Electronic control system and method for cold weather garment

• US 5,105,067 A
• Filed: 09/08/1989
• Issued: 04/14/1992
• Est. Priority Date: 09/08/1989
• Status: Expired due to Fees

• Current Assignee: Environwear Incorporated
• Original Assignee: Environwear Incorporated
• Inventors: Nguyen, Nghia N., Aghai-Tabriz, Kamyab, Batcheller, Barry D., Brekkestran, Kevin L.
• Primary Examiner(s): Paschall, Mark H.
• Application Number:
  US07/405,626
• Time in Patent Office: 949 Days
• Field of Search: 219/211, 219/212, 219/494, 219/497, 219/499, 219/501, 219/505, 219/508-509, 2/69, 2/81, 2/2
• US Class Current: 219/497
• CPC Class Codes: G05D 23/1934 each space being provided with one sensor acting on one or more control means
• CPC Class Codes: G05D 23/2401 using a heating element as a sensing element
• 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 microcomputer-based, closed-loop electronic temperature control system and method for an electrically heated cold weather garment having a plurality of independently heated zones. In one preferred embodiment the system comprises a potentiometer for selecting the desired temperature at which a plurality of areas of the garment are to be maintained, a thermistor for determining a reference temperature of the interior areas of the garment, and a plurality of conductive heating wires operable to heat each area of the garment independently. The system further includes a plurality of solid-state semiconductor power devices for controllably allowing current flow through each heating wire and, a plurality of current sensing circuits for sensing the current flow through each heating wire. The microcomputer receives information from the potentiometer, the thermistor and the current sensing circuits, and determines therefrom the level of heating required for each zone. The microcomputer then generates and applies a plurality of pulse width modulated output signals to the solid-state switches to thereby control the amount of heat produced by each heating wire, thus controlling the temperature of each zone.

Claims

1. A portable, wearable electronic temperature control system for an electrically heated garment having at least first and second independent heating zones, with each such zone being provided with at least one heating element, the system comprising:

means for selecting a desired temperature level to be maintained within the first and second independent heating zones;

means for sensing substantially simultaneously actual temperature levels within each of the independent heating zones;

a plurality of means for electronically switching on and off independently and substantially simultaneously the independent heating zones of the electrically heated garment;

electronic means, receiving information from the temperature select means and temperature level sensing means, for controlling each of the switching means independently, whereby the desired temperature level selected via the temperature select means is independently achieved for each heating zone; and

wearable enclosure means for housing at least the plurality of switching means and the means for controlling each of the switching means;

the temperature control system being sufficiently light in weight to be readily portable and wearable by a person wearing the electrically heated garment.

2. The system of claim 1, wherein the means for sensing actual temperature levels includes a plurality of means for sensing current flowing through the heating elements.

4. The system of claim 1, wherein:

the plurality of means for electronically switching on and off the heating zones include a plurality of solid-state power switching devices, with one such switching device being provided for each zone; and

the means for controlling includes a microcomputer for generating substantially simultaneously a plurality of independently controlled pulse width modulated signals, with one such signal being provided to each of the solid-state power switching devices.

3. The system of claim 3, wherein the temperature level sensing means further includes means for detecting the voltage applied across the heating elements of the heating zones.

5. A portable, wearable electronic control system for regulating temperature within a plurality of discrete zones of an electrically heated garment for a person engaged in cold weather activities, with each such zone being provided with at least one heating element, the system comprising:

solid-state electronic means, having first, second and third inputs and a first output, for automatically controlling the operation of the control system;

means for selecting a desired temperature at which the zones of the garment are to be maintained and for providing information related thereto to the first input of the means for automatically controlling;

means for sensing an ambient temperature level associated with a particular location near the garment and providing information related thereto to the second input of the control means;

a plurality of independently controlled electronic on-off switching devices, with each such device being for independently enabling and disabling current flowing through a respective one of the heating elements to change selectively and controllably the temperature within the zone associated with such heating element by changing a duty cycle of the current flowing through such heating element;

means for sensing sequentially at predetermined intervals of time the current flowing through the heating element of each respective zone for providing information related thereto to the third input of the means for automatically controlling, and

wearable enclosure means for housing at least the plurality of switching means and the means for controlling each of the switching means,

the temperature control system being light in weight, portable and wearable by a person wearing the undergarment assembly, and

the means for automatically controlling having means for high speed timing and means for outputting in parallel a plurality of timed digital control signals for selectively enabling and disabling the plurality of switching devices, to regulate independently the current flowing through each such heating element, and thereby regulate closely the temperature of each zone of the garment.

