ELECTRIC HEATER FOR A SEAT ASSEMBLY

• US 20020170902A1
• Filed: 03/12/2001
• Published: 11/21/2002
• Est. Priority Date: 03/12/2001
• Status: Active Grant

• Current Assignee: Check Technology Solutions LLC
• Original Assignee: Check Incorporated (Intuit, Inc.)
• Inventors: Parnis, Willilam R., Stuef, Thomas A., Check, Robert
• Granted Patent: US 6,489,595 B1
• Time in Patent Office: Days
• US Class Current: 219/217
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 66/69 General aspects of joining filaments bundling articles B65B13/00; interconnecting successive lengths of material B65H69/00
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/73755 the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized
• CPC Class Codes: B29C 66/7394 characterised by the material of at least one of the parts being a thermoset
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/771 Seats
• CPC Class Codes: B29L 2031/779 Heating equipment
• CPC Class Codes: B60N 2/5685 Resistance
• CPC Class Codes: B60N 2/5891 characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: H05B 2203/004 using zigzag layout
• CPC Class Codes: H05B 2203/014 Heaters using resistive wires or cables not provided for in H05B3/54
• CPC Class Codes: H05B 2203/029 Heaters specially adapted for seat warmers
• CPC Class Codes: H05B 2203/033 Heater including particular mechanical reinforcing means
• CPC Class Codes: H05B 3/34 flexible, e.g. heating nets or webs
• CPC Class Codes: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
• CPC Class Codes: Y10T 156/1031 with preshaping of lamina
• CPC Class Codes: Y10T 29/49083 Heater type
• CPC Class Codes: Y10T 29/49085 : Thermally variable
• CPC Class Codes: Y10T 29/49087 : with envelope or housing
• CPC Class Codes: Y10T 29/49099 : Coating resistive material on a base
• CPC Class Codes: Y10T 29/49101 : Applying terminal
• CPC Class Codes: Y10T 29/49117 : Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49826 : Assembling or joining

Abstract

A heating element that can be incorporated into a molded foam article closely adjacent to the outer cover sheet without showing any evidence that a heating element is encapsulated within the foam portion of the article and provides essentially the same relatively softness and “feel” that would be obtained if the heating element was not part of the article.

Claims

1. An electric heating element for an in-place foam molded seat assembly comprising a seat cushion member and a seat back member each of which has a core portion made of a plastic foam material bonded to an outer cover sheet, said heating element adapted to be encapsulated into one of said members and having a carrier member composed of a reticulated open cell flexible structure capable of being filled with said foam material during the molding process of said one of said members, said carrier member having a pair of spaced surfaces, an electric conductor secured to one of said surfaces, and a connector adapted to join the other of said surfaces of said carrier member to the inner surface of said cover sheet to hold said carrier member on said inner surface of said cover sheet so as to maintain said electric conductor spaced from and in a fixed position relative to said inner surface during the molding operation of said one of said members.

2. The electric heating element of claim 1 wherein said electric conductor is a wire provided with a pair of ends adapted to be electrically connected to the electrical system of a vehicle.

3. The electric heating element of claim 1 wherein said electric conductor is a resistance wire arranged in a zig-zag pattern to cover substantially the entire area of said one of said surfaces.

4. The electric heating element of claim 1 wherein said electric conductor is secured to said one of said surfaces of said carrier member by plastic welds.

5. The electric heating element of claim 1 wherein said connector is a double-faced adhesive tape.

6. The electric heating element of claim 1 wherein said connector is a double-faced adhesive tape having a scrim as a reinforcement member.

7. The electric heating element of claim 3 wherein said wire is secured to the webs of said carrier member by an adhesive.

8. The electric heating element of claim 7 wherein said zig-zag pattern is provided in a plurality of substantially parallel rows.

13. The electric heating element of claim 8 wherein said upper surface supports a thermostat for sensing the temperature of said electric heating element.

9. An electric heating element for an in-place foam molded seat cushion member having an integrally formed outer cover, said heating element comprising a carrier member having a flexible open-cell reticulated plastic structure adapted to be filled with liquid foam during the molding process, said carrier member being provided with spaced and upper and lower substantially planar surfaces, an electric conductor secured to said upper surface and covering substantially the entire area of said upper surface, and an adhesive located on said lower surface of said carrier member adapted to bond said carrier member to the inner surface of said outer cover so as to maintain said electric conductor spaced from and in a fixed position relative to said inner surface during the molding operation of said seat cushion member.

10. The electric heating element of claim 9 wherein said electric conductor is a wire provided with a pair of ends.

11. The electric heating element of claim 9 wherein said double-faced adhesive tape is provided with scrim as a reinforcing member, and a paper liner on one face of said tape adapted to be removed prior to the heating element being incorporated into said seat cushion member.

12. The electric heating element of claim 9 wherein said electric conductor is secured to said lower surface of said carrier member by a plurality of plastic welds.

14. The electric heating element of claim 13 wherein said pair of ends of said conductor and said thermostat are electrically connected through a cable to the electrical system of a vehicle.

15. The electric heater of claim 9 wherein said zig-zag pattern is provided in a plurality of substantially parallel rows.

17. The method of claim 16 wherein said other of said surfaces is connected to said inner surface of said cover sheet by an adhesive.

18. The method of claim 16 wherein said other of said surfaces is connected to said inner surface of said cover sheet by a double faced adhesive tape having a reinforcing scrim.

19. The method of claim 18 wherein said double-faced adhesive tape has one face thereof provided with a paper liner and said liner is removed prior to said tape being connected to said inner surface of said cover sheet.

20. The method of claim 16 wherein said conductor is a wire supported in a zig-zag pattern on said one of said surfaces.

16. A method of making a heated seat member comprising the steps of:

(a) preforming a cover sheet in the form of said seat member,

(b) placing said cover sheet into the cavity of a complementary mold,

(c) providing an electric heating element comprising a carrier member formed as a reticulated open cell structure having a pair of spaced surfaces, one of said pair of surfaces supporting an electric conductor,

(d) positioning said electric heating element in the buttocks support portion of said cover sheet with the other of said pair of surfaces facing the inner surface of said cover sheet so that said electric conductor is spaced from said inner surface,

(e) connecting said other of said surfaces of said heating element to said inner surface of said cover sheet so as to maintain said electric heating element in a fixed position relative to said inner surface of said trim cover and have said electric conductor spaced from said inner surface of said cover sheet,

(f) pouring a liquid plastic foaming material into said cavity of said mold so as to cause said liquid plastic foaming material to enter the open cells of said carrier member and completely encapsulate the exposed portion of said heating element, and

(g) closing the mold so as to cause said foaming material to expand, be cured, and be bonded to said cover sheet within said mold so as to completely encapsulate said electric heating element within said cured foaming material.