Hybrid electronic control system and method for cold weather garment

• US 5,023,430 A
• Filed: 09/08/1989
• Issued: 06/11/1991
• Est. Priority Date: 09/08/1989
• Status: Expired due to Fees

• Current Assignee: Environwear Incorporated
• Original Assignee: Environwear Incorporated
• Inventors: Batcheller, Barry D., Brekkestran, Kevin L.
• Primary Examiner(s): PASCHALL, MARK H
• Application Number:
  US07/405,142
• Time in Patent Office: 641 Days
• Field of Search: 219/211, 219/212, 219/494, 219/497, 219/499, 219/501, 219/505, 219/507, 219/508, 219/509, 219/491, 219/483-486, 307/38-41, 2/69
• US Class Current: 219/486
• CPC Class Codes: A41D 13/0051 Heated garments heated divers' suits B63C11/28
• CPC Class Codes: G05D 23/1934 each space being provided with one sensor acting on one or more control means
• CPC Class Codes: G05D 23/24 the sensing element having a resistance varying with temperature, e.g. a thermistor
• CPC Class Codes: H05B 1/0227 Applications
• 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 2203/035 Electrical circuits used in resistive heating apparatus
• CPC Class Codes: H05B 2203/036 Heaters specially adapted for garment heating
• CPC Class Codes: H05B 3/342 heaters used in textiles

Abstract

A hybrid, open-loop electronic temperature control system and method of heating for an electrically heated cold weather garment having a plurality of independent heating zones. In one embodiment the system includes: a plurality of conductive heating wires, with at least one such heating wire being disposed in each zone of the garment and operable to heat each zone of the garment independently; a plurality of solid-state semiconductor power switching devices for controllably allowing current flow through each heating wire; and plurality of power selection circuits, with each having a potentiometer and being associated with each solid-state power switching device, for providing individual power level selection for each heating wire of the garment. This gives the wearer individual control over the temperature level of each zone of the garment. Further power control is provided by a master power level selection circuit and potentiometer which operates to simultaneously and uniformly increase or decrease the overall power level applied to the switching devices, which increases or decreases uniformly and simultaneously the temperature of each of the zones of the garment. A triangular waveform generator is included for providing pulse width modulated control over the heating elements to help conserve electrical power. Overcurrent protection circuitry is also included which monitors the total current drawn by the heating elements.

Claims

1. A portable, wearable electronic temperature control system for an electrically heated garment having a plurality of independent heating zones, the system comprising:

a plurality of electrically heatable flexible heating elements, each said heating element being associated with a particular heating zone, and being independent of the other heating zones, and being operable to generate heat in response to current flowing therethrough;

a plurality of independent electric current switching means, each switching means being associated with at least one particular heating element and operable to selectively enable and interrupt current flowing therethrough;

a plurality of independent first power selection means, each being associated with a particular switching means of a particular heating zone and each being for independently selecting a desired level of heating for the particular heating zone;

second power selection means, working cooperatively with each first power selection means, for simultaneously and uniformly adjusting the desired level of heating for each of the heating zones in proportion to one another; and

current limiting means for detecting an aggregate current flowing through the heating elements and for controlling simultaneously the switching means to limit such aggregate current.

2. The system of claim 1, further comprising oscillator means for providing an intermittent control signal having a repetition rate greater than about 1 Hz simultaneously to each switching means to help turn on and off the switching means in a controlled, intermittent fashion as part of regulating the current provided to the heating element connected thereto.

3. The system of claim 2, wherein the oscillator means includes an astable multivibrator and the intermittent control signal is a triangular waveform.

4. The system of claim 2, wherein the intermittent control signal is an analog signal, and the oscillator means operates cooperatively with each switching means and its associated first power selection means to pulse width modulate each switching means.

5. The system of claim 4, wherein:

each first power selection means produces a desired power level signal corresponding to the desired level of heating for its associated heating zone; and

each switching means includes means for comparing the analog intermittent control signal produced by the oscillator means with the desired power level signal of its associated first power level selection means, and for generating a controlled switching signal in response to the comparison for pulse width modulating the switching means.

6. The system of claim 1, wherein the heating elements include a plurality of insulated wires arranged within their respective zones in a serpentine pattern to help distribute heat evenly throughout the heating zones and to facilitate flexion of the heating elements without breakage.

7. The system of claim 1, wherein each electric current switching means includes a power transistor.

8. The system of claim 1, wherein each of the independent first power selection means includes an independent potentiometer, each potentiometer being operable to provide a first voltage indicative of the desired level of heating for its associated zone, each first voltage being operable to at least partially control when its associated switching means enables and interrupts current flowing through its associated heating element.

9. The system of claim 1, wherein the second power selection means is a potentiometer operable to provide a second voltage simultaneously to each of the first power selection means, which second voltage may be increased or decreased to substantially uniformly and simultaneously increase or decrease the amount of current to be provided to each of the heating elements.

