JP6867980B2 - Conductive heater with sensing function - Google Patents

Description

The teaching generally relates to a device that includes both heat-generating and sensing functions such that the whole body or part of the occupant is sensed and heated.

The teaching is based on providing improved heaters, more preferably improved heaters for vehicles. Generally, the heater comprises a single wire formed in a pattern. When electricity is applied to this wire, it heats up. In some cases, this wire is placed in a carbonaceous material, and as the wire generates heat, the heat is diffused in the carbonaceous material to heat a wider area. However, in these devices, uniform heat generation is not always realized, and a plurality of hot spots may be generated around each heat-generating line. Further, if the heating wire is disconnected, the heater may not generate heat. There are also heaters that include a plurality of electrodes connected by a temperature coefficient material so that heat is generated by conducting electricity from one electrode to the other electrode through the temperature coefficient material. The other heaters have a woven fabric shape in which a plurality of long materials are woven together. Since these materials can generate current drift along one line, these heaters may have hot spots along one or more of these materials.

In addition to the heater, sensors may be installed within the components of the vehicle. These sensors may also be occupant sensors that determine the presence of an occupant in the seat of the vehicle, the weight of the occupant, the size of the occupant, or a combination thereof. In this case, for example, the airbag can be switched on or off based on the perceived characteristics. Generally, when a heater and an occupant sensor are used, two individual components are installed within one component so that one generates heat and the other senses. Having two separate devices can make the system more complex, increase installation costs, increase the number of components that can fail, increase mounting space, and cause electrical interference between the two devices. These may be combined. Therefore, it is desirable to have a dual-purpose heater that includes a sensing function to detect and generate heat for the presence of the occupant, the position of the occupant, or both.

A plurality of examples of heaters can be found in Patent Documents 1-9. All of these documents are incorporated herein by reference for all purposes. A plurality of examples of sensors and heaters can be found in Patent Documents 10-14.

It would be attractive to have a heater / sensor that does not contain multiple individual components. It would be attractive to have a heater that acts as a sensor without adding any additional sensing elements. What is needed is to provide good heat generation performance so that the heater / sensor can be installed in a compact space, in a space where high flexibility is required, or both. It is a flexible heater that can also be used as a sensor.

U.S. Pat. No. 5,824,996 U.S. Pat. No. 5,935,474 U.S. Pat. No. 6,057,530 U.S. Pat. No. 6,150,642 U.S. Pat. No. 6,172,344 U.S. Pat. No. 6,294,758 U.S. Pat. No. 7,053,344 U.S. Pat. No. 7,285,748 U.S. Pat. No. 7,838,804 U.S. Pat. No. 5,006,421 U.S. Pat. No. 7,500,536 U.S. Patent Application Publication No. 2009/0255916 U.S. Patent Application Publication No. 2011/0290775 U.S. Patent Application Publication No. 2013/0020305

The teaching is improved to include a heater and sensor comprising (a) a heating layer, a sensing layer, or both, and (b) one or more power application units, one or more sensing units, or both. The heating layer and the sensing layer are arranged in the same plane, and the heating layer is composed of a plurality of metal coating fibers randomly arranged so that the heating layer supplies heat by applying electric power. Meet one or more (if not all) current requirements by providing an apparatus formed by the formed non-woven layers.

The teachings herein are: (a) (i) a plurality of randomly arranged individual fibers and (ii) a plurality of voids and / or fine fibers interspersed between the randomly arranged individual fibers. A sensor comprising a non-woven sensing layer having a hole and (b) one or more power applying portions connecting the sensing layer to a signal source, the presence of an occupant, contact with the sensor, or. A sensor that senses both of these is provided.

The teachings of the present specification are (a) to install the heater / sensor in the components of the automobile, and (b) to supply power to the heater / sensor so that the heat generating layer of the heater / sensor generates heat. , (C) Supply signals to the heater / sensor such that the sensing layer of the heater / sensor generates a signal to determine the presence of the occupant, the contact between the occupant and the components of the vehicle, or both. It provides methods including (d) monitoring this signal for occupants, absence of occupants, lack of contact between components and occupants, or combinations thereof.

The teachings of the present application surprisingly solve one or more of the above problems by providing a heater and sensor that does not include individual components. The teachings herein provide a heater that acts as a sensor without the addition of any additional sensing elements. The teachings herein are as sensors, providing good heat generation performance so that the heater / sensor can be installed in a compact space, in a space where high flexibility is required, or both. Also provides a flexible heater that can be used.

