Electric blanket and control

• US 6,222,162 B1
• Filed: 09/30/1999
• Issued: 04/24/2001
• Est. Priority Date: 06/03/1999
• Status: Expired due to Term

• Current Assignee: E & E Company Limited
• Original Assignee: Barry P. Keane
• Inventors: Keane, Barry P.
• Primary Examiner(s): PASCHALL, MARK H
• Application Number:
  US09/410,475
• Time in Patent Office: 572 Days
• Field of Search: 219/501, 219/212, 219/502, 219/497, 219/494, 219/507-508, 219/504, 307/117, 323/235, 323/236
• 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 2203/017 Manufacturing methods or apparatus for heaters
• 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

An electric blanket includes a heating element extending through the blanket so that, upon receiving electric current from a power source, the element heats the blanket. A regulator circuit is connected to the element. It is configured to measure the resistance of the element and to control delivery of the electric current from the power source to the element responsively to the resistance so that the element heats to a desired temperature.

Claims

1. An electric blanket, said blanket comprising:

a heating element extending through said blanket so that, upon receiving electric current from a power source, said element heats said blanket;

a resistive element having a resistance (R1) and being disposed electrically in series between said power source and said heating element;

a full-wave rectifier disposed between said power source and said heating element so that said rectifier fully rectifies said current applied to said heating element; and

a regulator circuit connected to said heating element, said regulator circuit including a processor in communication with said power source and said resistive element and configured to measure a voltage drop (V1) across said power source and a voltage drop (V2) across said resistive element, wherein said processor is configured to

divide V2 by R1, thereby determining a current (I)through said heating element,

divide V1 by I, thereby determining a resistance (R2) having a known relationship to the resistance of said heating element,

control delivery of said electric current from said power source to said heating element responsively to R2 so that said heating element heats to a desired temperature, and

discontinue delivery of said electric current from said power source to said heating element when I exceeds a predetermined threshold.

2. The blanket as in claim 1, wherein said heating element is a wire wound about a core and surrounded by an insulating sheath.

3. The blanket as in claim 1, wherein said heating element is a wire having a generally circular cross-section.

4. The blanket as in claim 3, wherein said wire is at least thirty gauge.

5. The blanket as in claim 3, wherein said wire is approximately 37 gauge.

6. The blanket as in claim 1, wherein said heating element is a wire having a polygonal cross-section.

7. The blanket as in claim 1, wherein said heating element is a wire having a thermal coefficient of at least approximately 0.194%/°

F.

8. The blanket as in claim 1, wherein said regulator circuit includes

a connection circuit configured to connect said heating element to a power source, and

a control circuit in operative communication with said connection circuit and said heating element, said control circuit configured to selectively connect said heating element to said power source through said connection circuit responsively to R2.

9. The blanket as in claim 8, wherein said connection circuit includes a first triac operatively in line between said heating element and a connection to said power source and wherein said control circuit drives a control input to said first triac.

10. The blanket as in claim 9, wherein said regulator circuit includes an optically isolated triac operatively between said control input to said first triac and a signal line in said connection circuit between said power source connection and said heating element and wherein said control circuit drives a control input to said optically isolated triac, thereby driving said control input to said first triac.

11. The blanket as in claim 8, wherein said control circuit is configured to alternatingly connect and disconnect said heating element from said power source to maintain said desired temperature.

12. The blanket as in claim 11, wherein said control circuit is configured to connect said heating element from said power source during a predetermined phase of an alternating current signal on said connection circuit.

13. The blanket as in claim 8, wherein said regulator circuit is configured to electrically disconnect said heating element from said power source upon detection of said resistance above a predetermined level.

14. The blanket as in claim 8, wherein said regulator circuit is configured to electrically disconnect said element from said power source upon detection of said resistance below a predetermined level.

15. The blanket as in claim 13, wherein said regulator circuit is configured to electrically connect said heating element to said power source after a predetermined period following said detection.

16. The blanket as in claim 12, wherein said regulator circuit is configured to electrically disconnect said heating element from said power source upon detection of said resistance above a predetermined level.

17. An electric blanket, said blanket comprising:

a heating element wire wound about a core and extending through said blanket so that, upon receiving electric current from a power source, said heating element heats said blanket;

a first triac operatively in line between said heating element and a connection to a power source;

an optically isolated triac operatively between a control input to said first triac and a signal line between said power source connection and said heating element so that activation of said optically isolated triac activates said first triac to deliver electric current from said power source connection to said heating element;

a resistive element having a resistance (R1) and being disposed electrically in series between said power source and said heating element;

a full-wave rectifier disposed between said power source and said heating element so that said rectifier fully rectifies said current applied to said heating element; and

a processor in communication with said power source and said resistive element and configured to measure a voltage drop (V1) across said power source and a voltage drop (V2) across said resistive element, wherein said processor is configured to

divide V2 by R1, thereby determining a current (I) through said heating element,

divide V1 by I, thereby determining a resistance (R2) having a known relationship to the resistance of said element, and

activate said optically isolated triac responsively to R2 so that said element heats to a desired temperature, and

discontinue delivery of said electric current from said power source to said element when I exceeds a predetermined threshold.

18. The blanket as in claim 17, wherein said processor is configured to alternatingly activate and deactivate said first triac to maintain said desired temperature.

