Heater for an automotive vehicle and method of forming same

• US 8,507,831 B2
• Filed: 05/12/2010
• Issued: 08/13/2013
• Est. Priority Date: 11/21/2002
• Status: Active Grant

• Current Assignee: Gentherm GmbH (Gentherm Incorporated)
• Original Assignee: Wet Automotive Systems AG (Gentherm Incorporated)
• Inventors: Howick, Shaun Calvin, Bajic, Goran
• Primary Examiner(s): Yuen, Henry
• Assistant Examiner(s): NGUYEN, PHUONG T
• Application Number:
  US12/778,238
• Publication Number:
  US 20100219664A1
• Time in Patent Office: 1,189 Days
• Field of Search: 219/217, 219/212, 219/202, 219/211, 219/203, 219/219, 219/210, 219/529, 219/549, 219/543, 219/544, 219/545, 219/552, 219/528, 219/548, 219/345, 297/219.2, 297/225, 297/229, 297/228.1, 297/228.13
• US Class Current: 219/210
• CPC Class Codes: B60N 2/002 Seats provided with an occupancy detection means mounted therein or thereon detection means responsive to presence or absence of children B60N2/266
• CPC Class Codes: B60N 2/5678 characterised by electrical systems
• CPC Class Codes: B60N 2/5685 Resistance
• CPC Class Codes: B60R 1/12 Mirror assemblies combined with other articles, e.g. clocks
• CPC Class Codes: H05B 1/0238 For seats
• 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 2203/006 using interdigitated electrodes
• 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 3/34 flexible, e.g. heating nets or webs
• CPC Class Codes: H05B 3/845 specially adapted for reflecting surfaces, e.g. bathroom - or rearview mirrors

Abstract

There is disclosed a heater for an automotive vehicle or other article of manufacture. The heater typically includes a first conductive medium and a second conductive medium disposed upon a carrier. In a preferred embodiment, the first conductive medium includes a first section and a second section that are electrically connected by a second conductive medium. The second conductive medium preferably exhibits a positive thermal coefficient.

Claims

1. A heated seat comprising;

a seat with a cavity;

a heater overlaying the seat the heater including;

i) a polymeric film flexible carrier having;

1) a longitudinal axis;

2) a first lengthwise edge; and

3) a second lengthwise edge;

wherein the heater has a width that spans between the first lengthwise edge and the second lengthwise edge, and

wherein each of the first lengthwise edge and he second lengthwise edge include a cutout that defines a narrower width region at a location corresponding with the cavity of the seat;

ii) a first conductive medium printed upon the carrier, wherein the first conductive medium includes;

1) a negative section having a plurality of first extensions; and

2) a positive section having a plurality of second extensions; and

iii) a second printed conductive medium on the carrier that includes a plurality of strips, each of the strips in overlapping relation with at least one of the plurality of first extensions and at least one of the plurality of second extensions, wherein the second printed conductive medium exhibits relatively high positive thermal coefficient characteristics;

iv) a first heating portion; and

v) a second heating portion;

wherein the second heating portion is longitudinally spaced apart and separated from the first heating portion by the narrower width region;

wherein the narrower width region of the carrier is free of the second screen printed conductive medium so that the narrower width portion is free of heating by the second screen printed conductive medium;

wherein the narrower width region includes a centralized through-hole opening, and

wherein the first heating portion and the second portion are electrically connected by the first conductive medium extending along each side of the centralized through-hole opening.

2. The heated seat in claim 1, wherein the first conductive medium cooperatively defines the cutout, which bends about a contour of the seat,

3. The heated seat as in claim 1, wherein the heater includes only a first electrical connection and a second electrical connection.

4. The heated seat as in claim 1, wherein the plurality of strips are substantially uniformly spaced apart from each other.

5. The heated seat as in claim 4, wherein each strip of the plurality of strips has substantially the same shape.

6. The heated seat as n claim 1, further including one or more electrical connections attached to the base portion of the heater by a rivet;

wherein the one or more electrical connections are, covered by a patch.

7. The heated seat as in claim 1, wherein the first lengthwise edge and the second lengthwise edge are spaced apart and generally parallel.

8. The heated seat, as in claim 7, further including one or more contours, openings, or cavities for aiding bending of the heater so that the heater conforms to contours of the seat.

9. The heated seat as in claim 8, wherein the cavity is a trench and the narrower width region extends at least partially into the trench.

10. The heated seat as in claim 1 wherein the centralized through-hole opening is a generally rectangular cutout.

11. The heated seat as in claim 1, further including an occupancy sensor,

12. The heated seat a in claim 11 wherein the occupancy sensor is a pressure sensor to determine the presence of an applied force acting on the heater or the sensor.

13. The heated seat of claim 1, wherein the plurality of strips of the second conductive medium are figured as a serpentine with respect to the plurality of first extensions and the plurality of second extensions.

14. A heated seat comprising:

a seat with a cavity;

a trim layer provided over the seat; and

a heater located between the seat and the trim layer, the heater in including;

ii) a polymeric film flexible carrier having;

1) a longitudinal axis;

2) a first lengthwise edge; and

3) a second lengthwise edge

wherein the heater has a width that spans between the first lengthwise edge and the second lengthwise edge, and

wherein each of the first lengthwise edge and the second lengthwise edge include a cutout that defines narrower width region at a location corresponding with the cavity of the seat;

ii) a first conductive medium printed upon the carrier, wherein the first conductive medium includes;

1) a negative section having a first base portion and a plurality of first extensions extending from the first base portion; and

2) a positive section having a second base portion and a plurality of second extensions extending from the second base portion; and

iii) a second printed conductive medium on the carrier that includes a plurality of strips, each of the strips in overlapping relation with at least one of the plurality of first extensions and at least one of the plurality of second extensions,

wherein the second printed conductive medium exhibits relatively high positive thermal coefficient characteristics;

vi) a first heating portion; and

vii) a second heating portion;

wherein the second heating portion is longitudinally spaced apart and separated from the first heating portion by the narrower width region;

wherein the narrower width region of the carrier is free of the plurality of first extensions, the plurality of second extensions, and the second printed conductive medium so that the narrower width portions free of heating the second heating portion;

wherein the narrower width region includes a centralized through-hole opening located between the cutout in the first lengthwise edge and the cutout in the second lengthwise edge, and

wherein the first heating portion and the second portion are electrically connected by the first conductive medium extending along each side of the centralized through-hole opening.

15. The heated seat of claim 14, wherein the plurality of strips of the second conductive medium are configured as a serpentine with respect to the plurality of first extensions and the plurality of second extensions.

16. The heated seat as in claim 14, wherein the centralized through-hole opening is a generally rectangular cutout.

18. The heated seat as in claim 14, wherein the heater includes an insulation layer.

19. The heated seat as in claim 18, wherein the insulation layer is located over the first conductive medium and the second conductive medium.

20. The heated seat as in claim 18, wherein the insulation layer is a fleece, gauze, or the like that is fastened to the heater via an adhesive.

17. The heated seat as in clam 14, further including one or more electrical connections attached to the base portion of the heater by a rivet;

wherein the one or more electrical connections are covered by a patch.