Soft heating element and method of its electrical termination

• US 6,403,935 B2
• Filed: 02/27/2001
• Issued: 06/11/2002
• Est. Priority Date: 05/11/1999
• Status: Active Grant

• Current Assignee: Thermosoft International Corporation
• Original Assignee: Thermosoft International Corporation
• Inventors: Lavit, Mikhail, Kochman, Dmitry, Kochman, Arkady
• Primary Examiner(s): Hoang, Tu Ba
• Application Number:
  US09/793,485
• Publication Number:
  US 20010025846A1
• Time in Patent Office: 469 Days
• Field of Search: 219/529, 219/544-549, 219/212, 338/208, 338/210, 338/211, 338/275, 338/262, 338/258, 338/259
• US Class Current: 219/545
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/76 with sockets, clips or analogous contacts and secured to apparatus or structure, e.g. to a wall
• CPC Class Codes: H01R 4/14 by wrapping
• CPC Class Codes: H01R 4/20 using a crimping sleeve H01R4/01 takes precedence
• CPC Class Codes: H01R 4/5016 using a cone
• CPC Class Codes: H01R 9/03 Connectors arranged to contact a plurality of the conductors of a multiconductor cable , e.g. tapping connections
• CPC Class Codes: H02H 5/043 the temperature dependent resistor being disposed parallel to a heating wire, e.g. in a heating blanket
• 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 2203/011 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 2203/036 Heaters specially adapted for garment heating
• CPC Class Codes: H05B 3/34 flexible, e.g. heating nets or webs
• CPC Class Codes: H05B 3/342 heaters used in textiles
• CPC Class Codes: H05B 3/56 : Heating cables
• CPC Class Codes: H05B 3/58 : Heating hoses; Heating collars

Abstract

A soft heating element, utilizing electro conductive textile threads as a heating means having additional safety functions as TCO (thermal cut-off) and TSL (temperature self-limiting) devices. The thermal cut-off function is achieved through melting of the electro conductive threads at the temperatures above 120° C. and below 350° C., which results in termination of electrical continuity in the heating element. The temperature self-limiting capability is achieved through a heating thread electrical resistance increase during slow elevation in its temperature, which is below its melting point. Methods of electrical and mechanical connection between heating threads and metal conductors, utilizing winding of connections with flexible strands of fibers or wires, with optional subsequent placement of a rigid mechanical fastener over the winding. Method of providing electrical redundancy of heating circuits by stitching, laminating, weaving or knitting an electrically conductive thread across the multiple runs of the heating thread.

Claims

1. A soft and flexible heating element having a durable construction for incorporation into a plurality of articles, said heating element comprising:

a conductive textile comprising at least one electrically conductive heating textile thread as temperature self limiting heating means;

said at least one heating textile thread, melts at the temperatures above 120°

C. and below 350°

C., which terminates electrical continuity in said temperature self limiting heating means.

2. The soft heating element according to claim 1, further including electrically redundant means for providing redundant electrical circuits in said heating element.

3. The soft heating element according to claim 2, wherein said electrically redundant means comprise electrically conductive textile threads bridging electrical circuits between said at least one heating textile thread in said heating element.

4. The heating element according to claim 1, further comprising an electrical connection comprising at least one flexible strand, wound around a bundle, made by joining of said at least one heating textile thread with at least one metal containing conductor means.

5. The heating element according to claim 4, wherein said flexible strand comprises nonconductive textile fiber thread.

6. The heating element according to claim 4, wherein said flexible strand comprises electrically conductive textile fiber thread.

7. The heating element according to claim 4, wherein said flexible strand comprises metal wire.

8. The heating element according to claim 4, wherein said flexible strand comprises monofilament polymer strand.

9. The heating element according to claim 4, further including fastening means, placed around said electrical connection to enhance mechanical and electrical connection in said bundle.

10. The heating element according to claim 1, further comprising at least one temperature sensing discrete device, attached to the surface of said heating element in the location of enhanced heating.

11. The heating element according to claim 10, wherein said location of enhanced heating comprises plastic housing.

12. The heating element according to claim 1, further comprising at least one electrical connector box to enable quick disconnection of electrical continuity in said heating element, providing that the at least one cavity cross section of said connector box narrows down from the opening of said cavity cross section to the location of the inside base of said cavity cross section of the connector box.

20. A method for providing reliable mechanical and electrical termination of the soft heating element according to claim 1, said method comprising the steps of:

joining at least one uninsulated current carrying conductor and said electrically conductive heating textile thread together into at least one bundle;

winding at least one flexible strand around said at least one bundle to provide reliable mechanical and electrical connection between said electrically conductive heating textile threads and said at least one current carrying conductor.

21. The method for providing reliable mechanical and electrical termination of said soft heating element according to claim 20, wherein said at least one flexible strand comprises nonconductive textile fiber thread.

22. The method for providing reliable mechanical and electrical termination of said soft heating element according to claim 20, wherein said at least one flexible strand comprises electrically conductive textile fiber thread.

23. The method for providing reliable mechanical and electrical termination of said soft heating element according to claim 20, wherein said at least one flexible strand comprises metal wire.

24. The method for providing reliable mechanical and electrical termination of said soft heating element according to claim 20, wherein said at least one flexible strand comprises polymer monofilament strand.

25. The method for providing reliable mechanical and electrical termination of said soft heating element according to claim 20, further including step of placing a fastening means around said at least one bundle.

26. A method of joining electrode fastening means with the soft heating element recited in claim 1, said method comprising the steps of:

inserting uninsulated ends of said at least one electrically conductive thread into electrode fastening means having a hollow interior;

joining said electrode fastening means with at least one additional electrode fastening means having another hollow interior, so that said at least one electrically conductive thread are disposed between surfaces of at least two of said electrode fastening means.

crimping of said electrode fastening means to provide reliable mechanical and electrical contact between said electrically conductive threads and said electrode fastening means.

27. The method of joining electrode fastening means with soft heating element according to claim 26, wherein at least one surface of said electrode fastening means is electrically conductive.

28. The method of joining electrode fastening means with soft heating element according to claim 26, wherein at least one said electrode fastening means comprises plastic material.

29. The method of joining electrode fastening means with soft heating element according to claim 26, wherein said step of joining of said electrode fastening means with at least one additional electrode fastening means, having hollow interior, comprises step of folding of said uninsulated ends of electrically conductive threads to an angle of at least 90°

after insertion them into said electrode fastening means.

13. A flexible heating element having a durable construction for incorporation into a plurality of articles, said heating element comprising:

at least one flexible bus electrode conductor comprising at least one electrically conductive temperature self limiting textile thread as conductive means;

said at least one electrically conductive textile thread melts at the temperatures above 120°

C. and below 350°

C., which terminates electrical continuity in said bus electrode conductor.

14. The flexible heating element according to claim 13 further comprising electrical connection comprising at least one flexible strand wound around said bus conductor and at least one metal containing conductor to provide reliable electrical and mechanical connection between said bus electrode conductor and said at least one metal containing conductor.

15. The heating element according to claim 14, wherein said at least one flexible strand comprises nonconductive textile fiber thread.

16. The heating element according to claim 14, wherein said at least one flexible strand comprises electrically conductive textile fiber thread.

17. The heating element according to claim 14, wherein said at least one flexible strand comprises metal wire.

18. The heating element according to claim 14, wherein said at least one flexible strand comprises monofilament polymer strand.

19. The flexible heating element according to claim 14, further including fastening means, placed around said electrical connection to enhance its mechanical and electrical properties.