central axis 30 and about another central axis, which is orthogonal to axis 30 .
- FIG. 4C illustrates shell 40 forming flaps 35 A, 35 B and 350 , each of which having a mirrored counterpart across central axis 30 and across the central axis orthogonal to axis 30 .
- each of flaps 35 A, B are weighted in a fashion similar to that described for flaps 25 of blanket 200 include weighting members 305 , which are similar to members 255 of blanket 200 , and which may stiffen flaps 35 A,B (dashed lines indicate outlines of members 305 held between the sheets of cover 40 by surrounding areas of seal zone 32 ).
- FIG. 4C further illustrates straps 38 , each extending between respective flaps 35 A-B.
- FIG. 4D which is a schematic end view of blanket 300 draped over an upper body portion of a patient, it may be appreciated that flaps 35 A-B and 350 extend downward to enclose the outstretched arms of the patient in order to prevent heat loss and that straps 38 secure blanket 300 about the patient.
- Opposing straps 38 may be secured together with reversible fasteners, examples of which include, without limitation, magnetic fasteners, either embedded within straps 38 or coupled to outer surfaces thereof, mating hook-and-loop fasteners, attached to opposing straps 38 , and mating snap fasteners, attached to opposing straps.
- portions of perimeter edge 4000 defining narrowed portion 39 which extends across a chest of the patient, are either rounded or padded to provide a softer interface with the patient's chin if blanket 300 were to slip off the patient's chest toward the patient's chin.
- each strap 38 is positioned in proximity to an elbow of the patient so that either end portion of blanket 300 , corresponding to each pair of flaps 35 A, may be temporarily folded back, as illustrated, per arrow C, in order for a clinician to access the patient's arm, for example, to insert or adjust an IV.
- super over-temperature sensors for example, sensors 41 , previously described, are included in blanket 300 being located according to the anticipated folds, for example at general locations 410 illustrated in FIGS. 4 B-C, in order to detect over-heating, which may occur if blanket 300 is folded over on itself, as illustrated in FIG.
- FIG. 4D further illustrates connector cord 330 plugged into connector 23 to couple heating element 30 and temperature sensor assembly 421 of blanket 300 to control console 333 .
Abstract
Description
- The present application claims priority to co-pending provisional applications Ser. No. 60/825,573, entitled HEATING BLANKET SYSTEM filed on Sep. 13, 2006; Ser. No. 60/722,106, entitled ELECTRIC WARMING BLANKET INCLUDING TEMPERATURE ZONES AUTOMATICALLY OPTIMIZED, filed Sep. 29, 2005; and Ser. No. 60/722,246, entitled HEATING BLANKET, filed Sep. 29, 2005; all of which are incorporated by reference in their entireties herein.
- The present application is related to the following commonly assigned utility patent applications, all of which are filed concurrently herewith and all of which are hereby incorporated by reference in their entireties: A) ELECTRIC WARMING BLANKET HAVING OPTIMIZED TEMPERATURE ZONES, Practitioner docket number 49278.2.5.2; B) TEMPERATURE SENSOR ASSEMBLIES FOR ELECTRIC WARMING BLANKETS, Practitioner Docket Number 49278.2.9.2; C) FLEXIBLE HEATING ELEMENT CONSTRUCTION, Practitioner Docket Number 49278.2.15; D) BUS BAR ATTACHMENTS FOR FLEXIBLE HEATING ELEMENTS, Practitioner Docket Number 49278.2.16; and E) BUS BAR INTERFACES FOR FLEXIBLE HEATING ELEMENTS, Practitioner Docket Number 49278.2.17.
- The present invention is related to heating or warming blankets or pads and more particularly to those including electrical heating elements.
- It is well established that surgical patients under anesthesia become poikilothermic. This means that the patients lose their ability to control their body temperature and will take on or lose heat depending on the temperature of the environment. Since modern operating rooms are all air conditioned to a relatively low temperature for surgeon comfort, the majority of patients undergoing general anesthesia will lose heat and become clinically hypothermic if not warmed.
- Over the past 15 years, forced-air warming (FAW) has become the “standard of care” for preventing and treating the hypothermia caused by anesthesia and surgery. FAW consists of a large heater/blower attached by a hose to an inflatable air blanket. The warm air is distributed over the patient within the chambers of the blanket and then is exhausted onto the patient through holes in the bottom surface of the blanket.
- Although FAW is clinically effective, it suffers from several problems including: a relatively high price; air blowing in the operating room, which can be noisy and can potentially contaminate the surgical field; and bulkiness, which, at times, may obscure the view of the surgeon. Moreover, the low specific heat of air and the rapid loss of heat from air require that the temperature of the air, as it leaves the hose, be dangerously high—in some products as high as 45° C. This poses significant dangers for the patient. Second and third degree burns have occurred both because of contact between the hose and the patient's skin, and by blowing hot air directly from the hose onto the skin without connecting a blanket to the hose. This condition is common enough to have its own name—“hosing.” The manufacturers of forced air warming equipment actively warn their users against hosing and the risks it poses to the patient.
- To overcome the aforementioned problems with FAW, several companies have developed electric warming blankets. However, these electric blankets have a number of inadequacies, for example, the risk of heat and pressure injuries that may be suffered by a patient improperly coming into contact with the electrical heating elements of these blankets. It is well established that heat and pressure applied to the skin can rapidly cause thermal injury to that skin. Such contact may arise if a patient inadvertently lies on an edge of a heated blanket, if a clinician improperly positions an anesthetized patient atop a portion of the heated blanket, or if a clinician tucks an edge of the blanket about the patient. Thus, there is a need for a heating blanket that effectively forms a cocoon about a patient, in order to provide maximum efficacy in heating, without posing the risk of burning the patient.
