Electrically heated garment

• US 5,032,705 A
• Filed: 09/08/1989
• Issued: 07/16/1991
• Est. Priority Date: 09/08/1989
• Status: Expired due to Fees

• Current Assignee: Environwear Incorporated
• Original Assignee: Environwear Incorporated
• Inventors: Minch, Roger L., Batcheller, Barry D., Brekkestran, Kevin L.
• Primary Examiner(s): WALBERG, TERESA J
• Application Number:
  US07/405,627
• Time in Patent Office: 676 Days
• Field of Search: 219/211, 219/212, 219/528, 219/529, 219/549
• US Class Current: 219/211
• CPC Class Codes: A41D 13/0051 Heated garments heated divers' suits B63C11/28
• CPC Class Codes: G05D 23/2401 using a heating element as a sensing element
• CPC Class Codes: H05B 2203/003 using serpentine layout
• CPC Class Codes: H05B 2203/005 using multiple resistive elements or resistive zones isolated from each other
• 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 2203/036 Heaters specially adapted for garment heating
• CPC Class Codes: H05B 3/342 heaters used in textiles

Abstract

An electrically heated, cold weather garment. The garment includes a lightweight, stretchable, form-fitting fabric for covering portions of the body of a wearer of the garment; a plurality of flexible, electrical heating wires cover stitched to the fabric by sewing; an electronic controller for controlling current flowing through each of the heating wires in a pulse-width modulated fashion, to thereby independently control the heat generated by each heating wire; a plurality of potentiometers for controlling the level of power supplied to each heating wire; and a master power level potentiometer for controlling the power supplied to each of the heating wires in a uniform and simultaneous fashion. In a first preferred embodiment the controller utilizes a combination of analog and digital-like signals to control in a pulse-width modulated fashion the current flow through the heating elements. In a second preferred embodiment the controller includes a microprocessor which is operable to sense changes in the temperature of the heating wires themselves, and to regulate automatically and independently the power supplied to each of the heating wires.

Claims

1. A portable, wearable electrically heated, cold-weather garment system having a plurality of independently, controllable heating zones, comprising:

a lightweight, stretchable, form-fitting fabric assembly defining shirt and pants portions, at least one glove portion and at least one sock portion, and wherein each portion of the fabric assembly includes fabric made from material which is operable to wick away moisture from the skin of a wearer and dissipate the moisture relatively quickly, thereby helping to keep the wearer dry;

a plurality of flexible conductors, each such conductor being operable to generate heat in response to current flowing therethrough, at least one such conductor being independently associated with the pants portion and constituting a first heating zone, at least one such conductor being independently associated with the shirt portion and constituting a second heating zone, at least one such conductor being independently associated with the glove portion and constituting a third heating zone, and at least one such conductor being independently associated with the sock portion and constituting a fourth heating zone;

portable, wearable electronic controller means for controlling in independent fashion the electrical current flowing through each such conductor constituting a zone, thereby controlling independently the heat generated by each such conductor for each such zone, the controller means including a plurality of solid-state power switching devices, with at least one such device for each such flexible conductor and zone through which electrical current is controlled in independent fashion, and power level selection means for allowing manual control over the controller means by a wearer of the form-fitting fabric assembly; and

connector means for helping to connect the controller means with the independent conductors.

2. The garment system of claim 1, wherein the shirt portion further comprises:

a left arm portion having a first portion of a single such conductor associated therewith, the conductor further being arranged on the left arm portion in a serpentine pattern to evenly distribute the heat generated by the conductor throughout the left arm section; and

a right arm portion having a second portion of a said single such conductor independently associated therewith, the conductor further being arranged in a serpentine pattern to evenly distribute heat generated by the conductor throughout the right arm portion and

wherein the first and second portions of said single such conductor of the left arm and right arm portions are connected in series on the garment in such a fashion so as to not overlap other conductors.