An infrared image of the heater according to the teachings of the present specification is shown. The heater / sensor according to the teaching of the present specification is shown. The close-up view of the power application part of FIG. 2 is shown. A close-up view of an alternative power application unit according to the teaching of the present specification is shown. A cross-sectional view of the steering wheel is shown. An example of a heater / sensor including one central power application unit and a power application unit on each side is shown. A heater / sensor having a plurality of parts including individual power application parts is shown. A heater / sensor having a plurality of parts in which a plurality of power application parts are electrically connected to each other is shown. The heater / sensor including a plurality of power application parts in the longitudinal direction is shown. The heater / sensor of FIG. 6A disposed on the steering wheel is shown. The heater / sensor extending along the length of the heater / sensor and including a plurality of individual power application parts for power supply is shown. Two individual heaters / sensors, each containing a longitudinal power application, are shown. The two individual heaters / sensors of FIG. 8A disposed on the surface of the steering wheel are shown. The heater / sensor extending along the length of the heater / sensor and including a plurality of individual power application parts for power supply is shown. An example of the electrical configuration for the heater / sensor is shown. Another example of the electrical configuration is shown. An example of a heater / sensor in which both ends are arranged adjacent to each other without leaving a gap between the ends of the heater / sensor is shown. An example of a heater / sensor having an individual power application unit for applying power and an individual power application unit for signal application is shown. The sensing circuit according to the teaching of the present specification is shown. An example of a heat generating circuit and a sensing circuit is shown. An example of the electric power and the signal applied to the heater is shown.

The descriptions and figures presented herein are intended to inform other skilled in the art of the present invention, its principles, and its practical use. One of ordinary skill in the art may adapt and apply the teachings in many forms thereof to best suit the requirements of a particular application. Therefore, the particular embodiments of this teaching described do not attempt to cover or limit this teaching. Therefore, the scope of this teaching should not be determined with reference to the above description, but with reference to the appended claims and the entire scope of equivalents covered by such claims. Should be decided. Disclosure of all treatises and references shall be incorporated by reference for any purpose, including patent application and publication. Other combinations, such as those found in the appended claims, are possible and these combinations are also incorporated herein by reference.

This teaching claims priority to US Patent Provisional Application No. 61 / 823,642 filed May 15, 2013, which shall incorporate the entire teaching content into the specification of the present application by reference for all purposes. .. The device taught herein can be useful as a heater and / or can be incorporated into another device. In the latter case, this alternative device can be used as a heater. The apparatus taught herein can be used in any known heating application. For example, heaters can be used to heat beds, plants, therapeutic heaters, vehicle seats, steering wheels, mirrors, glass, flooring, door panels, armrests, headliners, etc., or a combination of these. Can be used for. The devices taught herein are preferably connected to, / or incorporated into, vehicle seats, steering wheels, or both. The heaters described herein are overlaid on the cushions of the vehicle seats (ie, vans or back), after which the trim cover is placed over the heaters, or around the steering wheel and then. It may be an individual piece that is covered with a trim piece or both. A portion of the heater may be placed in the trench of the cushion so that the heater, cushion, trim cover, or a combination thereof can be attached to the seat frame. The heater may be shapeable, moldable, cuttable, or a combination thereof, so that heating of the trench area of the vehicle seat by the heater can be largely prevented. For example, a portion of the heater may be cut off such that substantially only electrodes, buses, conductors, or combinations thereof extend into the trenches of the vehicle seats. The trim cover may have mounting features that extend through the heater so that the heater is connected to the trim cover and vehicle components.

Vehicle seats and / or steering wheels with one or more heaters by mechanical clamps, adhesives, pressure from one or more adjacent layers, welding, caulking, ultrasonic welding, bonding, or a combination thereof. Can stick to. For example, a thread of the same material as the heater may allow the heater to be attached to the trim layer, the support, or both so that the heater is anchored within the component. Adhesives can be peelable adhesives to the heater, or permanent adhesives to the heater, pressure sensitive adhesives, glues, hook-and-loop fasteners, spray adhesives, peelable adhesives, or A combination of these may be used. The heater may be attached directly to the trim layer, or to the seat cushion (ie, van, back, or both), or directly to the steering wheel, or they may be attached. May be combined. Whether the mechanical clamp is extended through the heater, connected to the heater, or attached to the heater so that the heater can be secured in the seat, in the steering wheel, or both. Alternatively, these may be combined. The mechanical clamp may be a hog ring or a metal bar that extends over a portion of the heater and pulls the heater and trim layer closer to the cushion, part of the heater, part of the trim layer, Alternatively, it may be a plastic tag that penetrates both of them, or a combination thereof. The heater as taught herein can be used in combination with other devices.

One or more sensors (eg, contact sensors, passenger sensors, or both) may be used with one or more heaters. The heater can be a sensor. The sensor may be sewn into the heater. For example, conductive threads, wires, conductors, printed electrodes, or a combination thereof may be connected to the heater so that the signal is created when a signal, power, or both are applied. The sensor may be any type of passenger sensor as long as it is a passenger sensor that senses the presence of a passenger, contact with a heater, adjacent contact with a heater, occupant size, or a combination thereof. The heater, steering wheel, vehicle seat, or combination thereof may not include individual sensors. For example, as described herein, the heater itself can be used as a sensor. The passenger sensor may be a capacitance sensor, a pressure sensor, a membrane sensor, an infrared sensor, a passive and / or active ultrasonic sensor, a mass sensor, or a combination thereof. This sensor detects a system that activates an alarm when the user is not in contact with the steering wheel, or a system that turns on the vehicle guidance system when the user is not in contact with the steering wheel, or a passenger is detected. It may be connected to a system that alerts when the passenger is not wearing a seatbelt, or a system that turns off airbags when an occupant under a given weight is in the seat, or a combination of these. The heater and passenger sensor can be used in combination with an active cooling system, an active heating system, a ventilated system, or a combination thereof.