6. The system of claim 5, wherein the automatic control means is a programmed microcomputer.

7. The system of claim 5, wherein the temperature selection means includes a potentiometer, and the ambient temperature level sensing means is a thermistor.

8. The system of claim 5, further comprising a plurality of reactive heating elements formed of electrically conductive wires, each having a predetermined conductivity at a given temperature.

9. The system of claim 8, wherein the resistive heating elements are formed from multi-stranded electrically conductive wire being at least 98% pure copper.

10. The system of claim 5, wherein each of the current sensing means includes a shunt resistor used to sense current, and means for measuring voltage across such shunt resistor.

11. The system of claim 5, wherein each of the switching devices includes a power MOSFET having relatively high conductance when rendered fully conducting, thereby minimizing heating losses within the MOSFET.

12. An electronic temperature control system and electrically heated undergarment assembly for a cold weather garment having a plurality of separately heatable zones, the system comprising:

a lightweight, form-fitting undergarment assembly including a plurality of separately heatable zones and a plurality of independently controllable heating means, at least one such heating means being disposed in each such zone of the undergarment assembly, each such heating means being operable to generate heat in response to a current flowing therethrough;

means for sensing the temperature level of each of the heating means;

a plurality of independently controllable electronic switching means, each switching means being associated with a particular one of the heating means and operable to selectively enable and disable the current flowing therethrough; and

control means, receiving information form at least the means for sensing temperature level, for selectively applying a plurality of independent signals at least in partial response to the received information to operate the plurality of electronic switching means, thereby controllably enabling and disabling the current flow through each heating means, and thereby selectively heating each zone of the garment independently of the others; and

wearable enclosure means for housing at least the plurality of switching means and the means for controlling each of the switching means;

the temperature control system being light in weight, portable and wearable by a person wearing the undergarment assembly.

13. The system of claim 12, further comprising power supply means for providing DC electrical power of no more than about 24 volts across each of the switching means.

14. The system of claim 13, further comprising means for measuring the level of DC voltage provided by the power supply means.

15. The system of claim 12, wherein the means for sensing temperature includes a reference temperature sensing device.

16. The system of claim 12, wherein each of the means for sensing temperature includes a plurality of current sensing means, with each such current sensing means including a resistance device through which the current to be sensed flows.

17. The system of claim 16, wherein the control means is based around a microprocessor, and includes a plurality of analog-to-digital converters for transforming analog signals indicative of sensed currents to digital signals.

18. The system of claim 12, wherein:

the control means includes means forms part of the means for sensing temperature, and means for measuring the level of DC voltage applied to the control system from a power source; and

the means for sensing temperature further includes a plurality of precision resistance devices, with at least one such resistance device associated with each zone, for respectively facilitating measurement of the magnitude of current flowing through such zone;

whereby the electrical power dissipated at each such zone can be calculated in accordance with Ohm'"'"'s Law.

19. The system of claim 12, wherein each said heating means includes an electrically conductive insulated wire element including multiple highly flexible conductors.

20. The system of claim 12, wherein the independent signals from the control means are pulse width modulated signals.

21. An electronic temperature control system for a cold weather garment having a plurality of discrete, independently heated areas, the system comprising:

temperature level selecting means for selecting a desired temperature at which each independently heated area of the garment is to be maintained;

thermistor means for sensing a representative ambient temperature that the garment is exposed to;

a plurality of independent heating means operable to generate heat in response to current flowing therethrough;

a plurality of independent current sensing means for sensing the current flowing through each of the heating means;

a plurality of solid-state switching means for independently enabling the current flowing through each said heating means;

reference means for providing a reference signal indicative of the voltage being applied to a particular said heating means at a given time; and

microcomputer means, receiving information from the temperature selection means, the thermistor means, each said current sensing means, and the reference means, for producing a plurality of pulse width modulated (PWM) signals, for controlling the switching means, whereby each of said switching means is operated independently, to control the average current flowing through each said heating means and the heat generated thereby.