3. The garment system of claim 1, wherein the shirt portion comprises front and rear torso portions, each such torso portion having different portions of a single conductor associated therewith;

and

wherein the conductor portions associated with the front and rear torso portions are connected in series and in such a manner so as to not overlap other conductors of the garment.

4. A portable, wearable electrically heated, cold weather garment system comprising:

relatively light weight, stretchable, form-fitting fabric means for covering at least a portion of the body of a wearer of the garment;

flexible conductor means, including a plurality of conductors secured to the fabric means, each being associated with an independently controlled heating zone, for generating heat in response to current flowing therethrough, to thereby provide warmth to a wearer of the garment;

portable, wearable electronic controller means, including a plurality of solid-state power switching devices each of which is associated with a distinct heating zone, for controlling in a pulse width modulated fashion current flowing through the conductor means, thereby controlling the heat generated by the conductor means; and

a plurality of first power level selection means for allowing manual control over the controller means by a wearer of the garment, thereby providing wearer control over current flowing through the conductor means, and thereby providing wearer control over the heat generated by the conductor means.

5. The garment system of claim 4, wherein direct current (D.C.) electrical power is used as the source of power to the controller means, and the controller means utilizes a combination of analog and digital signals operable to control in a pulse width modulated fashion the direct current flowing through the conductor means, thereby controlling the heat generated by the conductor means.

6. The garment system of claim 4, wherein the fabric means is divided into and defines a plurality of independent heating zones;

and

wherein the plurality of conductors are each associated with a single such heating zone to thereby heat independently a particular heating zone of the garment.

7. The garment system of claim 4, further comprising

second power level selection means which includes a single manually operable power level selection device to control the controller means to uniformly and simultaneously increase or decrease the current flow through each of the conductors in each of the heating zones.

8. A portable, wearable electrically heated, cold weather garment system comprising:

at least an upper body garment portion having at least first and second independent heating zones;

at least one independent conductor associated with each such independent heating zone of the garment portion, each such conductor being operable to generate heat in response to a current flowing therethrough; and

portable, wearable electronic controller means operating on direct current (D.C.) electrical power for simultaneously and independently controlling in pulse width modulated fashion the current flowing through each such independent conductor, thereby independently and simultaneously controlling the heat generated by each such independent conductor, to thereby provide independent and simultaneous control of the level of heating provided to each independent heating zone of the garment.

9. The garment system of claim 8, further comprising:

a plurality of first power level selection devices, each such first device being independently associated with one such independent conductor, and operable to control current flowing through its associated conductor; and

a master power level selection device for uniformly and simultaneously increasing or decreasing the current flowing through each such conductor, to thereby uniformly and simultaneously increase or decrease the heat generated by each conductor of each heating zone.

10. An electrically heated, cold weather garment system comprising:

lightweight, stretchable, form-fitting fabric means for covering at least a portion of a body of a wearer of the garment;

flexible conductor means arranged in a serpentine pattern for generating heat in response to a current flow therethrough, and for distributing the heat uniformly throughout the fabric means;

cover stitch means for securing the conductor means to the fabric means and for substantially circumscribing at least a portion of the conductor means;

portable, wearable, electronic controller means for controlling in pulse width modulated fashion the current flow through the conductor means, the controller means further being secured to a portion of the garment;

power level selection means for providing manual control over the controller means by a wearer of the garment;

a flexible wiring harness having first and second ends, the first end being connectable to the controller means; and

electrical connector means securely mounted to a portion of the fabric means for removably connecting the second end of the wiring harness with the conductor means, the electrical connector having at least one wing portion for helping to facilitate mounting of the connector means to the fabric means.

11. The garment system of claim 10, wherein the fabric means defines a plurality of independent heating zones;

and

wherein the flexible conductor means comprises a plurality of electrical conductors, each such conductor being independently associated with a particular such heating zone of the garment.

12. The garment system of claim 10, wherein the controller means comprises:

means for providing an analog control signal operable to help control the current flowing through the conductor means in accordance with a first power level adjustment by the wearer of the garment; and

means for providing a digital control signal for further helping to control, in combination with the means for providing an analog control signal, the current flowing through the conductor means.