The heater can be used in combination with active heating, active cooling, ventilation, or a combination thereof. The heater may be porous so that air can pass directly through the heater. The heater is one or more porous to cover the heater so that air passes directly through the heater to one or more layers (eg, a fleece layer, an adhesive layer, a protective coating layer, or a combination thereof) that covers the heater. May include layers. The heater may include one or more barrier layers that completely and / or partially cover the heater. This barrier layer facilitates directing the fluid flow to the heater region that can be contacted. This barrier layer (if present) can be formed in any shape so that air can be directed to the desired location. For example, a non-porous or barrier material that can make the central "U" -shaped portion of the heater substantially porous and prevent the passage of fluid so that the moving fluid is directed towards the contact area is the "U" -shaped portion. It may be provided in the area surrounding the. The heater may include one or more through holes so that air can pass through the heater. The heater may include a fan and / or a blower, and / or may communicate the fluid to the fan and / or the blower, adjacent to the blower and / or fan so that the fluid passes through and / or around the heater. A heater, fan, blower, or combination thereof may include a Peltier device, a thermoelectric device, or both so as to move hot and / or cold air (ie, regulated air) towards the occupant. The heater may be indirectly connected to a Peltier device, a thermoelectric device, or a fan, blower, or both, including both.

The heater can be connected to an insert (ie, bag) that facilitates the distribution of regulated air towards the occupants. The heater may have one or more holes that are mirror images of the holes in the insert. The heater may be provided with no holes so that the air from the bag passes directly through the heater to the occupants. The heater layer may be directly connected to the insert. All or part of the heater layer may be connected to the insert. The insert may be one or more polymer layers that form a layer that is substantially impermeable to air and / or a layer that is impermeable to air so that the air delivered into the insert is directed to a predetermined area. The insert may include one or more spacer materials. The heaters taught herein can function as part of a spacer layer and / or spacer material that forms an open space within the insert. Further aspects of the insert and its various layers and materials are incorporated herein by reference in column 1, row 45-column 3, row 67, column 4 of US Pat. No. 7,083,227. , Row 54 to Column 6, Row 32, and FIGS. 2-3, US Pat. No. 7,735,932, Column 3, Row 34 to Column 10, Row 2, Column 11, Row 4 to Column 13, Row 18, And can be found from the teachings herein, including the teachings of FIGS. 1, 4, 15A, and 15B. These patent documents provide various alternative embodiments of inserts, insert materials, and insert structures that can be used in conjunction with the heaters taught herein.

The one or more heaters may be formed as a sheet. The heater may be one or more sheets. The heater may be a plurality of physically discontinuous sheets that are electrically connected to each other. The heater taught in the present specification is preferably a non-woven sheet. For example, the heating layer taught herein can be composed of a plurality of individual fibers that may be cut to a predetermined length and randomly arranged in order to form a heater. The heater can be adapted to virtually any shape. For example, the heater can be wrapped around a circular object so that a circular object (eg, a steering wheel) is heated. The heater may include a plurality of fibers forming a heating layer. The heating layer can be composed of about 50 weight percent or more, about 60 weight percent or more, preferably about 70 weight percent or more, more preferably about 80 weight percent or more of fibers. The heating layer can be composed of about 82 weight percent or more, 85 weight percent or more, about 90 weight percent or more, about 92 weight percent or more, or about 95 weight percent or more fibers. The heating layer can be composed of fibers of about 99 weight percent or less, about 98 weight percent or less, or about 97 weight percent or less. The heating layer is a fiber from about 50 weight percent to 99 weight percent, preferably a fiber from about 70 weight percent to about 99 weight percent, more preferably about 80 weight percent to about 99 weight percent (ie, about 80 weight percent). May contain up to about 90 weight percent).

It is preferable that the plurality of fibers are randomly dispersed throughout the heating layer. More preferably, these fibers have a short average fiber length so that the heating layer has a non-woven structure when the plurality of fibers are combined and the fibers are not woven together by a mechanical device. It is more preferred that the average fiber length and arrangement of these fibers produce a nearly constant thermal gradient, a nearly constant heat density, or both throughout the heater when power is applied. An array of these fibers transfers power and spreads it throughout the heater, resulting in nearly uniform heat generation, uniform heat density, or both, so that the power does not move along a particular line. Can be arranged sufficiently randomly. In one example, the heating layer taught herein has almost no fiber alignment so that the heating layer does not have longitudinal, horizontal, or both. The heating layer may not include a plurality of individual heating wires, heating threads, or both, and heat generation may be generated through a plurality of randomly arranged fibers. The expression randomly arranged described herein is about 60 percent or less, about 50 percent or less, preferably about 40 percent or less, more preferably about 30 percent or less, and even more preferably. It means that less than about 20 percent are arranged in the same direction. The average fiber length can affect the arrangement of fibers.