- The following drawings are illustrative of particular embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.
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FIG. 1A is a plan view of a flexible heating blanket subassembly for a heating blanket, according to some embodiments of the present invention. - FIGS. 1B-C are end views of two embodiments of the subassembly shown in
FIG. 1A . -
FIG. 1D is a schematic showing a blanket including the subassembly ofFIG. 1A draped over a body. -
FIG. 2A is a top plan view of a heating element assembly, according to some embodiments of the present invention, which may be incorporated in the blanket shown inFIG. 3A . -
FIG. 2B is a section view through section line A-A ofFIG. 2A . -
FIG. 2C is an enlarged plan view and corresponding end view schematic of a portion of the assembly shown inFIG. 2A , according to some embodiments of the present invention. -
FIG. 2D is an enlarged view of a portion of the assembly shown inFIG. 2A , according to some embodiments of the present invention. -
FIG. 3A is a top plan view, including partial cut-away views, of a lower body heating blanket, according to some embodiments of the present invention. -
FIG. 3B is a schematic side view of the blanket ofFIG. 3A draped over a lower body portion of a patient. -
FIG. 3C is a top plan view of a heating element assembly, which may be incorporated in the blanket shown inFIG. 3A . -
FIG. 3D is a cross-section view through section line D-D ofFIG. 3C . -
FIG. 4A is a plan view of flexible heating element, according to some alternate embodiments of the present invention. -
FIG. 4B is a top plan view, including a partial cut-away view, of a heating element assembly, according to some embodiments of the present invention, which may be incorporated in the blanket shown inFIG. 4C . -
FIG. 4C is a top plan view, including a partial cut-away view, of an upper body heating blanket, according to some embodiments of the present invention. -
FIG. 4D is a schematic end view of the blanket ofFIG. 4B draped over an upper body portion of a patient. - The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides practical illustrations for implementing exemplary embodiments of the present invention. Examples of constructions, materials, dimensions, and manufacturing processes are provided for selected elements, and all other elements employ that which is known to those of skill in the field of the invention. Those skilled in the art will recognize that many of the examples provided have suitable alternatives that can be utilized. The term ‘blanket’, used to describe embodiments of the present invention, may be considered to encompass heating blankets and pads.
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FIG. 1A is a plan view of a flexibleheating blanket subassembly 100, according to some embodiments of the present invention; and FIGS. 1B-C are end views of two embodiments of the subassembly shown inFIG. 1A .FIG. 1A illustrates a flexible sheet-like heating element 10 ofsubassembly 100 including afirst end 101, asecond end 102, a firstlateral portion 11 extending betweenends lateral portion 12, opposite firstlateral portion 11, also extending betweenends heating element 10 comprises a conductive fabric or a fabric incorporating closely spaced conductive elements such thatheating element 10 has a substantially uniform watt density output, preferably less than approximately 0.5 watts/sq. inch, and more preferably between approximately 0.2 and approximately 0.4 watts/sq. inch, across a surface area, of one or bothsides 13, 14 (FIGS. 1B-C), the surface area including and extending betweenlateral portions heating element 10. Some examples of conductive fabrics which may be employed by embodiments of the present invention include, without limitation, carbon fiber fabrics, fabrics made from carbonized fibers, woven or non-woven non-conductive substrates coated with a conductive material, for example, polypyrrole, carbonized ink, or metalized ink. -
FIG. 1A further illustrates subassembly 100 including twobus bars 15 coupled toheating element 10 for poweringelement 10; eachbar 15 is shown extending alongside opposinglateral portions FIG. 1B , according to some embodiments, bus bars 15 are coupled toheating element 10 within folds of opposing wrapped perimeter edges 108 ofheating element 10 by a stitchedcoupling 145, for example, formed with conductive thread such as silver-coated polyester or nylon thread (Marktek Inc., Chesterfield, Mo.), extending throughedges 108 ofheating element 10, bars 15, and again throughheating element 10 on opposite side ofbars 15. According to alternateembodiments heating element 10 is not folded overbus bars 15 as shown. Alternative threads or yarns employed by embodiments of the present invention may be made of other polymeric or natural fibers coated with other electrically conductive materials; in addition, nickel, gold, platinum and various conductive polymers can be used to make conductive threads. Metal threads such as stainless steel, copper or nickel could also be used for this application. According to an exemplary embodiment, bars 15 are comprised of flattened tubes of braided wires, such as are known to those skilled in the art, for example, a flat braided silver coated copper wire, and may thus accommodate the thread extending therethrough, passing through openings between the braided wires thereof. In addition such bars are flexible to enhance the flexibility ofblanket subassembly 100. According to alternate embodiments, bus bars 15 can be a conductive foil or wire, flattened braided wires not formed in tubes, an embroidery of conductive thread, or a printing of conductive ink. Preferably, bus bars 15 are each a flat braided silver-coated copper wire material, since a silver coating has shown superior durability with repeated flexion, as compared to tin-coated wire, for example, and may be less susceptible to oxidative interaction with a polypyrrole coating ofheating element 10 according to an embodiment described below. Additionally, an oxidative potential, related to dissimilar metals in contact with one another is reduced if a silver-coated thread is used for stitchedcoupling 145 of a silver-coatedbus bar 15. - According to some preferred embodiments, two or more rows of stitches are applied to each