22. The system of claim 21, wherein the temperature level selection means includes a potentiometer.

23. The system of claim 21, wherein the PWM signals are repetitively generated and each have a frequency of at least about five hertz when enabled.

24. The system of claim 21, wherein each heating means is an electrically conductive multi-stranded wire having an over-all gauge in the range of about 20 AWG to about 35 AWG.

25. The system of claim 21, wherein each current sensing means comprises a precision resistor used for current sensing and an amplifier for amplifying a signal obtained using the precision resistor.

26. The system of claim 21, wherein each switching means is a power MOSFET device.

27. The system of claim 21, wherein the reference means provides a voltage whose amplitude corresponds to the maximum nominal voltage applied to each heating means when such heating means has current passing therethrough.

28. A method for electronically regulating independently the temperatures of a plurality of discrete zones of an electrically heated garment for a person engaged in cold-weather activities, each such zone having at least one heating element, the method comprising the steps of:

selecting, for each such zone, a desired temperature level at which the zone is to be maintained;

sensing an actual temperature level in each zone by monitoring electrical current associated with at least one heating element in each of the zones;

determining, using the sensed electrical current, an actual temperature level of each such zone; and

regulating independently the temperature level of each such zone in accordance with the selected temperature level by independently providing to the heating element or elements of each such zone a selected amount of electrical power.

29. The method of claim 28, wherein a microprocessor is used to regulate the temperatures of the zones in a substantially simultaneous manner.

30. The method of claim 28, further comprising the step of generating a plurality of independent pulse width modulated signals to control the temperatures of the heating elements, and thereby control the temperatures of the zones in an independent fashion.

31. The method of claim 28, wherein the steps of sensing and determining an actual temperature level in each such discrete zone of the electrically heated garment uses Ohm'"'"'s Law temperature dependance of resistance, and substeps including:

determining a voltage applied to a resistive heating element disposed in each such zone;

measuring current flowing through the resistive heating element in each such zone;

using Ohm'"'"'s Law to calculate a resistance of the resistive heating element of each such zone from the determined voltage applied to, and the measured current flowing through, the resistive heating element; and

using the calculated resistance of the resistive heating element of each such zone to determine an associated, relative temperature level of the resistive heating element, and thus a relative temperature level of the zone within which the resistive heating element is disposed.

32. A method for regulating temperatures within a plurality of independent heating zones of a cold weather garment, the method comprising:

(a) providing a microprocessor having a plurality of inputs;

(b) using a plurality of wearer adjustable potentiometers to provide a plurality of first input signals to a plurality of first inputs of the microprocessor, the first input signals each being representative of a desired temperature level at which each zone of the garment is to be maintained;

(c) applying a plurality of first voltages to first sides of a corresponding plurality of electrically conductive elements, the elements each being operable to generate heat in response to current flowing therethrough;

(d) applying a second voltage corresponding to the first voltages to a second input of the microprocessor;

(d) using a plurality of current sensing resistors, each such resistor being associated with a particular one of the conductive elements, to provide a corresponding plurality of third input signals to inputs of the microprocessor representative of the current flowing through each such resistor;

(f) using a plurality of solid-state semiconductor switching devices, each such switching device being associated with a particular current sensing resistor and operable to interrupt the current flowing through the conductive element associated with the particular sensing resistor;

(g) using the microprocessor to determine an actual current flowing through each conductive element at a given time;

(h) using the microprocessor to determine an actual voltage being applied to the first side of each conductive element at a given time;

(i) using the microprocessor to determine, form the actual voltages being applied to and the actual currents flowing through each such conductive element, an actual resistance of each such conductive element at a given time;

(j) using the microprocessor to determine, at least in part from the actual resistances of each such conductive element, the actual temperature value of each zone at a given time;

(k) using the microprocessor to determine, from the actual temperature values of the zones, a plurality of pulse width modulated signals, with each pulse width modulated signal being associated with a particular conductive element of a particular zone, and operable to help force the actual temperature value of the particular zone toward the temperature level indicated by the input signal form the potentiometer associated with such zone; and

(l) applying the pulse width modulated signals to the solid-state switching devices, thereby selectively switching the switching devices rapidly between a conducting state and a non-conducting state, thereby controlling the respective temperatures of the individual zones in accordance with the temperature levels indicated by their respective potentiometers.