Low voltage power supply system for an electric blanket or the like

• US 6,888,108 B2
• Filed: 10/11/2002
• Issued: 05/03/2005
• Est. Priority Date: 10/11/2002
• Status: Active Grant

• Current Assignee: Perfect Fit Industries, Inc. (Littlejohn & Company LLC)
• Original Assignee: Perfect Fit Industries, Inc. (Littlejohn & Company LLC)
• Inventors: Carr, Sheldon P.
• Primary Examiner(s): HAN, YOUNGHUIE JESSICA
• Application Number:
  US10/269,189
• Publication Number:
  US 20040070996A1
• Time in Patent Office: 935 Days
• Field of Search: 363/16, 363/20, 363/21.01, 363/21.02, 363/21.04, 363/21.07, 363 2108- 21018, 363/56.05, 363/56.08, 363/56.11, 363/40, 363/44, 363/56.12, 219/482, 219/483, 219/485, 219/486, 219/507, 219/508
• US Class Current: 219/483
• CPC Class Codes: H02J 9/007 Detection of the absence of a load
• CPC Class Codes: H02M 1/0032 Control circuits allowing low power mode operation, e.g. in standby mode
• CPC Class Codes: H02M 3/33523 with galvanic isolation between input and output of both the power stage and the feedback loop
• 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 2203/035 Electrical circuits used in resistive heating apparatus
• CPC Class Codes: H05B 3/342 heaters used in textiles
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes
• CPC Class Codes: Y02B 70/30 Systems integrating technologies related to power network operation and communication or information technologies for improving the carbon footprint of the management of residential or tertiary loads, i.e. smart grids as climate change mitigation technology in the buildings sector, including also the last stages of power distribution and the control, monitoring or operating management systems at local level
• CPC Class Codes: Y04S 20/20 End-user application control systems

Abstract

A power supply system for outputting low voltage electrical power from a high voltage power source includes an isolation-type power conversion device, such as a transformer having a primary high voltage side and an isolated secondary low voltage side. The low voltage side is interconnected with a power output arrangement, which is adapted to supply low voltage power to a load, which may be in the form of an electric blanket or the like. A switching arrangement is interconnected with the high voltage primary side of the power conversion device, for providing intermittent operation of the power conversion device. The period of intermittent operation of the power conversion device is controlled via a control arrangement, to vary the power output from the low voltage secondary side of the transformer and thereby to the electrical load. The control arrangement is preferably in the form of a pulse width modulation (PWM) control, which receives inputs from a controller that is powered from the isolated secondary low power output of the power conversion device via isolated primary and secondary circuits, to vary the duty cycle of the switching power conversion device. The power supply includes a burst logic circuit that provides high frequency intermittent operation of the power conversion device through the switching arrangement when the controller is off, to supply low voltage power to the controller which enables initial operation of the controller and thereby operation of the power conversion device. The low voltage output is interconnected with a load detection arrangement which disables the controller in the event the load is disconnected from the low voltage output. An over-voltage switch is also interconnected with the low voltage output, to shutdown the power supply in the event the voltage of power supplied to the low voltage output exceeds a predetermined low voltage threshold.

Claims

1. An electrically powered device, comprising:

a pliable heating member having a resistive heating element; and

a power supply for supplying power to the resistive heating element of the pliable heating member, comprising;

a power input arrangement adapted to receive input power having a high voltage exceeding a predetermined low voltage threshold;

an isolation-type power conversion device including an input and an isolated output, wherein the input is interconnected with the power input arrangement;

a switching arrangement interconnected with the power conversion device, wherein the switching arrangement is configured and arranged to provide continuous intermittent operation of the power conversion device; and

a low voltage power output arrangement interconnected with the isolated output of the power conversion device, wherein the low voltage power output arrangement is interconnected with the resistive heating element of the pliable heating member;

wherein the intermittent operation of the power conversion device by the switching arrangement is operable to supply continuous low voltage output power having a voltage below the low voltage threshold to the resistive heating element of the pliable heating member through the isolated output of the power conversion device and the low voltage power output arrangement.