13. The garment system of claim 10, wherein the fabric means defines a plurality of independent heating zones of the garment;

and

wherein the conductor means comprises a plurality of electrical conductors, each such conductor being independently associated with a particular such heating zone of the garment; and

wherein the power level selection means comprises a plurality of first power level selection devices and a second power level selection device, each such first power level selection device being independently associated with a particular such electrical conductor and operable to provide manual control by the wearer of the garment over the current flow through its associated electrical conductor, the second power level selection device being operable to allow the wearer of the garment to uniformly and simultaneously increase or decrease the current flow through each such electrical conductor, thereby uniformly and simultaneously increasing or decreasing the heat generated by each such conductor.

14. The garment system of claim 10, wherein the conductor means comprises a plurality of electrical conductors.

15. The garment system of claim 14, wherein the fabric means comprises:

an independent shirt portion having an independent torso portion and independent sleeve portions, the torso portion being independently associated with at least one such electrical conductor, and the sleeve portions being independently associated with at least one such electrical conductor;

an independent pants portion having a plurality of leg portions, each such leg portion being independently associated with a particular such electrical conductor;

a plurality of sock portions, each such sock portion being independently associated with a particular such electrical conductor; and

a plurality of glove portions, each such glove portion being independently associated with a particular such electrical conductor.

16. The garment system of claim 10, wherein the conductor means comprises a plurality of independent electrical conductors;

and

wherein the electrical connector means comprises a plurality of electrical connectors, each such connector being independently associated with a particular such conductor and operable to interrupt the current flowing through its associated conductor when such current exceeds a predetermined level.

17. The garment system of claim 16, wherein each electrical connector further comprises a wearer removable fuse for interrupting current flowing through its associated conductor when such current exceeds a predetermined level.

18. For an electrically heated, cold-weather garment, an electrically heated sock, comprising:

lightweight, stretchable, form-fitting fabric means for covering a foot of a wearer of the sock, the fabric means further being operable to wick away moisture, thereby helping to keep the foot of the wearer and the fabric means dry;

flexible conductor means arranged on at least a portion of the fabric means in a serpentine pattern for generating heat in response to a current flow therethrough, and for distributing the heat evenly throughout portions of the fabric means; and

cover stitch means for securing the conductor means to the fabric means and for substantially circumscribing a portion of but not all of the circumference of the conductor means in a manner which allows the conductor to move slightly relative to the fabric means, the cover stitch means including stitching arranged to substantially cover the portion of the conductor not wrapped therearound by the fabric means.

21. The sock of claim 18, further comprising a removable connector assembly having at least one wing portion, the connector assembly being operable to connect the conductor means with an electronic controller to thereby allow the controller to regulate the current flow through the conductor means. and the wing portion being operable to help facilitate attachment of the connector assembly to the fabric means by sewing.

19. For an electrically heated, cold-weather garment, an electrically heated glove, comprising:

lightweight, stretchable, form-fitting fabric means for covering at least a portion of a hand of a wearer of the garment, the fabric means further being operable to wick away moisture, thereby helping to keep the hand of the wearer and the fabric means dry;

flexible conductor means arranged on at least a portion of the fabric means in a serpentine pattern for generating heat in response to a current flow therethrough, and for distributing the heat evenly throughout portions of the fabric means; and

cover stitch means for securing the conductor means to the fabric means and for substantially circumscribing a portion of but not all of the circumference of the conductor means in a manner which allows the conductor to move slightly relative to the fabric means, the cover stitch means including stitching arranged to substantially cover the portion of the conductor not wrapped therearound by the fabric means.

20. The glove of claim 19, further comprising a removable connector assembly having at least one winged portion, the connector assembly being operable to connect the conductor means with an electronic controller to thereby allow the controller to regulate the current flow through the conductor means, and the wing portion being operable to help facilitate attachment of the connector assembly to the fabric means by sewing.