The average fiber length is any length as long as a non-woven sheet is formed and the sheet is strong enough for bending, folding, cutting, power transfer, pushing into trenches, pulling, or a combination thereof. It may be long. The average fiber length is such that when power is applied, the power moves from fiber to fiber and the heater has a nearly uniform temperature gradient (ie, the temperature when randomly measured at both ends of the heater is about ± 5 ° C or less). Any length may be used as long as the fibers are sufficiently in contact with each other so as to generate about ± 3 ° C. or lower, or about ± 2 ° C. or lower). The average fiber length may be about 130 mm or less, about 110 mm or less, about 100 mm or less, about 80 mm or less, about 60 mm or less, and about 50 mm or less. The average fiber length is preferably relatively short. Therefore, the average fiber length can be about 40 mm or less, about 30 mm or less, preferably about 28 mm or less, more preferably about 25 mm or less, still more preferably about 22 mm or less. The average fiber length may vary from about 50 mm to about 1 mm, preferably from about 40 mm to about 3 mm, more preferably from about 25 mm to about 5 mm. The average fiber length described in the present specification is ± 5 mm or less, ± 4 mm or less, preferably ± 3 mm or less, more preferably about ± 2 mm or less, still more preferably about ± 1 mm or less, and most preferably about ± 0.5 mm or less. Can have a standard deviation of. The maximum fiber length (ie, the longest fiber in the heater) can be about 200 mm or less, preferably about 175 mm or less, more preferably about 150 mm or less, still more preferably about 100 mm or less, most preferably about 50 mm or less.

The heat generating layer may be made of any non-woven material as long as it is a non-woven material that generates heat through electricity. The heat generating layer is a non-woven material that can be cut, bent, folded, drilled, or a combination thereof, and is made of any non-woven material that can generate heat when electric power is applied. May be good. The heating layer may be made of a material that can be manufactured using the spunlacing method (eg, hydroentanglement), the needle punching method, or a combination of both. The heating layer may include carbon, metal-coated carbon, polymer, metal-coated polymer, binder, or a combination thereof. The heating layer preferably contains a plurality of carbon or polymer fibers coated with one or more metal material layers. One or more coatings may be applied to the fibers prior to layer formation, or one or more coatings may be applied to these fibers when these fibers are layers (eg, fiber mats or fiber sheets). Alternatively, a first coating may be applied to these fibers and then a second coating may be applied to the fibers when these fibers are part of a layer, or a combination thereof. In one example, a nylon mat may be formed, then the nylon mat may be coated with copper and then with nickel to prevent nickel from corroding and / or oxidizing the copper. The polymers that can constitute the fibers are nylon, polyester, polyurethane, polyamide, aramid, para-aramid, meta-aramid, vinyl alcohol, thermoplastic urethane, urethane, polyimide, carbon, carbon fibers, or a combination thereof. These fibers may be coated with any material that can conduct electricity.

Metals that can be used to coat carbon fibers, polymer fibers, or both are copper, silver, gold, nickel, aluminum, tungsten, zinc, lithium, platinum, tin, titanium, platinum 4, or a combination thereof. is there. In one preferred embodiment, these multiple fibers are made only of carbon. In another preferred embodiment, these fibers are made of nylon or carbon and are coated with nickel or silver. If coated fibers are used, the coating can be used as a percentage of the total weight of the heating layer. The percentage of the coating film to the total weight may be any weight as long as the heat generating layer generates heat when electric power is supplied to the heat generating layer. It is preferable that the percentage of the coating film in the total weight of the heating layer can be a sufficient amount so that the heating layer generates heat at a temperature of about 80 ° C. to about 110 ° C. by applying electric power. The percentage of the coating in the total weight of the heating layer can be sufficient such that the resistivity of the heating layer is from about 1Ω to about 5Ω, preferably from about 1.5Ω to about 2.5Ω. The coating can account for about 5 percent or more, about 10 percent or more, preferably about 15 percent or more of the total weight of the heating layer. The coating may account for about 50 percent or less, about 40 percent or less, or about 30 percent or less (ie, about 20 percent to about 25 percent of the total weight) of the total weight of the heating layer. An example of a metal-coated nylon non-woven fleece is sold by YSShield under the trade name HNV80. Some examples of some carbon non-woven fabrics are sold by Marktek Inc. under the trade names C10001xxxT series, NC10004xxxT series, and C100040xxT series. Another example of non-woven fabrics is from Conductive Composites Nickel Nanostrands, Nickel CVD coated carbon fiber, or Nickel CVD coated non-woven carbon fiber. It is sold under the trade name of coated sintered carbon fiber). The fibers described herein can be held together by a binder.