bus bar 15 for added safety and stability of the bus bar/heating element interface. Preferably, the two rows of stitches are oriented in a “zigzag” pattern so that each row of stitches captures an edge ofbus bar 15. A zigzag pattern of relatively closely positioned stitches stabilizesflexible heating element 10 and holds it in close opposition tobus bar 15 so that the fabric cannot physically pull away from the bus bar during flexing. According to some additional embodiments, a ribbon of highly conductive material is interposed betweenbus bar 15 andheating element 10. - According to an exemplary embodiment, a conductive fabric comprising
heating element 10 comprises a non-woven polyester having a basis weight of approximately 130 g/m2 and being 100% coated with polypyrrole (available from Eeonyx Inc., Pinole, Calif.); the coated fabric has an average resistance, for example, determined with a four point probe measurement, of approximately 15-20 ohms per square inch at about 48 volts, which is suitable to produce the preferred watt density of 0.2 to 0.4 watts/sq. in. for surface areas ofheating element 10 having a width, betweenbus bars 15, in the neighborhood of about 20 inches. Such a width is suitable for a lower body heating blanket, some embodiments of which will be described below. A resistance of such a conductive fabric may be tailored for different widths between bus bars (wider requiring a lower resistance and narrower requiring a higher resistance) by increasing or decreasing a surface area of the fabric that can receive the conductive coating, for example by increasing or decreasing the basis weight of the fabric. Resistance over the surface area of the conductive fabrics is generally uniform in many embodiments of the present invention. However, the resistance over different portions of the surface area of conductive fabrics such as these may vary, for example, due to variation in a thickness of a conductive coating, variation within the conductive coating itself, variation in effective surface area of the substrate which is available to receive the conductive coating, or variation in the density of the substrate itself. Local surface resistance across a heating element, forexample element 10, is directly related to heat generation according to the following relationship:
Q(Joules)=I 2(Amps)×R(Ohms)
Variability in resistance thus translates into variability in heat generation, which is measured as a temperature. According to preferred embodiments of the present invention, which are employed to warm patients undergoing surgery, precise temperature control is desirable. Means for determining heating element temperatures, which average out temperature variability caused by resistance variability across a surface of the heating element, are described below in conjunction with FIGS. 2A-B. - A flexibility of
blanket subassembly 100, provided primarily byflexible heating element 10, and optionally enhanced by the incorporation of flexible bus bars, allowsblanket subassembly 100 to conform to the contours of a body, for example, all or a portion of a patient undergoing surgery, rather than simply bridging across high spots of the body; such conformance may optimize a conductive heat transfer fromelement 10 to a surface of the body. However, as illustrated inFIG. 1D ,heating element 10 may be draped over abody 16 such thatlateral portions body 16; the mechanism of heat transfer betweenportions body 16, as illustrated inFIG. 1D , is primarily radiant with some convection. - The uniform watt-density output across the surface areas of preferred embodiments of
heating element 10 translates into generally uniform heating of the surface areas, but not necessarily a uniform temperature. At locations ofheating element 10 which are in conductive contact with a body acting as a heat sink, for example,body 16, the heat is efficiently drawn away fromheating element 10 and into the body, for example by blood flow, while at those locations whereelement 10 does not come into conductive contact with the body, forexample lateral portions FIG. 1D , an insulating air gap exists between the body and those portions, so that the heat is not drawn off those portions as easily. Therefore, those portions ofheating element 10 not in conductive contact with the body will gain in temperature, since heat is not transferred as efficiently from these portions as from those in conductive contact with the body. The ‘non-contacting’ portions will reach a higher equilibrium temperature than that of the ‘contacting’ portions, when the radiant and convective heat loss equal the constant heat production throughheating element 10. Although radiant and convective heat transfer are more efficient at higher heater temperatures, the laws of thermodynamics dictate that as long as there is a uniform watt-density of heat production, even at the higher temperature, the radiant and convective heat transfer from a blanket of this construction will result in a lower heat flux to the skin than the heat flux caused by the conductive heat transfer at the ‘contacting’ portions at the lower temperature. Even though the temperature is higher, the watt-density is uniform and, since the radiant and convective heat transfer are less efficient than conductive heat transfer, the ‘non-contacting’ portions must have a lower heat flux. Therefore, by controlling the ‘contacting’ portions to a safe temperature, for example, via atemperature sensor 121 coupled toheating element 10 in a location whereelement 10 will be in conductive contact with the body, as illustrated inFIG. 1D , the ‘non-contacting’ portions, for example,lateral portions heating element 10 comprises a conductive fabric having a relatively small thermal mass so that when a portion of the heater that is operating at the higher temperature is touched, suddenly converting a ‘non-contacting’ portion into a ‘contacting’ portion, that portion will cool almost instantly to the lower operating temperature. - According to embodiments of the present invention, zones of
