Resettable safety circuit for PTC electric blankets and the like

• US 5,770,836 A
• Filed: 11/08/1996
• Issued: 06/23/1998
• Est. Priority Date: 11/08/1996
• Status: Expired due to Fees

• Current Assignee: Sunbeam Products, Inc. d/b/a Jarden Consumer Solutions (Newell Brands Inc.)
• Original Assignee: Micro Weiss Electronics
• Inventors: Weiss, John
• Primary Examiner(s): Paschall, Mark H.
• Application Number:
  US08/745,884
• Time in Patent Office: 592 Days
• Field of Search: 219/212, 219/481, 219/494, 219/505, 219/501, 219/506, 219/497, 219/488, 219/517, 323/235, 323/901, 307/117, 361/78, 361/87, 361/57
• US Class Current: 219/481
• CPC Class Codes: H05B 1/0272 For heating of fabrics
• CPC Class Codes: H05B 2203/014 Heaters using resistive wires or cables not provided for in H05B3/54
• CPC Class Codes: H05B 2203/02 Heaters using heating elements having a positive temperature coefficient
• CPC Class Codes: H05B 2203/035 Electrical circuits used in resistive heating apparatus
• CPC Class Codes: H05B 3/34 flexible, e.g. heating nets or webs

Abstract

A safety-assuring control device for an electric blanket which includes a PTC heater includes an integrated circuit microcontroller unit having first and second safety circuit inputs and an output connected to a control input of an electrically controlled heater switch. A neon tube is connected between the primary safety link return conductor of the heater and the first safety circuit input, to indicate whether there is a first type of fault in the PTC heater. A connection between the second safety circuit input and the secondary safety link return conductor of the PTC heater is provided which indicates whether there is a second type of fault in the heater. The microcontroller unit includes a preliminary fault detection circuit for supplying a limited power test signal in a test mode to the heater for a predetermined period of time prior to a full power operation of the heater. The microcontroller unit also includes a circuit for controlling operation of the microcontroller unit to terminate supply of current to the heater if at least one fault is detected by the microcontroller at least one of the first and second safety circuit inputs during the predetermined period of time, and for controlling operation of the microcontroller unit to supply current to the heater in the full power operation if no fault is detected during the predetermined period of time.

Claims

1. A safety-assuring control device for an electric alternating current appliance which includes a heater having first and second heater feed conductors, said first heater feed conductor being connected to a protective fuse and connectable therethrough to an ungrounded pole of a source of electric alternating current and said second heater feed conductor being connected to an electrically controllable heater switch and connectable therethrough to a grounded pole of said source of electric alternating current, said first and second heater feed conductors, at respective ends remote from said fuse and from said heater switch, being respectively connected to primary and secondary safety link return conductors which lead towards respective connections thereof in said control device, said primary safety link conductor being connected with said secondary safety link conductor, said control device comprising:

an integrated circuit microcontroller unit including;

a first safety circuit input,

a second safety circuit input, and

an output connected to a control input of said electrically controlled heater switch;

a safety circuit including;

at least one gas discharge current breakdown element connected between said primary safety link return conductor and said first safety circuit input, and producing;

a voltage drop when said at least one gas discharge current breakdown element conducts so as to produce, at said first safety input, a voltage clamped at a steady potential during half waves of one polarity of said alternating current of said alternating current source and at ground potential during half waves of another and opposite polarity of said alternating current, and

an open circuit when said at least one gas discharge current breakdown element fails to conduct such that an input signal is supplied to said first safety circuit input which indicates whether there is a first type of fault in said heater, and

a first connection between said second safety circuit input and said secondary safety link return conductor such that an input signal is supplied to said secondary safety circuit input which indicates whether there is a second type of fault in said heater; and

said microcontroller unit including;

preliminary fault detection means for supplying a limited power test signal in a test mode to said heater for a predetermined period of time prior to a full power operation of said heater, and

means for;

controlling operation of said microcontroller unit to terminate supply of current to said heater if at least one fault is detected by said microcontroller at least one of said first and second safety circuit inputs during said predetermined period of time, and

controlling operation of said microcontroller unit to supply current to said heater in said full power operation if no fault is detected during said predetermined period of time.