The heat generating layer is a non-woven material. The heating layer is preferably felt-like (that is, a flat homogeneous non-woven structure). More preferably, the heating layer can be a non-woven material having a randomly arranged microstructure. The heater does not have to have holes. The heater may include a plurality of holes. These holes may have any shape as long as heat is generated to heat adjacent surfaces, people, items, devices, or combinations thereof. These holes may be circular, oval, square, cross, elongated, symmetrical, asymmetric, geometric, non-geometric, or a combination thereof. The heater may include a side notch. The heater preferably does not include side notches. The heater may have a meandering shape. The heater is preferably not meandering. The microstructure of the heating layer may include multiple pores, multiple voids, or both. The voids and pores described herein are part of the microstructure of the heating layer, and the through holes and notches are, for example, larger spaces from which material has been removed. The heating layer can contain a sufficient amount of voids and / or pores so that the air from the air mover can pass through the heating layer, or the fibers of the heating layer are randomly arranged, or power is randomly distributed throughout the heating layer. Distributing, or allowing the protective layer to penetrate the heating layer, or a combination thereof. The voids and / or pores of the heating layer cover an area of about 10% or more, about 15% or more, about 20% or more, about 25% or more, about 30% or more, or about 40% or more of the total surface area of the heating layer. It may be equivalent. The voids and / or pores of the heating layer may correspond to an area of about 90 percent or less, about 80 percent or less, about 70 percent or less, about 60 percent or less, or about 50 percent or less of the total surface area of the heating layer. .. The heating layer is sufficient so that one or more other layers are connected to the heating layer, or the protective layer can form a flat surface on the heating layer, or both. An amount of fiber and / or material may be present in the heating layer.

The heater may include a plurality of electrodes. The heater may not contain any additional conductive layers (eg, buses, electrodes, terminals, traces, tributaries, branches, or combinations thereof). The heater preferably includes a plurality of buses, electrodes, or both (eg, power application portions) that extend substantially along the length and / or width of the heater to assist in applying power to the heater. It is more preferable that the heating layer does not include a terminal for connecting the power supply to the heater (that is, a single power application point). The heating layer may not contain gold, silver, copper, or a combination thereof. The heater may include a positive temperature coefficient (PTC) material. The heating layer does not include additional conductive layers, temperature coefficient layers, adducts, or combinations thereof that help generate heat, generate signals, or both, which are added to the heating layer in another step. Good. The heating layer may be free of stabilizing materials, soft fillers, impregnated fillers, or combinations thereof. For example, the heating layer does not contain stabilizers, soft fillers, impregnated fillers, or combinations thereof that are added to the heater to aid in power transfer between the fibers. It is more preferable that the heat generating layer is only the heater portion required for heat generation. For example, the heating layer does not have to be a substrate, and the heating layer may be one or more materials arranged or printed on its surface to form the heating layer, materials woven into this material, or a combination thereof. It does not have to be included. The structure of the heating layer can be used to change the resistivity of the heating layer, the surface output density, or both.

The heat generating layer described in the present specification has a resistivity and a surface output density. The resistance and surface output density of the heating layer are the voltage applied to the heating layer by changing the size and shape of the heating layer, or by changing the material composition of the front coating layer, the back coating layer, or both. It can be changed by changing the amount, by changing the amperage applied to the heating layer, or by combining these. For example, the resistivity and surface power density of the heating layer can be changed by removing material from the heating layer (eg, by adding notches, through holes, slits, or a combination thereof). In another example, the material can be effectively removed from the heating layer so that the resistivity of the heater is increased. The resistivity of the heat generating layer may be about 1.0 Ω or more, preferably about 1.5 Ω or more, and more preferably about 1.8 Ω or more. The resistivity of the heating layer may be about 7Ω or less, about 5Ω or less, about 3Ω or less, or about 2.5Ω or less (ie, about 1.5Ω to about 2.3Ω). The resistivity can be directly proportional to the surface output density of the heating layer. The resistivity is preferably inversely proportional to the surface output density of the heating layer. As a result, as the resistivity increases, the surface output density decreases.

The surface output density of the heat generating layer may be about 100 W / m ² or more, about 200 W / m ² or more, about 300 W / m ² or more, or about 400 W / m ² or more. Surface power density of about 2000 W / ^{m 2} or less, about 1500 W / ^{m 2} or less, even about 1000W / ^{m 2} or less, or about 750W / ^{m 2} or less (i.e., from about 600W / ^{m 2} to about 450 W / ^{m 2)} Good. One or more other factors described herein, such as the base weight of the heating layer, the basis weight, or both, can affect resistivity, surface output density, or both.

