HEATER FOR AN AUTOMOTIVE VEHICLE AND METHOD OF FORMING SAME

• US 20140299591A1
• Filed: 06/20/2014
• Published: 10/09/2014
• Est. Priority Date: 11/21/2002
• Status: Active Grant

• Current Assignee: Gentherm GmbH (Gentherm Incorporated)
• Original Assignee: Wet Automotive Systems AG (Gentherm Incorporated)
• Inventors: Howick, Shaun Calvin, Bajic, Goran
• Granted Patent: US 9,315,133 B2
• Time in Patent Office: Days
• US Class Current: 219/202
• CPC Class Codes: B60N 2/002 Seats provided with an occupancy detection means mounted therein or thereon detection means responsive to presence or absence of children B60N2/266
• CPC Class Codes: B60N 2/5678 characterised by electrical systems
• CPC Class Codes: B60N 2/5685 Resistance
• CPC Class Codes: B60R 1/12 Mirror assemblies combined with other articles, e.g. clocks
• CPC Class Codes: H05B 1/0238 For seats
• CPC Class Codes: H05B 2203/003 using serpentine layout
• CPC Class Codes: H05B 2203/004 using zigzag layout
• CPC Class Codes: H05B 2203/005 using multiple resistive elements or resistive zones isolated from each other
• CPC Class Codes: H05B 2203/006 using interdigitated electrodes
• CPC Class Codes: H05B 2203/011 Heaters using laterally extending conductive material as connecting means
• CPC Class Codes: H05B 2203/013 Heaters using resistive films or coatings
• CPC Class Codes: H05B 2203/016 Heaters using particular connecting means
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/02 Heaters using heating elements having a positive temperature coefficient
• CPC Class Codes: H05B 2203/026 Heaters specially adapted for floor heating
• CPC Class Codes: H05B 2203/029 Heaters specially adapted for seat warmers
• CPC Class Codes: H05B 3/34 flexible, e.g. heating nets or webs
• CPC Class Codes: H05B 3/845 specially adapted for reflecting surfaces, e.g. bathroom - or rearview mirrors

Abstract

There is disclosed a heater for an automotive vehicle or other article of manufacture. The heater typically includes a first conductive medium and a second conductive medium disposed upon a carrier. In a preferred embodiment, the first conductive medium includes a first section and a second section that are electrically connected by a second conductive medium. The second conductive medium preferably exhibits a positive thermal coefficient.

Claims

1. An article of manufacture, comprising:

a carrier of the article of manufacture, the carrier having a surface;

a heater overlaying the surface, the heater including;

i) a polymeric film flexible carrier having;

a longitudinal axis;

ii) a first conductive medium disposed upon the polymeric film flexible carrier wherein the first conductive medium includes;

1) a negative section having;

a. a first base portion and

b. a plurality of first extensions extending from the first base portion; and

2) a positive section having;

a. a second base portion and

b. a plurality of second extensions extending from the second base portion; and

wherein the plurality of first extensions have substantially a same shape and are substantially uniformly spaced apart from each other, and the plurality of second extensions have a same shape and are substantially uniformly spaced apart from each other;

iv) a second conductive medium disposed on the polymeric film flexible carrier in overlapping relation with the plurality of first extensions and the plurality of second extensions;

wherein the second conductive medium is a plurality of resistive strips that are each in contact with one of the plurality of first extensions and one of the plurality of second extensions; and

wherein the plurality of resistive strips are sectioned and broken into pieces

6. An article of manufacture as in claim 1, wherein the article of manufacture includes electrical connections and the only electrical connections of the heater are a first electrical connection and a second electrical connection.

44. An article of manufacture as in claim 1, wherein the carrier of the article of manufacture is an interior trim component

45. An article of manufacture as in claim 1, wherein the carrier of the article of manufacture is an automotive trim component that generally comes into contact with an occupant of a vehicle

46. An article of manufacture as in claim 1, further including an electrical connection attached to and covered by a patch.

47. An article of manufacture as in claim 1, wherein the base portion of the first conductive medium and the second conductive medium are disposed on opposite sides of the polymeric film flexible carrier.

48. An article of manufacture as in claim 47, wherein the base portion of the first conductive medium and the second conductive medium are symmetrical in shape.

49. An article of manufacture as in claim 1, wherein the carrier of the article of manufacture is an article of clothing.

50. An article of manufacture as in claim 1, wherein a width of the first base portion and the second base portion progressively narrow along the longitudinal axis of the heater.

51. An article of manufacture as in claim 50, wherein the width of the first base portion and the second base portion progressively expand along the longitudinal axis of the heater as the first base portion and the second base portion extend away from a section that progressively narrows.

52. An article of manufacture as in claim 1, wherein heater includes an insulating layer formed of fleece, or gauze and fastened to the carrier by an adhesive.

53. An article of manufacture as in claim 1, wherein the heater is integrated with an occupant sensor

54. An article of manufacture as in claim 1, wherein the heater includes an occupant sensor.

55. An article of manufacture as in claim 53, wherein the occupant sensor is a pressure sensor to determine the presence of an applied force acting on the heater or the sensor.

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

7. -43. (canceled)

56. An article of manufacture, comprising:

a carrier of the article of manufacture, the carrier having a surface;

a heater overlaying the surface of the carrier, the heater including;

ii) a polymeric film flexible carrier having;

a. a longitudinal axis;

b. a first lengthwise edge;

c. a second lengthwise edge on an opposite side of the longitudinal axis, the second lengthwise edge opposing the first lengthwise edge;

iii) a first conductive medium disposed upon the polymeric film flexible carrier wherein the first conductive medium includes;

1) a negative section having;

a. a base portion and

b. a plurality of first extensions extending from the base portion; and

2) a positive section having;

a. a base portion and

b. a plurality of second extensions extending from the base portion;

iv) a second conductive medium disposed on the polymeric film flexible carrier in an overlapping relation with the plurality of first extensions and the plurality of second extensions; and

v) an insulating layer over the first conductive medium and the second conductive medium, the insulating layer being a film, a vinyl sheet, or a flexible sheet;

vi) a sensor;

wherein the second conductive medium is a plurality of strips and the strips are sectioned and broken into pieces; and

wherein the second conductive medium is a positive thermal coefficient material.

57. The article of manufacture of claim 56, wherein the heater is connected to the surface of the carrier and the carrier is a gear shifter, panel, footwell, or a floor mat, cargo or bed liner.

58. The article of manufacture of claim 56, wherein the heater includes one or more electrical connections that are attached to the negative section and the positive section respectively by a rivet, and

wherein the one or more electrical connections are covered by a patch.

59. The article of manufacture of claim 57, wherein the heater is asymmetric.

60. The article of manufacture of claim 59, wherein the negative section and the positive section are located on both sides of the longitudinal axis and are symmetrical in shape.

61. The article of manufacture of claim 59, wherein the negative baser portion is partially or fully enclosed within the positive base portion.