heating element 10 may be differentiated according to whether or not portions ofelement 10 are in conductive contact with a body, for example, a patient undergoing surgery. In the case of conductive heating, gentle external pressure may be applied to a heating blanket includingheating element 10, which pressureforces heating element 10 into better conductive contact with the patient to improve heat transfer. However, if excessive pressure is applied the blood flow to that skin may be reduced at the same time that the heat transfer is improved and this combination of heat and pressure to the skin can be dangerous. It is well known that patients with poor perfusion should not have prolonged contact with conductive heat in excess of approximately 42° C. 42° C. has been shown in several studies to be the highest skin temperature, which cannot cause thermal damage to normally perfused skin, even with prolonged exposure. (Stoll & Greene, Relationship between pain and tissue damage due to thermal radiation. J. Applied Physiology 14(3):373-382. 1959. and Moritz and Henriques, Studies of thermal injury: The relative importance of time and surface temperature in the causation of cutaneous burns. Am. J. Pathology 23:695-720, 1947) Thus, according to certain embodiments of the present invention, the portion ofheating element 10 that is in conductive contact with the patient is controlled to approximately 43° C. in order to achieve a temperature of about 41-42° C. on a surface a heating blanket cover that surroundselement 10, for example, a cover orshell FIGS. 3A and 4C . With further reference toFIG. 1D , flaps 125 are shown extending laterally from either side ofheating element 10 in order to enclose the sides ofbody 16 thereby preventing heat loss; according to preferred embodiments of the present invention, flaps 125 are not heated and thus provide no thermal injury risk to body if they were to be tucked beneath sides ofbody 16. - Referring now to the end view of
FIG. 1C , an alternate embodiment to that shown inFIG. 1B is presented.FIG. 1C illustrates subassembly 100 wherein insulatingmembers 18, for example, fiberglass material strips having an optional PTFE coating and a thickness of approximately 0.003 inch, extend betweenbus bars 15 andheating element 10 at each stitchedcoupling 145, so that electrical contact points betweenbars 15 andheating element 10 are solely defined by the conductive thread of stitchedcouplings 145. Alternatively, the electrical insulation material layer could be made of polymeric film, rubber sheeting, polymeric or rubber coated fabric or woven materials or any other suitable electrically insulating material. Each of the conductive thread stitches ofcoupling 145 maintains a stable and constant contact withbus bar 15 on one side andheating element 10 on the other side ofinsulator 18. Specifically, the stitches produce a stable contact in the face of any degree of flexion, so that the potential problem of intermittent contact betweenbus bar 15 and heating element 10 (that could arise for the embodiment shown inFIG. 1B , wherebus bar 15 is in physical contact with heating element 10) can be avoided. The stitches are the only electrical connection betweenbus bar 15 andheating element 10, but, since the conductive thread has a much lower electrical resistance than the conductive fabric ofheating element 10, the thread does not heat under normal conditions. In addition to heating blanket applications described herein, such a design for providing for a uniform and stable conductive interface between a bus bar and a conductive fabric heater material can be used to improve the conductive interface between a bus bar or electrode and a conductive fabric in non-flexible heaters, in electronic shielding, in radar shielding and other applications of conductive fabrics. - Preferably,
coupling 145 includes two or more rows of stitches for added security and stability. However, due to the flexible nature ofblanket subassembly 100, the thread of stitchedcouplings 145, for either embodiment ofFIG. 1B orFIG. 1C , may undergo stresses that, over time and with multiple uses of ablanket containing subassembly 100, could lead to one or more fractures along the length ofstitching 145. Such a fracture, if it occurred in the embodiment ofFIG. 1B , could also result in intermittent contact points, betweenbus bar 15 andheating element 10, that could lead to a melt down ofelement 10 along bus bar. But, if such a fracture were to occur in the embodiment ofFIG. 1C , insulatingmember 18 may prevent a meltdown ofelement 10, so that only the conductive thread ofstitching 145 melts down alongbus bar 15. - Referring back to
FIG. 1A , bus bars 15 are shown extending past ends 101 and 102 ofheating element 10, according to preferred embodiments. If bus bars did not extend at least to ends 101 and 102, increased current would flow from ends ofbus bars 15 and into the fabric ofheating element 10. Normally the current flows approximately perpendicularly betweenbus bars 15, therefore, each point on one ofbus bars 15 supplies a narrow line of current to the other of bus bars 15. If eitherbus bar 15 terminates before reaching the end of the heater fabric, current will flow out the end of that bus bar. The excess current flow can result in excessive heating of the fabric ofheating element 10, adjacent the end of that bus bar, which can cause degradation of the fabric leading to a catastrophic failure ofheating element 10 by spreading along the entire bus bar. To avoid such a failure and to improve manufacturing reliability, both ends ofbus bars 15 are extended beyond ends 101, 102 ofheating element 10, preferably over a length of at least approximately ½ cm. According to these embodiments, the conductive thread stitches, previously described, also extend past ends 101, 102 being terminated on the bus bar extensions. This design advantageously creates an easy manufacturing process, which assures a dependable and repeatedly manufacturable bus bar termination which avoids the creation of hot spots at the ends of bus bars 15. -
