Flat heating element

• US 7,838,804 B2
• Filed: 05/07/2007
• Issued: 11/23/2010
• Est. Priority Date: 05/08/2006
• Status: Expired due to Fees

• Current Assignee: Gentherm GmbH (Gentherm Incorporated)
• Original Assignee: Wet Automotive Systems AG (Gentherm Incorporated)
• Inventors: Krobok, Martin
• Primary Examiner(s): FUQUA, SHAWNTINA T
• Application Number:
  US11/800,669
• Publication Number:
  US 20070257027A1
• Time in Patent Office: 1,296 Days
• Field of Search: 219528- 9, 219211- 2, 219552- 3, 219 48- 9, 219/545, 219/538, 219/202, 219/217, 165/158
• US Class Current: 219/549
• CPC Class Codes: H05B 2203/003 using serpentine 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 2203/014 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 2203/029 Heaters specially adapted for seat warmers
• CPC Class Codes: H05B 3/34 flexible, e.g. heating nets or webs

Abstract

The present invention pertains to an electric heating element with at least one flat heating resistor to be arranged near a surface to be heated, and at least one electrode that serves to feed a current into the heating resistor and features at least two contact conductor strands that are, at least locally, connected to one another and to the heating resistor, at least in an elongated contacting region. The invention proposes that at least at one location along the electrode and/or the contacting region at which at least one of the contact conductor strands, at least locally, extends parallel to the direction of the electrode, and/or the contacting region, at least one additional contact conductor strand, at least locally, extends at an angle thereto.

Claims

1. An electric heating element comprising:

a. at least one flat heating resistor for disposed near a surface to be heated; and

b. at least one electrode for feeding a current into the flat heating resistor, the at least one electrode comprising

at least two contact conductor strands including

an elongated contacting region;

wherein, within the elongated contacting region of the electrode feeds a current into the flat heating resistor, wherein the at least two of the contact conductor strands are at least locally in contact to one another and to the heating resistor, and wherein further at least one point at least one of the contact conductor strands at least locally extends directionally generally parallel to the direction of the electrode and at least one other contact conductor strand at least locally extends angular to the direction of the electrode or of the elongated contacting region or both.

2. The electric heating element as in claim 1 wherein at least two contact conductor strands, at least in some sections, extend in a non-linear manner.

3. The electric heating element as in claim 1 wherein at least two contact conductor strands extend in a periodic oscillation fashion with the same oscillation pattern, wherein the individual contact conductor strands are separated by a phase-shift relative to their longitudinal direction.

4. The electric heating element as in claim 1 wherein the at least one of the flat heating resistors is comprised at least partially of an electrically conductive material and at least one of the flat heating resistors comprises at least partially an electrical resistance material or electrically insulating material.

5. The electric heating element as in claim 1 wherein at least one contact conductor strand at least partially is made of a metallic wire.

6. The electric heating element as in claim 1 wherein the electric heating element is contained in a seat.

7. The electric heating element as in claim 1 wherein the at least one electric heating element is in a vehicle.

8. The electric heating element as in claim 4 wherein the electrically conductive material further comprises at least one material selected from the group consisting of carbon fibers, metal foil, metallized, foil and metallized plastic fibers.

9. The electric heating element as in claim 4 wherein the electrically insulating material further comprises at least one material selected from the group consisting of knitted fabric, non-woven fabric, natural fibers and man-made fibers.

10. The electric heating element as in claim 5 wherein the metallic wire further comprises at least one material selected from the group consisting of silver-plated cooper, stainless steel, electrically conductive coated plastic and silver coated plastic.

11. An automotive vehicle having at least one seat that is heated by an electric heating element comprising:

a. a flat carrier;

b. at least one electrode comprising a conductor network arranged on the flat carrier, including at least two contact conductor strand bundles that are generally curved and generally parallel to each another but phase shifted relative to each other such that they contact one another in at least one contact point, such that in the event of local failure, heating current can be distributed to adjacent heating conductors contacting the conductor network; and

c. at least one connecting line associated with the carrier for supplying a current from a current source to the conductor network.

12. The vehicle of claim 11, wherein the strand bundles contain between 10 and 70 individual strands.

13. The vehicle of claim 12, wherein the individual strands include a coating of a nonoxidizing or passivated metal.

14. The vehicle of claim 13, wherein the individual strands consist of copper or a copper alloy and is at least partly provided with a coating of silver or a silver alloy.

15. An electric heating element comprising:

a. a non-woven flat carrier;

b. at least one electrode comprising a conductor network stitched on the flat carrier, including at least two contact conductor strand bundles that have a generally sinusoidal contour and generally parallel to each another but phase shifted relative to each other at regular spacings such that they contact one another in at least one contact point, such that in the event of local failure, heating current can be distributed to adjacent heating conductors contacting the conductor network; and

c. at least one connecting line associated with the carrier for supplying a current from a current source to the conductor network.

16. The electric heating element of claim 15, wherein the strand bundles contain between 10 and 70 individual strands.

17. The electric heating element of claim 16, wherein the individual strands include a coating of a nonoxidizing or passivated metal.

18. The electric heating element of claim 17, wherein the individual strands consist of copper or a copper alloy and is at least partly provided with a coating of silver or a silver alloy.