The heating layer can be characterized by a basis weight (ie, weight per unit area of fabric). The basis weight is about 50 g / m ² or more, about 60 g / m ² or more, about 70 g / m ² or more, preferably about 80 g / m ² or more, more preferably about 90 g / m ² or more, and most preferably about 100 g / m. ^{Can be 2} or more. The basis weight can be about 500 g / m ² or less, about 400 g / m ² or less, preferably about 300 g / m ² or less, and more preferably about 200 g / m ² or less. The basis weight is between about 50 g / m ² and about 300 g / m ² , preferably between about 75 g / m ² and about 250 g / m ² , more preferably between about 100 g / m ² and about 200 g / m ^2. obtain.

One characteristic of the fibers of the heating layer is density. The fiber density may be about 0.5 g / cm ³ or more, about 0.75 g / cm ³ or more, about 1.0 g / cm ³ or more, or about 1.2 g / cm ³ or more. The fiber density may be about 10 g / cm ³ or less, about 5.0 g / cm ³ or less, about 3.0 g / cm ³ or less, or about 2.0 g / cm ³ or less. The fiber density is between about 0.5 g / cm ³ and about 3.0 g / cm ³ , preferably between about 1.0 g / cm ³ and about 2.0 g / cm ³ , more preferably about 1. It can be between 1 g / cm ³ and about 1.5 g / cm ^3.

The fibers of the heating layer can be characterized by diameter. The diameter of the fiber can be about 0.0001 mm or more, preferably about 0.001 mm or more, preferably about 0.005 mm or more, most preferably about 0.0065 or more. The fiber diameter is about 1 mm or less, about 0.5 mm or less, about 0.1 mm or less, preferably about 0.05 mm or less, more preferably about 0.02 mm or less, most preferably about 0.008 or less (ie, about. It can be between 0.007 and about 0.006 mm). The fiber diameter can be between about 0.0005 mm and about 0.1 mm, preferably between about 0.001 mm and about 0.05 mm, more preferably between about 0.005 mm and about 0.02 mm.

The material of the heating layer has a thickness. The thickness of the heat generating layer may be any thickness as long as the heat generating layer generates heat when electric power is applied. By making the thickness of the heat generating layer sufficiently thin, the resistivity can be increased from about 1 Ω to about 3 Ω, preferably from about 1.5 Ω to about 2.5 Ω, and the heat generation performance is higher than that of the heat generating layer taught in the present specification. The heat generation performance of the heat generating layer may be improved as compared with the low heat generating layer. The thickness of the heat generating layer can be about 0.001 mm or more, about 0.005 mm or more, preferably about 0.07 mm or more. The thickness of the heat generating layer can be about 30 mm or less, about 10 mm or less, preferably about 5 mm or less, more preferably about 2 mm or less, and more preferably about 1.0 mm or less. The thickness of the heating layer can be between about 0.001 mm and about 10 mm, preferably between about 0.005 mm and about 5 mm, more preferably between about 0.07 mm and about 1 mm.

The material of the heating layer has a basic weight. The basic weight of the heat generating layer may be about 10 g / m ² or more, about 30 g / m ² or more, about 50 g / m ² or more, or about 70 g / m ² or more. The material of the heating layer can have a basic weight of ^{about 200 g / m 2} or less, about 150 g / m ² or less, or about 100 g / m ^{2 or less.}

The material of the heating layer can be characterized by thermal conductivity. The thermal conductivity at 23 ° C. may be about 2.0 W / m * k or less, about 1.0 W / m * k or less, about 0.5 W / m * k or less, or about 0.005 W / m * k or less. .. The thermal conductivity at 23 ° C. may be about 0.001 W / m * k or more, about 0.005 W / m * k or more, or about 0.01 W / m * k or more. Thermal conductivity measured at 23 ° C. using ASTM STP1426 or ASTM STP1320 from about 1.0 W / m * k to about 0.001 W / m * k, preferably from about 0.5 W / m * k. It can be between about 0.005 W / m * k, more preferably between about 0.01 W / m * k and about 0.075 W / m * k. The thermal conductivity at 600 ° C. is about 3.0 W / m * k or less, about 2.0 W / m * k or less, about 1.0 W / m * k or less, about 0.5 W / m * k or less, or about. It may be 0.01 W / m * k or less. The thermal conductivity at 600 ° C. may be about 0.001 W / m * k or more, about 0.005 W / m * k or more, about 0.01 W / m * k or more, or about 0.05 W / m * k or more. .. Thermal conductivity measured at 600 ° C. using ASTM STP1426 or ASTM STP1320 from about 1.5 W / m * k to about 0.001 W / m * k, preferably from about 0.7 W / m * k. It can be between about 0.007 W / m * k, more preferably between about 0.1 W / m * k and about 0.01 W / m * k.