FIG. 2A is a top plan view of aheating element assembly 250, according to some embodiments of the present invention, which may be incorporated byblanket 200, which is shown inFIG. 3A and further described below.FIG. 2B is a section view through section line A-A ofFIG. 2A . FIGS. 2A-B illustrate atemperature sensor assembly 421 assembled onside 14 of heating element andheating element 10 overlaid on bothsides layer 210, preferably formed of a flexible non-woven high loft fibrous material, for example, 1.5 OSY (ounces per square yard) nylon, which is preferably laminated tosides layer 210 andheating element 10. Other examples of suitable materials forlayer 210 include, without limitation, polymeric foam, a woven fabric, such as cotton or fiberglass, and a relatively thin plastic film, cotton, and a non-flammable material, such as fiberglass or treated cotton. According to preferred embodiments, overlaidlayers 210, without compromising the flexibility ofheating assembly 250, prevent electrical shorting of one portion ofheating element 10 with another portion ofheating element 10 ifheating element 10 is folded over onto itself.Heating element assembly 250 may be enclosed within a relatively durable and waterproof shell, forexample shell 20 shown with dashed lines inFIG. 2B , and will be powered by a relatively low voltage (approximately 48V).Layers 210 may even be porous in nature to further maintain the desired flexibility ofassembly 250. -
FIG. 2C is an enlarged plan view and a corresponding end view schematic showing some details of the corner ofassembly 250 that is circled inFIG. 2A , according to some embodiments.FIG. 2C is representative of each corner ofassembly 250.FIG. 2C illustrates insulatinglayer 210 disposed overside 14 of heating element and extending beneathbus bar 15, optional electrical insulatingmember 18, andlayer 210 disposed overside 13 ofheating element 10 and terminatedadjacent bus bar 15 withinlateral portion 12 so that threads ofconductive stitching 145 securingbus bars 15 toheating element 10 electricallycontact heating element 10 alongside 13 ofheating element 10.FIG. 2C further illustrates two rows ofconductive stitching 145coupling bus bar 15 toheating element 10, andbus bar 15 and insulatingmember 18 extendingpast end 102; abacktack securing stitching 145 may be approximately 0.375 inches long and also extends beyondend 102. -
FIG. 2A further illustratesjunctions 50 coupling leads 205 to eachbus bar 15, and another lead 221 coupled to and extending fromtemperature sensor assembly 421; each of leads 205, 221 extend overinsulating layer 210 and into anelectrical connector housing 225 containing aconnector 23, which will be described in greater detail below, in conjunction with FIGS. 3A-C.FIG. 2D is an enlarged view ofjunction 50, which is circled inFIG. 2A , according to some embodiments of the present invention.FIG. 2D illustratesjunction 50 including aconductive insert 55 which has been secured tobus bar 15, for example, by insertinginsert 55 through a side wall ofbus bar 15 and into an inner diameter thereof, thebus bar 15 of the illustrated embodiment being formed by a braided wire tube so that an opening between the wires may be formed for access to the inner diameter. - Returning now to
FIG. 2B ,temperature sensor assembly 421 will be described in greater detail.FIG. 2B illustrates assembly 421 including asubstrate 211, for example, of polyimide (Kapton), on which atemperature sensor 21, for example, a surface mount chip thermistor (such as a Panasonic ERT-J1VG103FA: 10K, 1% chip thermistor), is mounted; aheat spreader 212, for example, a copper or aluminum foil, is mounted to an opposite side ofsubstrate 211, for example, being bonded with a pressure sensitive adhesive;substrate 211 is relatively thin, for example about 0.0005 inch thick, so that heat transfer betweenheat spreader 212 and sensor is not significantly impeded.Temperature sensor assembly 421 may be bonded to layer 210 with anadhesive layer 213, for example, hotmelt EVA. Although not shown, it should be noted thatsensor assembly 421 may be potted with a flexible electrically insulating material, such as silicon or polyurethane.Heat spreader 212 is a desirable component of a temperature sensor assembly, according to some embodiments of the present invention, since conductive fabrics employed byheating element 10, such as those previously described, may not exhibit uniform resistance across surface areas thereof. Some alternate embodiments of the present invention address a non-uniform resistance across a surface area ofelement 10 by employing a distributed temperature sensor, for example, a resistance temperature detector (RTD) laid out in flat plane across a surface ofheating element 10, or by employing an infrared temperature measurement device positioned to receive thermal radiation from a given area ofheating element 10. An additional alternate embodiment is contemplated in which an array of temperature sensors are positioned over the surface ofheating element 10, being spaced apart so as to collect temperature readings which may be averaged to account for resistance variance. - According to some embodiments of the present invention, for example as illustrated in
FIG. 2A , superover-temperature sensors 41 are incorporated to detect overheating of areas ofassembly 250 susceptible to rucking, that is areas, for example,lateral portions assembly 250 is most likely to be folded over on itself, either inadvertently or on purpose to gain access to a portion of a patient disposed beneath ablanket including assembly 250. An area ofassembly 250 which is beneath the folded-over portion ofassembly 250, and not in close proximity tosensor assembly 421, can become significantly warmer due to the additional thermal insulation provided by the folded-over portion that goes undetected bysensor 21. According to preferred embodiments,sensors 41 are wired in series, as illustrated inFIG. 2A . Superover-temperature sensors 41 may be set to open, or significantly increase resistance in, a circuit, for example, the over-temperature circuit, thereby activating an alarm and/or cutting power toheating element 10, at prescribed temperatures that are significantly above the normal operating range, for example, temperatures between approximately 45° C. and approximately 60° C. Alternately,sensors 41 may be part of the bus bar power circuit, in whichcase sensors 41 directly shut down power toheating element 10 when in an open condition or add sufficient resistance when in a high resistance condition to substantially reduce heating ofelement 10. -