2. A safety-assuring control device according to claim 1, wherein, after said supply of current to said heater is terminated in said test mode, said control device can be reset to continue operation in said test mode.

3. A safety-assuring control device according to claim 1, wherein said microcontroller unit includes a fault counter for counting the number of successive faults that are detected, and means for controlling operation of said device in a safety mode after a predetermined number of successive faults have been detected by said microcontroller unit in said test mode, such that power is terminated to said heater in the safety mode.

4. A safety-assuring control device according to claim 3, wherein said predetermined number of successive faults is three.

5. A safety-assuring control device according to claim 3, wherein said microcontroller unit includes a failure counter for counting the number of times that said microcontroller unit controls operation of said device in said safety mode, and means for disabling said device to prevent immediate restarting thereof when the count in said failure counter reaches a predetermined number.

6. A safety-assuring control device according to claim 5, wherein said predetermined number of said failure counter is five.

7. A safety-assuring control device according to claim 1, wherein said predetermined period of time is 30 seconds.

8. A safety-assuring control device according to claim 1, wherein said limited power test signal has a 1/6 duty cycle with 10 continuous AC on cycles and 50 off cycles per second, lasting for said predetermined period of time of 30 seconds.

9. A safety-assuring control device according to claim 1, wherein said microcontroller unit includes:

full power fault detection means for detecting if there is at least one fault in response to input signals to at least one of said first and second safety circuit inputs during said full power operation, and

means for;

controlling operation of said microcontroller unit to terminate supply of current to said heater to stop full power being supplied thereto if at least one fault is detected, and

controlling operation of said microcontroller unit to supply current to said heater in said full power operation if no fault is detected.

10. A safety-assuring control device according to claim 9, wherein, after said supply of current to said heater is terminated during said full power operation, said control device can be reset to continue operation in said full power operation.

11. A safety-assuring control device according to claim 9, wherein said microcontroller unit includes fault counter for counting the number of successive faults that are detected, and means for controlling operation of said device in a safety mode after a predetermined number of successive faults have been detected by said microcontroller unit during said full power operation, such that power is terminated to said heater in said safety mode.

12. A safety-assuring control device according to claim 11, wherein said predetermined number of successive faults during said full power operation is three.

13. A safety-assuring control device according to claim 11, wherein said microcontroller unit includes a failure counter for counting the number of times that said microcontroller unit controls operation of said device in said safety mode, and means for disabling said device to prevent immediate restarting thereof when the count in said failure counter reaches a predetermined number.

14. A safety-assuring control device according to claim 13, wherein said predetermined number of said failure counter is five.

15. A safety-assuring control device according to claim 1, further comprising a source of electric direct current supplied at a steady potential;

and wherein said microcontroller unit includes an input for an alternating voltage derived from said source of electric alternating current and an input connected with said source of direct current.

16. A safety-assuring control device according to claim 15, further comprising a clamping diode pair connected between said at least one gas discharge current breakdown element and said first safety circuit input for clamping said first safety circuit input of said microcontroller unit to ground or to said potential of said source of direct current.

17. A safety-assuring control device according to claim 15, wherein said connection between said second safety circuit input and said secondary safety link return conductor of said safety circuit includes:

a resistive voltage divider connected between said secondary safety link return conductor and ground potential; and

a branch circuit connected between a tap of said resistive voltage divider and said second safety circuit input, said branch circuit including;

a load resistor connected between ground and said second safety circuit input, and

a transistor having a switched path with one terminal of said switched path interposed between said second safety circuit input of said microcontroller unit and said load resistor and another terminal of said switched path connected with said source of direct current.

18. A safety-assuring control device according to claim 15, further comprising a low current resistive path connected between said first and secondary safety link return conductors.

