Convective cushion with positive coefficient of resistance heating mode

• US 20070086757A1
• Filed: 10/05/2005
• Published: 04/19/2007
• Est. Priority Date: 12/28/2004
• Status: Active Grant

• Current Assignee: Steve Feher
• Original Assignee: Steve Feher
• Inventors: Feher, Steve
• Granted Patent: US 7,480,950 B2
• Time in Patent Office: Days
• US Class Current: 392/397
• CPC Class Codes: A47C 21/044 with active means, e.g. by using air blowers or liquid pumps
• CPC Class Codes: A47C 21/048 for heating
• CPC Class Codes: A47C 27/008 protecting against wear or damage
• CPC Class Codes: A47C 27/082 with non-manual inflation, e.g. with electric pumps
• CPC Class Codes: A47C 31/006 Use of three-dimensional fabrics
• CPC Class Codes: A47C 7/74 for ventilation, heating or cooling actuated by rocking the chair A47C3/02
• CPC Class Codes: A47C 7/742 for ventilating or cooling A47C31/116 takes precedence
• CPC Class Codes: A47C 7/748 for heating
• CPC Class Codes: B60N 2/5635 coming from the passenger compartment
• CPC Class Codes: B60N 2/5657 blown towards the seat surface
• CPC Class Codes: Y10S 5/941 Blanket with forced air flow

Abstract

A cushion that is heated convectively using a positive temperature coefficient of resistance type resistive heating element that is provided with heat exchanging surfaces, includes a mattress pad, seat or the like with a bottom surface secured around its perimeter to an air permeable top surface, forming a plenum and containing tubular spacer material or other air flow structure therein. The plenum is connected to a power unit housing a blower, a heating module and a controller unit. The heating module includes a PTC type heating element in conduction with a base plate and a number of heat exchanger fins. Preferably the heating element is sandwiched between a pair of the base plates and the heat exchanger fins, and there is a seal between the base plates to minimize air flow from the blower from passing there between. A remote control for the user'"'"'s convenience may be provided, and a foldable antenna attachable to the convective unit facilitates wireless communication between the remote control and controller unit. The user resting atop the cushion is able to control the blower and heating module to deliver air of a desired temperature and quantity to the cushion and through the top surface. The invention advantageously replaces the current carrying, conductive wires and insulation found inside prior art heated mattresses, enhancing safety and performance while at the same time offering a cooled or ventilated capability.

Claims

1. A convective cushion comprising:

a plenum defined by a bottom surface secured around its perimeter to a top surface and containing an air flow structure therein;

a power unit located outside the plenum but in fluid communication with the plenum, and housing a blower in fluid communication with a heating module having a PTC type heating element;

a controller unit in communication with the blower and the heating element;

whereby a user resting atop the cushion is able to control the blower and heating module to deliver air of a desired temperature and quantity to the cushion.

2. The convective cushion of claim 1 wherein the top surface is generally air permeable

3. The convective cushion of claim 1 wherein the plenum has an opening at one end, and further comprising an air duct with one end sized to be received into the plenum opening and a second end extending to the power unit.

4. The convective cushion of claim 1 wherein the heating module comprises a heat exchanger in conduction with the PTC type heating element.

5. The convective cushion of claim 4 wherein the heat exchanger comprises a base plate and a plurality of heat exchanging fins.

6. The convective cushion of claim 5 wherein the heating element is sandwiched between a pair of the base plates and the plurality of heat exchanging fins.

7. The convective cushion of claim 6 further comprising a seal between the base plates to minimize air flow from passing therebetween.

8. The convective cushion of claim 1 further comprising a remote control in communication with the controller unit.

9. The convective cushion of claim 8 further comprising an antenna attachable to the power unit to facilitate wireless communication between the remote control and controller unit.

10. The convective cushion of claim 1 wherein the controller unit includes a speed control for the blower.

11. The convective cushion of claim 3 wherein the air duct comprises an outer shell and an inner insulating sleeve with an air gap there between.

12. The convective cushion of claim 1 further comprising a vent at the opposing end of the plenum.

13. The convective cushion of claim 1 wherein the bottom surface of the plenum is generally air impermeable.

14. The convective cushion of claim 1 wherein the plenum is adapted to be placed on a conventional mattress.

15. The c onvective cushion of claim 1 wherein the plenum is adapted to be inserted within a vehicle seat.

16. The selectively-controlled convective cushion of claim 1 wherein the power unit comprises a plurality of PTC type heating elements.

17. The selectively-controlled convective cushion of claim 1 wherein the air flow structure is tubular spacer material.

28. The mattress pad of claim 15 wherein the air flow structure is tubular spacer material.

18. A mattress pad comprising:

a plenum defined by a bottom surface secured around its perimeter to a generally air permeable top surface, the plenum containing an air flow structure and having an opening at one end;

an air duct with one end sized to be received into the opening and a second end extending outside the plenum;

a power unit housing a blower in fluid communication with a heating module and connected to the second end of the air duct;

a controller unit in communication with the blower and the heating element; and

,

wherein the heating module comprises a PTC type heating element in conduction with a heat exchanger.

19. The mattress pad of claim 18 wherein the heat exchanger comprises a base plate and a plurality of heat exchanging fins.

20. The mattress pad of claim 19 wherein the heating element is sandwiched between a pair of the base plates and the plurality of heat exchanging fins.

21. The mattress pad of claim 20 further comprising a seal between the base plates to minimize air flow from the blower from passing there between;

and

22. The mattress pad of claim 18 further comprising a remote control in communication with the controller unit.

23. The mattress pad of claim 22 wherein the remote control is portable.

24. The mattress pad of claim 22 further comprising a foldable antenna attachable to the power unit to facilitate wireless communication between the remote control and controller unit.

25. The mattress pad of claim 18 wherein the controller unit includes a speed control for the blower.

26. The mattress pad of claim 18 wherein the air duct comprises an outer shell and an inner insulating sleeve with an air gap there between.

27. The mattress pad of claim 18 further comprising a vent at the opposing end of the plenum.