10. The system of claim 1, wherein the current limiting means comprises:

a plurality of resistors, each resistor being associated with a particular switching means and operable to provide a signal representative of the current flowing through its associated switching means;

means for summing the signals representative of the current flowing through the switching means to provide an aggregate signal representative of the aggregate current flowing through the heating elements;

comparator means for determining when the aggregate signal exceeds a predetermined value and for generating a control signal when the aggregate signal exceeds the predetermined value; and

analog control means for limiting the aggregate current by adjusting simultaneously and substantially uniformly in real time when each switching means selectively enables and interrupts the current flowing in each of the heating elements, said analog control means being responsive the control signal from the comparator means.

11. The system of claim 1, wherein at least one heating zone has associated with it a plurality of heating elements.

12. A portable, electronic temperature control system for an electrically heated garment having at least first and second independent heating zones, with each such zone being associated with at least one electric heating element for applying heat to the zone, the system comprising:

a plurality of first power level selection means, each such means being associated with a respective one of the heating zones and being for independently selecting under control of a wearer of the garment a power level to be produced by the heating element of its associated heating zone;

master power level selection means for simultaneously and uniformly adjusting under control of the wearer of the garment an overall level of heating to be achieved by the heating zones, said means being arranged to work simultaneously in conjunction with each of the first power level selection means by effectively modifying in proportion to one another the power levels selected via the first power level selection means; and

a plurality of solid-state electric current switching means, each such means being associated with a respective one of the heating zones, and being for switching one and off independently and substantially simultaneously electric current to the heating element associated with its respective heating zone, each such switching means operating automatically and in accordance with at least one time-varying signal received thereby and with the power level selected by the first power level selection means associated with the same heating zone as the switching means is associated with,

whereby the levels of heating applied to the zones may be independently controlled via the first power selection level means and may be simultaneously and uniformly adjusted via the master power selection level means.

13. The system of claim 12, further comprising means for sensing an aggregate current flowing through said heating elements and controlling each of said switching means in a substantially uniform manner to limit the aggregate current flowing through said heating elements to not exceed a predetermined value.

14. The system of claim 12, further comprising master time base means for working cooperatively with each first power selection means to produce a pulse width modulated control signal for the switching means associated with the first power selection means, thereby producing an intermittent switching on and off of each heating element.

15. The system of claim 12, wherein each switching means is a solid-state semiconductor device.

16. The system of claim 12, wherein each first power level selection means is a wearer adjustable potentiometer.

17. The system of claim 12, wherein the master power level selection means is a wearer adjustable potentiometer.

18. A portable, wearable electronic control system for selectively heating in an independent fashion a plurality of independent zones of a cold weather garment, the system comprising:

means for generating a time-varying signal having a frequency of at least two Hertz;

a plurality of independent heating wires, each heating wire being disposed in a particular zone of the garment and operable to generate heat in response to current flowing therethrough;

a plurality of independent, wearer adjustable first temperature control potentiometers for facilitating selection of a desired temperature level for each zone by a wearer of the garment;

control circuit means, including a second temperature control potentiometer adjustable by a wearer of the garment, for increasing or decreasing proportionately and simultaneously the desired temperature levels of all of the zones; and

a plurality of independently controllable switching means, each such switching means being associated with a particular heating wire and being for selectively enabling and disabling current flowing through its respective heating wire in response to the time-varying signal, the control circuit means, and a respective one of the first potentiometers.

19. The system of claim 18, wherein the power switching device is a field effect transistor.

20. A method of independently regulating heating in a plurality of independent heating zones of an electrically heated garment, each such zone having at least one electric heating element disposed therein, the method comprising:

providing a plurality of solid-state electric current switching devices, and connecting each such device to at least one heating element in each heating zone of the garment;

generating a master power level signal indicating a desired level of overall heating which is adjustable by a wearer of the garment;

generating a plurality of independent, pulse width modulated signals, each such sign being associated with a particular solid-state switching device and zone of the garment and having a duty cycle controllable by a wearer of the garment and by the master power level signal;

applying each such pulse width modulated signal to its respective switching device substantially simultaneously; and

whereby the pulse width modulated signals applied to the switching devices in a simultaneous and independent fashion operate to controllably and independently start and stop current flowing through the heating elements, thereby regulating independently heating power levels applied to the zones, and

whereby the level of heating in each of the zones may be adjusted simultaneously an din proportion to one another through adjustments to the master power level signal.

21. The method of claim 20, further comprising the step of

providing an analog master time base signal having a triangular waveform and at least one predetermined frequency, and wherein

the step of generating includes the sub-step of modifying the master time base signal in accordance with the power levels selected by the wearer for the zones such that each of the pulse width modulated signals has a duty cycle proportional to the selected power level of its respective zone.

22. The method of claim 20, further comprising the steps of:

monitoring current being drawn through the electric heating elements; and

reducing the duty cycle of each of the pulse width modulated signals when the current being drawn exceeds a predetermined amount.