The heat generating layer contains a specific heat. The specific heat at 23 ° C. is about 0.001 W * sec / g * K or more, about 0.01 W * sec / g * K or more, preferably about 0.1 W * sec / g * K, more preferably about 0.5 W *. It can be sec / g * K or more. The specific heat at 23 ° C. can be about 5.0 W * sec / g * K or less, about 2.0 W * sec / g * K or less, or about 1.0 W * sec / g * K or less. The specific heat measured at 23 ° C. using ASTM STP1426 or ASTM STP1320 is between about 2.0 W * sec / g * K and about 0.001 W * sec / g * K, preferably about 1.5 W * sec / g. It can be between * K and about 0.01 W * sec / g * K, more preferably between about 1.0 W * sec / g * K and about 0.1 W * sec / g * K. The specific heat at 600 ° C. may be about 10 W * sec / g * K or less, about 5.0 W * sec / g * K or less, or about 3.0 W * sec / g * K or less. The specific heat at 600 ° C is about 0.1 W * sec / g * K or more, about 0.5 W * sec / g * K or more, about 1.0 W * sec / g * K or more, or about 1.5 W * sec / It may be g * K or more. The heating layer is between about 10.0 W * sec / g * K and about 0.01 W * sec / g * K, preferably about 5 W *, as the specific heat measured at 600 ° C. using ASTM STP1426 or ASTM STP1320. It has a specific heat between sec / g * K and about 0.1 W * sec / g * K, more preferably between about 2.5 W * sec / g * K and about 0.75 W * sec / g * K. obtain.

The heating layer includes the breaking point tensile strength. The breaking point tensile strength can be about 1 N / cm or more, about 1.5 N / cm or more, or preferably about 2 N / cm. The breaking point tensile strength may be about 100 N / cm or less, about 80 N / cm or less, or about 60 N / cm or less. The thermal breaking point tensile strength of the heating layer is from about 0.5 N / cm to 100 N / cm, preferably from about 1.0 N / cm to 80 N / cm, more preferably from about 1.5 N / cm to 60 N / cm. Can be.

The material of the heating layer may have chemical resistance. In general, the material of the heating layer may exhibit one or more of the following chemical resistance and / or material properties: The material of the heating layer can have good strong acid resistance. The material of the heating layer can have excellent weak acid resistance. The material of the heating layer may have weak strong basic resistance. The material of the heating layer can have good weak basicity. The material of the heating layer may have excellent chemical resistance to organic solvents. The material of the heating layer may exhibit a low modulus (ie, the material does not stretch), wear resistance, non-curability, self-slip, or a combination thereof.

The heating layer can be formed by mixing one or more of the compositions described herein. By extrusion molding this mixed composition, fibers, sheets, mats, threads, or combinations thereof can be formed. A heating layer can be formed by injecting this composition into a mold. The heating layer can be formed by mixing a plurality of fibers to form a mat. These materials can form a first substance capable of exhibiting the exothermic properties described herein. These materials may be subjected to a secondary treatment.

Since the heat generating layer can be attached to one or more terminals, the heat generating layer generates heat when electricity (for example, electric power) is applied. The heating layer may be connected to one or more power application lines that apply power, signals, or both. The power application line may apply power only, signal only, or both. The power application line can apply both power and signal. The power supply line can be connected to a power supply, microprocessor, processor, computer, or a combination thereof. The heating layer uses two or more, three or more, or four or more terminals and / or power applications to apply power and / or signals to the power application to generate heat and / or sense using a heater / sensor. Can be connected to a wire. For example, the heating layer may include positive and negative wires connected to each end of the heating layer such that a total of four wires are connected to the heating layer. When connected to one or more positive and one or more negative power sources (ie, power application layer or power application material), the heating layer can generate heat and / or can be used for sensing. The heating layer preferably does not include terminals that connect the bus and / or electrodes to the heating layer. For example, the bus and / or electrode may be connected to the heating layer, or the bus and / or electrode may be connected to the power supply. By attaching the terminal directly and / or indirectly to the heat generating layer using any of the devices, electricity may enter the heat generating layer from this terminal to generate heat in the heat generating layer. The terminals may be crimped to the heat generating layer. For example, the power application unit may include a plurality of terminals for connecting the power supply to the power application unit. The terminals may be connected to a heating layer, each power application layer, or both by bonding, joining, mechanical clamps, or a combination thereof. The heating layer preferably does not include a plurality of terminals attached directly to the heating layer (ie, a single power application point). The heater does not have to be equipped with a mechanical clamp that attaches the power supply to the heater. For example, the heating layer need not include a mechanical attachment device that grips the heating layer and fixes one or more wires to the heater. The heat generating layer may include two or more power application portions that help supply power to the heat generating layer.

