Configurable heating pad controller

• US 7,145,108 B2
• Filed: 07/22/2003
• Issued: 12/05/2006
• Est. Priority Date: 07/22/2003
• Status: Active Grant

• Current Assignee: Helen of Troy Limited
• Original Assignee: Kaz Incorporated (Helen of Troy Limited)
• Inventors: Kanel, Christopher S., Sherwood, Robert
• Primary Examiner(s): PASCHALL, MARK H
• Application Number:
  US10/625,472
• Publication Number:
  US 20050016989A1
• Time in Patent Office: 1,232 Days
• Field of Search: 219/212, 219/492, 219/497, 219/499, 219/501, 219/506, 219483-486, 307/117, 307 38- 41, 323/235, 323/236, 323/319
• US Class Current: 219/492
• CPC Class Codes: H05B 1/0272 For heating of fabrics
• 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

According to the present invention, a heating pad controller incorporating a discrete ASIC (Application Specific Integrated Circuit) is provided which varies the duty cycle characteristics of a periodic signal during which power is applied to a heating pad heating element during a portion of the signal (“on” time). An oscillator circuit is used to produce a controlled duty cycle control signal for controlling the power applied to the heating pad by varying the on-time of the duty cycle. User control of the length of the on-time of the duty cycle is provided by way of a user controlled switch, thereby providing for a plurality of controller operating modes (e.g., WARM, LOW, MEDIUM, HIGH, etc.). To configure the duty cycle for each heat setting the heating pad controller utilizes switchable electrical components of varying impedance connected to the ASIC. A heating pad controller according to the present invention can be configured for use with heating pads of varying sizes simply by installing electrical components with the appropriate impedance during manufacture of the circuit board.

Claims

1. A controller for a heating device for controllably applying power to a heating device and controlling the heating device temperature by varying the duty cycle characteristics of a periodic control signal, comprising:

an oscillator circuit operable to output a frequency signal;

a counter connected to the oscillator circuit operable to count oscillations of the frequency signal and output a periodic control signal based on said frequency signal;

a power supply circuit including a switch to thereby energize and de-energize said heating device;

an actuating circuit controlling said switch, said actuating circuit controlled by said periodic control signal, wherein said actuating circuit is operable to control said switch to energize said heating device during a portion of said periodic control signal;

a user controlled temperature adjustment circuit connected to the oscillator circuit, including means for varying the frequency of said frequency signal, whereby said periodic control signal is varied to thereby vary the heating device temperature, wherein said means for varying the frequency includes means for varying an impedance included in said oscillator; and

a plurality of LEDS connected to said user controlled temperature adjustment circuit wherein said LEDS provide a means for selecting available heating modes of said controller, such that said controller provides for at least one heat mode by detecting the presence of at least one of said plurality of LEDS, and deactivates a heat mode in response to the absence of said at least one of said plurality of LEDS.

2. A controller for a heating device for controllably applying power to a heating device and controlling the heating device temperature by varying the duty cycle characteristics of a periodic control signal, comprising:

an oscillator circuit operable to output a frequency signal;

a counter connected to the oscillator circuit operable to count oscillations of the frequency signal and output a periodic control signal based on said frequency signal, said periodic control signal including an on time signal portion and an off time signal portion;

a power supply circuit including a switch operable to energize and de-energize said heating device;

an actuating circuit controlling said switch, said actuating circuit controlled by said periodic control signal, wherein said actuating circuit is operable to control said switch to energize said heating device during said on-time signal portion and de-energize said heating device during said off-time signal portion;

a user controlled temperature adjustment circuit connected to the oscillator circuit, including means for adjusting the oscillator circuit to thereby vary the frequency of said frequency signal, whereby said on time signal portion and said off time signal portion are varied to thereby vary the heating device temperature; and

a plurality of LEDS connected to said user controlled temperature adjustment circuit wherein said LEDS provide a means for selecting available heating modes of said controller, such that said controller provides for at least one heat mode by detecting the presence of at least one of said plurality of LEDS, and deactivates a heat mode in response to the absence of said at least one of said plurality of LEDS.

3. A controller for a heating device for controllably applying power to a heating device and controlling the heating device temperature according to claim 2, further comprising:

a rapid heating control circuit constructed to control the switch means to energize said heating device for a predetermined time period upon activation of the controller by said user controlled temperature adjustment circuit to thereby rapidly increase the temperature of said heating device, whereby said rapid heating control circuit increases said signal on time by instructing said user controlled temperature adjustment circuit to vary the frequency of said frequency signal by varying an impedance included in said oscillator circuit.

9. A heating device temperature control apparatus according to claim 3, wherein the user controlled temperature adjustment circuit selectively operates using one of a plurality of switch modes.

10. A controller for a heating device for controllably applying power to a heating device and controlling the heating device temperature according to claim 9, wherein said switch modes comprise either a slide switch configuration or momentary pushbuttons.

11. A heating device temperature control apparatus according to claim 3, wherein the heating device temperature control apparatus is an ASIC.