2. The electrically powered device of claim 1, further comprising a controller for controlling operation of the switching arrangement to vary the low voltage power output of the power conversion device, wherein the controller is configured and arranged to control operation of the switching arrangement without interruption in the continuous supply of low voltage power to the resistive heating element from the power output arrangement.

3. The electrically powered device of claim 2, wherein the controller is interconnected with the power output arrangement so that the controller is powered by low voltage output power having a voltage below the low voltage threshold from the isolated output of the power conversion device.

4. The electrically powered device of claim 3, wherein the controller comprises a pulse width modulation control that provides variable duty cycle operation of the switching arrangement and thereby the low voltage power output of the power conversion device.

5. The electrically powered device of claim 4, wherein the pulse width modulation control includes a secondary isolated feedback circuit interconnected with the controller and a primary isolated feedback circuit interconnected with the switching arrangement, wherein the primary and secondary feedback circuits are isolated from each other and interact to control operation of the switching arrangement to vary the period of intermittent operation of the power conversion device and thereby the low voltage power output of the power conversion device.

6. The electrically powered device of claim 5, wherein the pulse width modulation control operates at a first frequency, and further comprising an override circuit that operates at a second frequency higher than the first frequency, wherein the override circuit interacts with the switching arrangement to operate the power conversion device so as to supply low voltage power to the controller when the controller is off, and wherein turning the controller on is operable to disable the override circuit and to initiate operation of the pulse width modulation control.

7. The electrically powered device of claim 3, wherein the power supply includes a primary side that receives high voltage power from the power input arrangement and which includes the switching arrangement, and a secondary side isolated from the primary side via the isolation-type power conversion device, wherein the secondary side further includes the low voltage power output arrangement and the controller, wherein the low voltage power output arrangement is interconnected with the resistive heating element via a removable connection of the resistive heating element to the low voltage power output arrangement, and further comprising a load detection circuit interconnected with the low voltage power output arrangement for enabling operation of the controller when the resistive heating element is connected and for disabling the controller when the resistive heating element is disconnected.

8. The electrically powered device of claim 1, further comprising a switch interconnected with the low voltage power output arrangement and configured to disable the power supply in the event the voltage of the low voltage power output arrangement exceeds the low voltage threshold.

9. An electrically operated heating arrangement, comprising:

a pliable heating member having a resistive load in the form of a resistive heating element;

a power supply to which the resistive heating element is connected, wherein the power supply includes a high voltage power input adapted to be supplied with power exceeding a predetermined low voltage threshold, a power conversion arrangement, and a low voltage power output that is supplied with power below the low voltage threshold from the power conversion arrangement, wherein the resistive heating element is connected to the low voltage power output and wherein the supply of low voltage power to the resistive heating element is operable to generate heat from the resistive heating element; and

a controller interconnected with the power supply to vary the low voltage power output and to thereby control the heat generated by the resistive heating element, wherein the controller is configured and arranged to control operation of the switching arrangement without interruption in the supply of low voltage power to the resistive heating element from the low voltage power output.

10. The heating arrangement of claim 9, wherein the power conversion arrangement includes a primary side supplied with power exceeding the low voltage threshold and an isolated secondary side that outputs power below the low voltage threshold.

11. The electrically operated heating arrangement of claim 10, wherein the controller is interconnected with and supplied with low voltage power from the isolated secondary side of the power conversion arrangement.

12. The electrically operated heating arrangement of claim 11, wherein the resistive heating element is interconnected with the low voltage power output via a removable connection arrangement, and further comprising a load detection circuit interconnected with the controller for enabling operation of the controller when the resistive heating element is connected to the low voltage power output and for disabling operation of the controller when the resistive heating element is disconnected from the low voltage power output.