FIG. 3A is a top plan view, including partial cut-away views, of a lowerbody heating blanket 200, according to some embodiments of the present invention, which may be used to keep a patient warm during surgery.FIG. 3A illustratesblanket 200 includingheating element assembly 250 covered byflexible shell 20;shell 20 protects and isolates assembly 250 from an external environment ofblanket 200 and may further protect a patient disposed beneathblanket 200 from electrical shock hazards. According to preferred embodiments of the present invention,shell 20 is waterproof to prevent fluids, for example, bodily fluids, IV fluids, or cleaning fluids, from contactingassembly 250, and may further include an anti-microbial element, for example, being a SILVERion™ antimicrobial fabric available from Domestic Fabrics Corporation. According to the illustrated embodiment,blanket 200 further includes a layer ofthermal insulation 201 extending over a top side (corresponding toside 14 of heating element 10) ofassembly 250;layer 201 may or may not be bonded to a surface ofassembly 250.Layer 201 may serve to prevent heat loss away from a body disposed on the opposite side ofblanket 200, particularly if a heat sink comes into contact with the top side ofblanket 200.FIG. 3C illustratesinsulation 201 extending over an entire surface ofside 14 ofheating element 10 and oversensor assembly 421. According to the illustrated embodiment,layer 201 is secured toheating element assembly 250 to form anassembly 250′, as will be described in greater detail below. According to an exemplary embodiment of the present invention, insulatinglayer 201 comprises a polymer foam, for example, a 1pound density 30 ILD urethane foam, which has a thickness between approximately ⅛th inch and approximately ¾th inch. Alternately, insulatinglayer 201 could be a non-woven, high-loft fibrous, polymeric material or fiberglass insulation material. -
FIG. 3A further illustratesshell 20 formingflaps 25 extending laterally from either side ofassembly 250 and a foot flap or drape 26 extending longitudinally fromassembly 250. According to exemplary embodiments of the present invention, a length ofassembly 250 is either approximately 28 inches or approximately 48 inches, the shorter length providing adequate coverage for smaller patients or a smaller portion of an average adult patient.FIG. 3B is a schematic side view ofblanket 200 draped over a lower body portion of a patient. With reference toFIG. 3B it may be appreciated that flaps 25, extending down on either side of the patient, andfoot drape 26, being folded under and secured by reversible fasteners 29 (FIG. 3A ) to form a pocket about the feet of the patient, together effectively enclose the lower body portion of the patient to prevent heat loss.Fasteners 29 may be any suitable type, for example, hook-and-loop or snap. With further reference toFIG. 3B , it may also be appreciated that neithershell 20 norinsulation layer 201 add appreciable stiffness toheating element 10 so thatblanket 200 conforms nicely to the contour of the patient's lower body. With reference toFIG. 2A , in conjunction withFIG. 3B , it may be appreciated thattemperature sensor assembly 421 is located onassembly 250 so that, whenblanket 200 includingassembly 250 is draped over the lower body of the patient, the area ofheating element 10 surroundingsensor assembly 421 will be in conductive contact with one of the legs of the patient in order to maintain a safe temperature distribution acrosselement 10. - According to some embodiments of the present invention,
shell 20 includes top and bottom sheets extending over either side ofassembly 250; the two sheets ofshell 20 are coupled together along a seal zone 22 (shown with cross-hatching in the cut-away portion ofFIG. 3A ) that extends about aperimeter edge 2000 ofblanket 200, and withinperimeter edge 2000 to form zones, or pockets, where a gap exists between the two sheets. According to an exemplary embodiment of the present invention,shell 20 comprises a nylon fabric having an overlay of polyurethane coating to provide waterproofing; the coating is on at least an inner surface of each of the two sheets, further facilitating a heat seal between the two sheets, for example, alongseal zone 22, according to preferred embodiments. It should be noted that, according to alternate embodiments of the present invention, a covering for heating assemblies, such asheating assembly 250, may be removable and, thus, include a reversible closure facilitating removal of a heating assembly therefrom and insertion of the same or another heating assembly therein. -
FIG. 3A further illustratesflaps 25 including zones where there are gaps between the sheets to enclose weighting members, which are shown as relatively flatplastic slabs 255. Alternately flaps 25 can be weighted by attaching weighting members to exterior surfaces thereof. Examples of other suitable weighting members include but are not limited to a metal chain, a metal spring, lead shot, plastic rods and sand. The weighting offlaps 25 causes flaps 25 to hang down in order to provide a more secure air seal about the patient. The weighting members may further discourage a clinician from tuckingflaps 25 under the patient as a safety feature to help to prevent a portion of the blanket containingheating element 10 from coming into relatively high pressure contact with the patient, where it could cause serious burns; as such, the weighting members are relatively stiff and/or form a lump at the outer edge offlaps 25. Relatively stiffflap weighting members 255 for example, batten-like flatplastic slabs 255, by extending along the length ofassembly 250, may further prevent inadvertent rucking ofblanket 200, that is, the folding ofblanket 200 over on itself which could lead to over-heating of a portion ofheating element 10, as previously described. However, with reference toFIG. 3A ,seal zone 22 extending betweenmembers 255 along eachflap 25 can predetermine a folding location; the predetermined folding location can prevent overheating (due to the location of sensor assembly 421) or can dictate the placement of superover-temperature sensors 41, as previously described. -
FIG. 3C is a top plan view, including partial cut-away views, ofheating element assembly 250′, which may be incorporated inblanket 200; andFIG. 3D is a cross-section view through section line D-D ofFIG. 3C . FIGS. 3C-D illustratesheating element assembly 250′ includingheating element 10 overlaid withelectrical insulation 210 on bothsides thermal insulation layer 201 extending over thetop side 14 thereof (dashed lines show leads and sensor assembly beneath layer 201). According to the illustrated embodiment,layer 201 is inserted beneath a portion of each insulatingmember 18, each which has been folded over therespective bus bar 15, for example as illustrated by arrow B inFIG. 1C , and then held in place by a respective row ofnon-conductive stitching 345 that extends throughmember 18,layer 201 andheating element 10. Although not shown, it should be appreciated thatlayer 201 may further extend over bus bars 15. Althoughlayer 210 is shown extending beneathlayer 201 onside 14 of heating element, according to alternate embodiments,layer 201 independently performs as a thermal and electrical insulation so thatlayer 210 is not required onside 14 ofheating element 10. - Returning now to