19. A safety-assuring control device according to claim 1, wherein the integrated circuit microcontroller includes a third safety circuit input, the control device further comprising:

a second connection between said third safety circuit input and said secondary safety link return conductor such that an input signal is supplied to said third safety circuit input which indicates whether there is a second type of fault in said heater.

20. A safety-assuring control device according to claim 19, further comprising a source of electric direct current supplied at a steady potential;

and wherein said microcontroller unit includes an input for an alternating voltage derived from said source of electric alternating current and an input connected with said source of direct current.

21. A safety-assuring control device according to claim 20, wherein said connection between said second safety circuit input and said secondary safety link return conductor of said safety circuit includes:

a resistive voltage divider connected between said secondary safety link return conductor and ground potential; and

a branch circuit connected between a tap of said resistive voltage divider and said second safety circuit input, said branch circuit including;

a load resistor connected between ground and said second safety circuit input, and

a transistor having a switched path with one terminal of said switched path interposed between said second safety circuit input of said microcontroller unit and said load resistor and another terminal of said switched path connected with said source of direct current.

22. A method for testing the safety of an electric alternating current appliance prior to full power operation thereof, said appliance including a heater having first and second heater feed conductors, said first heater feed conductor being connected to a protective fuse and connectable therethrough to an ungrounded pole of a source of electric alternating current and said second heater feed conductor being connected to an electrically controllable heater switch and connectable therethrough to a grounded pole of said source of electric alternating current, said first and second heater feed conductors, at respective ends remote from said fuse and from said heater switch, being respectively connected to primary and secondary safety link return conductors which lead towards respective connections thereof in said control device, said primary safety link conductor being connected with said secondary safety link conductor, said method comprising the steps of:

supplying a limited power test signal in a test mode to said heater for a predetermined period of time prior to a full power operation of said heater;

terminating supply of current to said heater if at least one fault is detected by said microcontroller at least one of said first and second safety circuit inputs during said predetermined period of time; and

supplying current to said heater in said full power operation if no fault is detected during said predetermined period of time.

23. A method according to claim 22, further comprising the step of resetting said control device to continue operation in said test mode after said supply of current to said heater is terminated in said test mode.

24. A method according to claim 22, further comprising the step of counting the number of successive faults that are detected, and controlling operation of said device in a safety mode after a predetermined number of successive faults have been detected in said test mode, such that power is terminated to said heater in the safety mode.

25. A method according to claim 24, wherein said predetermined number of successive faults is three.

26. A method according to claim 24, further comprising the step of counting the number of times that operation of said device enters said safety mode to provide a failure count, and disabling said device to prevent immediate restarting thereof when the failure count reaches a predetermined number.

27. A method according to claim 26, wherein said predetermined number of said failure counter is five.

28. A method according to claim 22, wherein said predetermined period of time is 30 seconds.

29. A method according to claim 22, wherein said limited power test signal has a 1/6 duty cycle with 10 continuous AC on cycles and 20 off cycles per second, lasting for said predetermined period of time of 30 seconds.

30. A method according to claim 22, further comprising the steps of:

detecting if there is at least one fault in response to input signals to at least one of said first and second safety circuit inputs during said full power operation;

controlling operation of said microcontroller unit to terminate supply of current to said heater to stop full power being supplied thereto if at least one fault is detected; and

controlling operation of said microcontroller unit to supply current to said heater in said full power operation if no fault is detected.

31. A method according to claim 30, further comprising the step of resetting said device to continue said full power operation after said supply of current to said heater is terminated during said full power operation.

32. A method according to claim 30, further comprising the steps of:

counting the number of successive faults that are detected, and

controlling operation of said de vice in a safety mode after a predetermined number of successive faults have been detected during said full power operation, such that power is terminated to said heater in said safety mode.

33. A method according to claim 32, wherein said predetermined number of successive faults during said full power operation is three.

34. A method according to claim 32, further comprising the steps of counting the number of times that said microcontroller unit controls operation of said device in said safety mode to provide a failure count, and disabling said device to prevent immediate restarting thereof when the failure count reaches a predetermined number.

35. A method according to claim 34, wherein said predetermined number of said failure counter is five.