19. The blanket as in claim 18, wherein said processor is configured to activate said first triac during a predetermined phase of an alternating current signal on a signal line between said power source connection and said heating element.

20. The blanket as in claim 17, wherein said processor is configured to deactivate said first triac upon detection of R2 above a predetermined level.

21. The blanket as in claim 17, wherein said processor is configured to deactivate said first triac upon detection of R2 below a predetermined level.

22. The blanket as in claim 20, wherein said processor is configured to activate said first triac after a predetermined period following said detection.

23. The blanket as in claim 19, wherein said processor is configured to deactivate said first triac upon detection of R2 above a predetermined level.

24. A method for heating an electric blanket, said method comprising the steps of:

providing a heating element extending through said blanket so that, upon receiving electric current from a power source, said heating element heats said blanket;

fully rectifying said current applied to said heating element;

measuring a voltage drop (V1) across said power source and a voltage drop (V2) across a resistive element in series between said power source and said heating element, wherein said resistive element has a known resistance (R1);

dividing V2 by R1, thereby determining a current (I) through said heating element;

dividing V1 by I, thereby determining a resistance (R2) having a known relationship to the resistance of said heating element;

controlling delivery of said electric current from said power source to said heating element responsively to R2 so that said heating element heats to a desired temperature; and

discontinuing delivery of said electric current from said power source to said heating element when I exceeds a predetermined threshold.

25. The method as in claim 24, wherein said controlling step includes alternatingly connecting and disconnecting said heating element from said power source to maintain said desired temperature.

26. The method as in claim 25, wherein said controlling step includes connecting said heating element from said power source during a predetermined phase of an alternating current signal for said power source.

27. The method as in claim 24, wherein said controlling step includes electrically disconnecting said heating element from said power source upon detection of R2 above a predetermined level.

28. The method as in claim 24, wherein said controlling step includes electrically disconnecting said heating element from said power source upon detection of R2 below a predetermined level.

29. The method as in claim 27, wherein said controlling step includes electrically connecting said heating element to said power source after a predetermined period following said detection.

30. The method as in claim 26, wherein said controlling step includes electrically disconnecting said heating element from said power source upon detection of R2 above a predetermined level.

31. An electric blanket, said blanket comprising:

a heating element extending through said blanket so that, upon receiving an alternating electric current from a power source, said element heats said blanket; and

a regulator circuit connected to said heating element, said regulator circuit configured to measure the resistance of said heating element and to control delivery of said electric current from said power source to said heating element responsively to said resistance so that said heating element heats to a desired temperature,

wherein said regulator circuit is configured to deliver said electric current to said heating element in at least one predetermined ratio of cycle on-time to cycle off-time, based on a predetermined scale, and

wherein said predetermined ratio is associated with said desired temperature and is less than one.

32. The blanket as in claim 31, wherein said regulator circuit is configured to selectively deliver said electric current to said heating element in any of a plurality of said ratios, and wherein each said ratio is associated with a said desired temperature different from said desired temperature associated with each other said ratio.

33. The blanket as in claim 31, wherein said predetermined scale is defined by a predetermined number of cycles of said current delivered to said heating element during a predetermined number of consecutive cycles of said current.

34. The blanket as in claim 33, wherein said predetermined number of cycles delivered to said heating element are consecutive.

36. An electric blanket, said blanket comprising:

a heating element extending through said blanket so that, upon receiving an alternating electric current from a power source, said element heats said blanket; and

a regulator circuit connected to said heating element, said regulator circuit including memory and being configured to

measure the resistance of said heating element,

determine a first temperature of said heating element corresponding to said resistance, and

control delivery of said electric current from said power source to said heating element responsively to said temperature so that said first temperature changes toward a desired temperature,

wherein said regulator circuit includes memory in which is stored a value corresponding to the length of said heating element, a value corresponding to a temperature coefficient of said heating element and a value corresponding to a rated resistance of said heating element, and wherein said regulator circuit is configured to calculate said first temperature based on said length, said temperature coefficient and said rated resistance.

35. The blanket as in claim 36, wherein said predetermined scale is defined by a predetermined phase during each cycle of said current during which said current is delivered to said heating element.

37. An electric blanket, said blanket comprising:

a heating element extending through said blanket so that, upon receiving an alternating electric current from a power source, said element heats said blanket; and

a regulator circuit connected to said heating element, said regulator circuit including memory and being configured to

measure the resistance of said heating element,

determine a first temperature of said heating element corresponding to said resistance; and

control delivery of said electric current from said power source to said heating element responsively to said temperature so that said first temperature changes toward a desired temperature,

wherein said regulator circuit includes memory in which is stored a plurality of tables, each table including a plurality of said first temperatures and a range of resistances respectively corresponding to said first temperatures,

wherein said ranges are non-overlapping and respectfully correspond to a plurality of different said heating elements, and

wherein said regulator circuit is configured to select said range within which said heating element resistance falls and to select one of said first temperatures corresponding to said selected range based on a comparison of said heating element resistance to said resistances within said selected range.

38. The blanket as in claim 37, wherein each said heating element resistance corresponds to a said first temperature based on the length of said heating element, the temperature coefficient of said heating element and the rated resistance of said heating element.