FIG. 2A , to be referenced in conjunction with FIGS. 3A-C,connector housing 225 andconnector 23 will be described in greater detail. According to certain embodiments,housing 225 is an injection molded thermoplastic, for example, PVC, and may be coupled toassembly 250 by being stitched into place, over insulatinglayer 210. With reference to FIGS. 3A-B, it can be seen thatconnector 23 protrudes fromshell 20 ofblanket 200 so that anextension cable 330 may couple bus bars 15 to apower source 234, andtemperature sensor assembly 421 to atemperature controller 232, both shown incorporated into aconsole 333. In certain embodiments,power source 234 supplies a pulse-width-modulated voltage to bus bars 15. Thecontroller 232 may function to interrupt such power supply (e.g., in an over-temperature condition) or to modify the duty cycle to control the heating element temperature. - FIGS. 3C-D further illustrate a pair of securing
strips 217, each extending laterally from and alongside respectivelateral portions heating element 10 and each coupled toside 13 ofheating element 10 by the respective row ofstitching 345. Another pair of securingstrips 271 is shown inFIG. 3C , eachstrip 271 extending longitudinally from and alongside respective ends 101, 102 ofheating element 10 and being coupled thereto by a respective row ofnon-conductive stitching 354.Strips 271 may extend overlayer 201 or beneathheating element 10.Strips 217 preferably extend overconductive stitching 145 onside 13 ofheating element 10, as shown, to provide a layer of insulation that can prevent shorting between portions ofside 13 ofheating element 10 ifelement 10 were to fold over on itself along rows ofconductive stitching 145 that couple bus bars 15 toheating element 10; however, strips 217 may alternately extend over insulatingmember 18 on the opposite side ofheating element 10. According to the illustrated embodiment, securingstrips shell 20 in corresponding areas ofheat seal zone 22 in order to secureheating element assembly 250′ within the corresponding gap between the two sheets of shell 20 (FIG. 3A ). According to an alternate embodiment, for example, shown by dashed lines inFIGS. 1A and 3D ,heating element 10 extends laterally out from eachbus bar 15 to a securingedge 27, which may include one or more slots orholes 207 extending therethrough so that inner surfaces of sheets ofshell 20 can contact one another to be sealed together and thereby hold edges 27. -
FIG. 4A is a plan view offlexible heating element 30, according to some alternate embodiments of the present invention.Heating element 30 is similar in nature to previously described embodiments ofheating element 10, being comprised of a conductive fabric, or a fabric incorporating closely spaced conductive elements, for a substantially uniform watt density output, preferably less than approximately 0.5 watts/sq. inch. While a shape of the surface area ofheating element 10 is suited for a lower body blanket, such asblanket 200, that would cover a lower abdomen and legs of a patient (FIG. 3B ) undergoing upper body surgery, the shape of a surface area ofheating element 30 is suited for an upper body heating blanket, for example,blanket 300 shown inFIG. 4C , that would cover outstretched arms and a chest area of a patient undergoing lower body surgery (FIG. 4D ). According to an exemplary embodiment for an adult upper body heating blanket, a distance between afirst end 301 ofelement 30 and asecond end 302 ofelement 30 is between about 70 and 80 inches, while a distance between a firstlateral edge 311 and a secondlateral edge 312 is about 7 to 10 inches. With reference toFIG. 4B , which showsheating element 30 incorporated into aheating element assembly 450, it can be seen that bus bars 15 are coupled toelement 30 alongside respectivelateral edges 311, 312 (FIG. 4A ). For the narrower spacing betweenbus bars 15, compared with that forheating element 10 incorporated inblanket 200,element 30, in order to have the desired watt density output, should be comprised of a conductive fabric having a higher resistance than the examples previously recited forheating element 10, for example, on the order of 100 ohms per square, measured with a four point probe. An example of a conductive fabric meeting this resistance requirement is a woven silk-like polyester, for example, known as Pongee, being 100% coated with polypyrrole. -
FIG. 4B is a top plan view, including partial cut-away views, ofheating element assembly 450, according to some embodiments of the present invention, which may be incorporated inblanket 300 shown inFIG. 4C .FIG. 4B illustrates assembly 450 having a configuration similar to that ofassembly 250′, which is illustrated in FIGS. 3C-D. According to the embodiment illustrated inFIG. 4B ,temperature sensor assembly 421 is coupled toheating element 30 at a location whereelement 30, when incorporated in an upper body heating blanket, for example,blanket 300, would come into conductive contact with the chest of a patient, for example as illustrated in FIG. 4D, in order to maintain a safe temperature distribution acrosselement 30;bus bar junctions 50 andconnector housing 225 are located in proximity tosensor assembly 421 in order to keep a length ofleads FIG. 4B , an electrical insulatinglayer 310 ofassembly 450 corresponds to insulatinglayers 210 ofassembly 250′, a thermal insulatinglayer 301 ofassembly 450 corresponds to layer 201 ofassembly 250′, and securingstrips assembly 450 generally correspond tostrips assembly 250′. -