13. The electrically operated heating arrangement of claim 10, further comprising a voltage detector interconnected with the secondary side of the power conversion arrangement, wherein the voltage detector is operable to discontinue operation of the power supply in the event the voltage of power to the secondary side of the power conversion arrangement exceeds the low voltage threshold.

14. The electrically operated heating arrangement of claim 13, wherein the voltage detector includes a timing arrangement that discontinues operation of the power supply when the voltage exceeds the predetermined threshold for a predetermined time period.

15. The electrically operated heating arrangement of claim 10, wherein the controller is interconnected with the secondary side of the power conversion arrangement, and further comprising a switching circuit interconnected with the primary side of the power conversion arrangement, wherein the switching circuit provides intermittent operation of the power conversion arrangement.

16. The electrically operated heating arrangement of claim 15, wherein the controller is electrically isolated from the switching circuit and is operable to control the switching circuit to vary the period of intermittent operation of the power conversion arrangement so as to vary the power output of the power conversion arrangement.

17. The electrically operated heating arrangement of claim 16, wherein the switching circuit comprises a pulse width modulation circuit and wherein the controller is operable to vary the duty cycle of the pulse width modulation circuit.

18. The electrically operated heating arrangement of claim 17, further comprising an override circuit that interacts with the switching circuit when the controller is off so as to supply low voltage power to the controller from the power conversion arrangement, wherein turning the controller on disables the override circuit.

19. A method of supplying low voltage output power to a resistive heating element of a pliable member from a high voltage power source, comprising the steps of:

supplying high voltage power from the high voltage power source to a high voltage power input associated with a power conversion device having a low voltage power output electrically isolated from the high voltage power input;

providing intermittent operation of the power conversion device to supply power to the low voltage output of the power conversion device;

supplying low voltage power from the low voltage power output of the power conversion device to the resistive heating element of the pliable member; and

controlling the intermittent operation of the power conversion device to vary the power supplied by the power conversion device to the low voltage output of the power conversion device, wherein the step of controlling intermittent operation of the power conversion device is carried out without disrupting the supply of low voltage power from the low voltage power output of the power conversion device.

20. The method of claim 19, wherein the step of providing intermittent operation of the power conversion device is carried out by operation of a power switch.

21. The method of claim 20, wherein the power switch is operated via a pulse width modulation arrangement, wherein the pulse width modulation arrangement is responsive to a controller which carries out the step of controlling the intermittent operation of the power conversion device through the pulse width modulation arrangement.

22. The method of claim 21, further comprising the step of supplying low voltage power to the controller from the low voltage output of the power conversion device.

23. The method of claim 22, further comprising the step of detecting the presence of the resistive heating element, and enabling operation of the controller in response to the presence of the resistive heating element and disabling the controller in response to the absence of the resistive heating element.

24. The method of claim 22, further comprising the step of providing low voltage power to the controller through the power conversion device to provide initial operation of the controller when the controller is placed in an on condition from an off condition.

25. The method of claim 24, wherein the pulse width modulation arrangement provides modulation of the power switch at a first frequency, and wherein the step of providing low voltage power to the controller is carried out by providing intermittent operation of the power switch at a second frequency, higher than the first frequency, to operate the power conversion device and to supply low voltage power to the controller.

26. The method of claim 20, further comprising the step of sensing current between the power switch and the power conversion device and enabling operation of the power switch in response thereto.

27. The method of claim 19, further comprising the steps of detecting the voltage of power supplied to the resistive heating element from the low voltage output of the power conversion device, and discontinuing the supply of power to the low voltage output of the power conversion device in response to detection of power to the resistive heating element exceeding a predetermined voltage threshold.

28. The method of claim 27, further comprising the step of delaying the discontinuance of the supply of power to the low voltage output for a predetermined time period so as to temporarily maintain the supply of power to the low voltage power output having a voltage exceeding the low voltage threshold.