12. A heating device temperature control apparatus according to claim 3, wherein the heating device comprises a heating pad.

4. A heating device temperature control apparatus for controlling the temperature of a heating device by applying electric power from a first power source to the heating device, comprising:

a first switch connected between the first power source and the heating device for switchably applying power to the heating device;

an oscillator circuit;

a second switch connected between a second power source and the oscillator circuit;

a counter connected to the oscillator circuit operable to count oscillations thereof and output an oscillation count value;

a control circuit connected to the counter and said first and second switches, said control circuit operable to control the first switch to thereby switchably connect the first power source to the heating device when the oscillation count value of the counter is below a predetermined count value and to disconnect the power source from the heating device when the oscillation count value reaches the predetermined count value;

said control circuit operable to control the second switch to thereby switchably connect the second power source to the oscillator circuit when a voltage associated with the oscillator circuit is below a predetermined voltage value and to disconnect the second power source from the oscillator circuit when the voltage reaches the predetermined voltage value, and to switchably reconnect the second power source to the oscillator circuit when the voltage reaches a second predetermined voltage value;

a user controlled temperature adjustment circuit connected to the oscillator circuit, including means for adjusting the oscillator circuit to vary a frequency of oscillation therein, thereby varying a time interval during which the oscillation count value of the counter is below the predetermined count value and in which the control circuit instructs the switch to connect the first power source to the heating device, wherein said means for adjusting the oscillator circuit includes means for varying an impedance included in said oscillator circuit; and

a plurality of LEDS connected to said user controlled temperature adjustment circuit wherein said LEDS provide a means for selecting available heating modes of said controller, such that said controller provides for at least one heat mode by detecting the presence of at least one of said plurality of LEDS, and deactivates a heat mode in response to the absence of said at least one of said plurality of LEDS.

5. A heating device temperature control apparatus according to claim 4, further comprising:

a rapid heating control circuit operable to control the first switch to connect the power source to the heating device for a predetermined time period upon activation of the controller by said user controlled temperature adjustment circuit to thereby rapidly increase the temperature of said heating device, whereby said user controlled temperature adjustment circuit selects at least one of a plurality of selectable impedances to thereby provide a lower frequency of oscillation output by said oscillator circuit and an increased time interval during which the oscillation count value of the counter is below the predetermined count value, and when said oscillation count value reaches the predetermined count value the control circuit instructs the first switch to continue to connect the first power source to the heating device and the temperature adjustment circuit de-selects said at least one of said plurality of selectable impedances and selects a second of said plurality of selectable impedances used to implement the selected heating mode, wherein said second of said plurality of selectable impedances provides a higher frequency of oscillation output by said oscillator circuit than said first.

6. A heating device temperature control apparatus according to claim 4, further comprising:

a second control circuit connected to said user controlled temperature adjustment circuit, constructed to output a second control signal indicative of whether an LED is connected to said user controlled temperature adjustment circuit for each of said heat modes; and

a monitoring circuit connected to said second control circuit which receives said second control signal and records whether an LED is connected to said user controlled temperature adjustment circuit for each of said heat modes, wherein said monitoring circuit controls said controller to allow the operation of said heat mode upon detection of said LED associated with said heat mode and to prevent the operation of the heat mode in response to the absence of said LED.

7. A heating device temperature control apparatus according to claim 6, wherein said second control circuit comprises a Schmidt trigger operable to sense a voltage across said LED and output a signal indicative of whether said at least one of said plurality of LEDs is connected to said user controlled temperature adjustment circuit.

8. A heating device temperature control apparatus according to claim 6, wherein said monitoring circuit comprises a skip latch operable to monitor said second control circuit and record whether at least one of said plurality of LEDs is connected to said user controlled temperature adjustment circuit.

13. A heating device temperature control apparatus according to claim 4, wherein the user controlled temperature adjustment circuit selectively operates using one of a plurality of switch modes.

14. A controller for a heating device for controllably applying power to a heating device and controlling the heating device temperature according to claim 13, wherein said switch modes comprise either a slide switch configuration or momentary pushbuttons.

15. A controller for a heating device for controllably applying power to a heating device and controlling the heating device temperature by varying the duty cycle characteristics of a periodic control signal, comprising:

an oscillator circuit operable to output a frequency signal;

a counter connected to the oscillator circuit operable to count oscillations of the frequency signal and output a periodic control signal based on said frequency signal;

a power supply circuit including a switch to thereby energize and de-energize said heating device;

an actuating circuit controlling said switch, said actuating circuit controlled by said periodic control signal, wherein said actuating circuit is operable to control said switch to energize said heating device during a portion of said periodic control signal;

a user controlled temperature adjustment circuit connected to the oscillator circuit, including means for varying the frequency of said frequency signal, whereby said periodic control signal is varied to thereby vary the heating device temperature, wherein said means for varying the frequency includes means for varying an impedance included in said oscillator circuit; and

said controller operable at a plurality of frequencies of a power supply.