FIG. 4C is a top plan view, including partial cut-away views, of upperbody heating blanket 300, according to some embodiments of the present invention.FIG. 4C illustratesblanket 300 includingheating element assembly 450 covered by aflexible shell 40;shell 40 protects and isolates assembly 450 from an external environment ofblanket 300 and may further protect a patient disposed beneathblanket 300 from electrical shock hazards. According to preferred embodiments,shell 40 is similar to shell 20 ofblanket 200 in thatshell 40 is relatively durable and waterproof and may further include an antimicrobial element or layer extending over an exterior surface thereof. According to the illustrated embodiment,shell 40, likeshell 20, includes top and bottom sheets; the sheets extend over either side ofassembly 450 and are coupled together along aseal zone 32 that extends around aperimeter edge 4000 and withinedge 4000 to form various zones, or pockets, where gaps exist between the two sheets. The sheets ofshell 40 may be heat sealed together alongzone 32, as previously described for the sheets ofshell 20. With reference toFIG. 4B , securingstrips 317 may be heat sealed between the sheets ofshell 40 in corresponding areas ofseal zone 32, on either side of a central narrowedportion 39 ofblanket 300, in order to secureheating element assembly 450 within the corresponding gap between the two sheets ofshell 40. According to an alternate embodiment, for example, as shown with dashed lines inFIG. 4A ,lateral edges heating element 30 extend out to form securingedges 27 that each include slots orholes 207 extending therethrough so that inner surfaces of sheets ofshell 40 can contact one another to be sealed together and thereby hold edges 27. It should be noted that either ofblankets heating element assembly 250/250′, 450. - With reference to
FIG. 4C , it may be appreciated thatblanket 300 is symmetrical about acentral axis 30 and about another central axis, which is orthogonal toaxis 30.FIG. 4C illustratesshell 40 formingflaps central axis 30 and across the central axis orthogonal toaxis 30. According to the illustrated embodiment, each offlaps 35A, B are weighted in a fashion similar to that described forflaps 25 ofblanket 200 includeweighting members 305, which are similar tomembers 255 ofblanket 200, and which may stiffenflaps 35A,B (dashed lines indicate outlines ofmembers 305 held between the sheets ofcover 40 by surrounding areas of seal zone 32). -
FIG. 4C further illustratesstraps 38, each extending betweenrespective flaps 35A-B. With reference toFIG. 4D , which is a schematic end view ofblanket 300 draped over an upper body portion of a patient, it may be appreciated that flaps 35A-B and 350 extend downward to enclose the outstretched arms of the patient in order to prevent heat loss and that straps 38secure blanket 300 about the patient. Opposingstraps 38 may be secured together with reversible fasteners, examples of which include, without limitation, magnetic fasteners, either embedded withinstraps 38 or coupled to outer surfaces thereof, mating hook-and-loop fasteners, attached to opposingstraps 38, and mating snap fasteners, attached to opposing straps. According to preferred embodiments, portions ofperimeter edge 4000 defining narrowedportion 39, which extends across a chest of the patient, are either rounded or padded to provide a softer interface with the patient's chin ifblanket 300 were to slip off the patient's chest toward the patient's chin. - With further reference to
FIG. 4D , it may also be appreciated that, whenblanket 300 is positioned over the patient, eachstrap 38 is positioned in proximity to an elbow of the patient so that either end portion ofblanket 300, corresponding to each pair offlaps 35A, may be temporarily folded back, as illustrated, per arrow C, in order for a clinician to access the patient's arm, for example, to insert or adjust an IV. According to some embodiments of the present invention, super over-temperature sensors, for example,sensors 41, previously described, are included inblanket 300 being located according to the anticipated folds, for example atgeneral locations 410 illustrated in FIGS. 4B-C, in order to detect over-heating, which may occur ifblanket 300 is folded over on itself, as illustrated inFIG. 4D , for too long a time, and, particularly, ifflaps 35A of folded-back portion of blanket are allowed to extend downward as illustrated with the dashed line inFIG. 4D .FIG. 4D further illustratesconnector cord 330 plugged intoconnector 23 to coupleheating element 30 andtemperature sensor assembly 421 ofblanket 300 to controlconsole 333. - In the foregoing detailed description, the invention has been described with reference to specific embodiments. However, it may be appreciated that various modifications and changes can be made without departing from the scope of the invention as set forth in the appended claims. Although embodiments of the invention are described in the context of a hospital operating room, it is contemplated that some embodiments of the invention may be used in other environments. Those embodiments of the present invention, which are not intended for use in an operating environment and need not meet stringent FDA requirements for repeated used in an operating environment, need not including particular features described herein, for example, related to precise temperature control. Thus, some of the features of preferred embodiments described herein are not necessarily included in preferred embodiments of the invention which are intended for alternative uses.
Claims (42)
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US11/537,212 Active 2027-04-01 US7714255B2 (en) | 2005-09-29 | 2006-09-29 | Bus bar attachments for flexible heating elements |
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US13/157,140 Active US8604391B2 (en) | 2005-09-29 | 2011-06-09 | Heating blankets and pads |
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US10136735B2 (en) | 2014-11-19 | 2018-11-27 | Polygroup Macau Limited (Bvi) | Systems and methods for air mattress temperature control |
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Also Published As
Publication number | Publication date |
---|---|
US8604391B2 (en) | 2013-12-10 |
CN101312698A (en) | 2008-11-26 |
EP1942847A1 (en) | 2008-07-16 |
CA2624454A1 (en) | 2007-04-12 |
US20110233185A1 (en) | 2011-09-29 |
US20070068923A1 (en) | 2007-03-29 |
US20100204763A1 (en) | 2010-08-12 |
WO2007041389A1 (en) | 2007-04-12 |
US7714255B2 (en) | 2010-05-11 |
US7786408B2 (en) | 2010-08-31 |
US20070068929A1 (en) | 2007-03-29 |
US20070068928A1 (en) | 2007-03-29 |
US20070068931A1 (en) | 2007-03-29 |
AU2006299636A1 (en) | 2007-04-12 |
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