Channeled warming blanket

• US 20060150331A1
• Filed: 05/18/2005
• Published: 07/13/2006
• Est. Priority Date: 01/12/2005
• Status: Abandoned Application

• Current Assignee: Andrew D. Child, Karen M. Green, Keith M. Blackwell, Shawn Davis
• Original Assignee: Andrew D. Child, Karen M. Green, Keith M. Blackwell, Shawn Davis
• Inventors: Davis, Shawn, Child, Andrew D., Blackwell, Keith M., Green, Karen M.
• Application Number:
  US11/131,821
• Publication Number:
  US 20060150331A1
• Time in Patent Office: Days
• US Class Current: 5/502
• CPC Class Codes: H05B 2203/003 using serpentine layout
• CPC Class Codes: H05B 2203/014 Heaters using resistive wires or cables not provided for in H05B3/54
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 3/342 heaters used in textiles

Abstract

A warming blanket incorporating channeled areas for accepting heat and/or sensor wires. The inventive blanket includes multiple layers of knitted, woven or non-woven fabrics that are welded together with ultrasonic seams to define channels through which wires for resistive heating can be placed. This composite may be produced in a continuous process, providing the composite in roll form.

Claims

1. A warming blanket composite shell comprising:

a first non-woven layer;

a second non-woven layer;

a first decorative fabric layer disposed on an outer surface of said first non-woven layer;

a second decorative fabric layer disposed on an outer surface of said second non-woven layer; and

a plurality of ultrasonic weld seams bonding the non-woven layers and decorative fabric layers together, wherein the ultrasonic weld seams are arranged in a pattern defining boundaries of wire accepting channels.

2. The invention of claim 1 wherein said composite shell is in roll form.

3. The invention of claim 1 wherein at least a portion of said weld seams are discontinuous along the length of the warming blanket composite shell.

4. The invention of claim 1 wherein said first and said second non-woven layers comprise spun-bond non-woven fabrics.

5. The invention of claim 1 wherein said first and said second non-woven layers are characterized by a fabric weight about 0.40 oz/yd² to about 1.1 oz/yd².

6. The invention of claim 1 wherein an ultrasonically fusible batting layer is disposed between said first non-woven layer and said first decorative fabric layer.

7. The invention of claim 6 wherein said batting layer is polyester resin-bond batting.

8. The invention of claim 6 wherein said batting layer is characterized by a loft of about 0.125 inches to about 0.50 inches.

9. The invention of claim 6 wherein said batting layer is characterized by a mass per unit area of about 1.1 ounces per square yard.

10. The invention of claim 1 wherein said first and said second decorative fabric layers are selected from the group consisting of a warp knit, circular knit, nap knit micro-denier, woven, non-woven, and needle punch fabric.

11. The invention of claim 10 wherein said first and said second decorative fabric layers are nap knit micro-denier fabric.

12. The invention of claim 10 wherein said first and said second decorative fabric layers are characterized by a fabric weight of about 2.5 oz/yd² to about 6.0 oz/yd².

13. The invention of claim 1 wherein said weld seams comprise elongate lines of a predetermined length.

14. A method of producing a composite warming blanket shell comprising the steps of;

(a) arranging let-off rolls such that two non-woven layers are adjacent to one another; and

(b) disposing of a first and second decorative fabric layers on the outer surfaces of said non-woven layers; and

(c) applying a plurality of ultrasonic weld seams across the non-woven layers and decorative fabric layers thereby bonding the non-woven layers and decorative fabric layers together such that the ultrasonic weld seams are arranged in a pattern defining boundaries of channels adapted to accept wire elements.

15. The method of claim 14 wherein said first and said second non-woven layers comprise spun-bond non-woven fabrics.

16. The method of claim 14 wherein said first and said second non-woven layers comprise a fabric characterized by a weight of about 0.40 oz/yd² to about 1.1 oz/yd².

17. The method of claim 14 comprising the further step of disposing a batting layer between said first non-woven layer and said first decorative fabric layer.

18. The method of claim 17 wherein said batting layer is polyester resin-bond batting.

19. The method of claim 17 wherein said batting layer is characterized by a loft of about 0.125 inches to about 0.50 inches.

20. The method of claim 17 wherein said batting layer is characterized by a mass per unit area of about 1.1 ounces per square yard.

21. The method of claim 14 wherein said first and said second decorative fabric layers are selected from the group consisting of a warp knit, circular knit, nap knit micro-denier, woven, non-woven, and needle punch fabric.

22. The method of claim 21 wherein said first and said second decorative fabric layers are nap knit micro-denier fabric.

23. The method of claim 21 wherein said first and said second decorative fabric layers are characterized by a fabric weight of about 2.5 oz/yd² to about 6.0 oz/yd².