The two or more power application units may be arranged at any position on the heater. It is preferable that two or more power application parts are separated from each other. The two or more power application units may be sufficiently separated so that the heater is partially and / or completely energized by the application of power. More preferably, the two or more power application portions are arranged in the edge region of the heater. For example, by arranging one power application unit along one edge of the heater and arranging the second power application unit along the opposite edge, the power can be transferred from the first edge to the second. The power may pass through the heater as it travels to the edge of the. The power application may be extended along the side edge of the heater (eg, width) or along the longitudinal edge of the heater (eg, length). The length of the power application line can be inversely proportional to the conductivity of the heater / sensor. So, for example, the longer the wire, the lower the conductivity of the heater / sensor. More specifically, the heater / sensor with the longitudinal power application may be made only of carbon material. In another example, the power application extending along the sides or edges may be connected to a heater having metal coated fibers that are more conductive than the heater made of carbon material. The heater may include more than two power application parts. For example, the heater is located in a power application section located approximately in the center of the heater and in a central power application section so that power and / or signals move from the central power application section to both ends and vice versa. It may include a power application unit provided on each side. The heater may include four or more power application units. For example, the heater may include two opposing power application portions extending from each edge to the opposite edge. The two opposing power application units are terminated before they are connected to each other so that there is a gap between the power application units. This gap can electrically insulate both sides / edges of the heater / sensor. Both sides of the heater / sensor so that this gap and / or insulator is not present between the sides / edges of the heater / sensor, or the heater / sensor is not short-circuited, or both are achieved. The portions / edges may have the same polarity. Therefore, each heater may include two or more, three or more, or four or more power application parts for applying heat and / or power. These power application units may be arranged on the heater / sensor so that the opposing sides / edges of the power application units have similar polarities. For example, the negative electrodes, the positive electrodes, or both may be arranged at opposite edges so that the positive electrodes or the negative electrodes are in close proximity to each other when the heater / sensor is wound around the core. In another example, the positive electrode property is arranged on both sides / edge edges located at a close distance when wound, and the negative electrode property is arranged in the middle between them.

Each power application unit may include one or more parts for applying power, a signal, or both. In one preferred example, each power application consists of two individual busbars, electrodes, wires, or a combination thereof connected to each other, each of the two busbars, electrodes, wires, or a combination thereof to a heating layer. Helps supply electricity. These power application units may apply signals, power, or both. The heater / sensor may include two power application units that are close to each other, one power application unit may supply power and the other power application unit may supply a signal. As described herein, these power application units may apply signals, power, or both. However, in order to apply signal only or power only, a plurality of individual power application units and a plurality of lines associated with them may be used. An individual sensing unit may be connected directly to the microprocessor or processor to determine if the user is in contact with the heater / sensor. Busbars, electrodes, wires, or combinations thereof may be made of the same material, different materials, or combinations thereof.

Each busbar and / or electrode in a single power application is preferably made of two or more different materials. Although the power application unit may include one or more wires, it is preferable that the power application portion may include two or more wires woven together. The one or more wires may be needle punched into the heater so that the power application is formed at one end or both ends of the heater. The needle punched wire may be connected to the heater and directly connected to the power supply. The needle-punched wire may be a silver-coated wire, a copper-coated wire, or a wire coated with both. The wire to be needle punched may be made of almost the same material as the heater. However, the needle-punched wire may have a longer fiber length than the fiber in the heater. These wires may be made of any conductive material that helps transfer power to the heating layer to generate heat. The resistivity of each wire may be about 5Ω * m or less, about 2Ω * m or less, or about 1Ω * m or less. The resistivity of each wire may be about 0.01Ω * m or more, about 0.05Ω * m or more, or about 0.01Ω * m or more (that is, about 0.25Ω * m). The weight of each line may be about 0.1 g / mm or less, about 0.01 g / mm or less, about 0.001 g / mm or less, or about 0.0001 g / mm or less. Each line is about 0.00001 g / mm or more, preferably about 0.00005 g / mm or more, more preferably about 0.0001 g / mm or more, most preferably about 0.0005 g / mm or more (ie, about 0.0007 g / mm). Can have a weight of mm). In one preferred embodiment, each line is a complex in which a plurality of lines are braided together to form a single line. For example, each wire may consist of 20 silver wires, each having a diameter of about 0.07 mm. Each of these 20 silver wires may be braided together to form a single wire. These wires are made of copper, silver, gold, nickel, or a combination thereof, and / or coated with copper, silver, gold, nickel, or a combination thereof, so that power is transmitted to the heating layer. Is preferable. In order to connect the one or more wires to the heating layer, use any device that fixedly connects the one or more wires to the heater without substantially interfering with the transmission of power to the heating layer. You may. Some examples of mounting devices and / or methods that may be used include gluing, gluing (eg, the use of conductive or non-conductive glue), joining, knitting, stapling, or a combination thereof. It is preferable that the one or more wires are connected to the heat generating layer by using an adhesive layer. An adhesive layer that secures one or more wires to the heating layer can also be used to connect a second busbar and / or electrode to the heating layer.

The power application unit may be made of any material as long as it is a material that assists in transmitting power to the heat generating layer by applying power so as to warm the heat generating layer. The power application unit may be made of any material as long as the heat generating layer can detect the state by applying the sensor signal. The power application unit may include bus bars and / or electrodes that are placed below one or more wires, preferably above one or more wires, or a combination of both. The power application portion does not have to include a wire, and may be made only of the non-woven material described in the present specification. For example, a clip that provides an electrical connection for supplying power to the heating layer may be attached directly to the non-woven material. The bus bar and / or the electrode may be a non-woven material having conductivity. The busbar and / or electrode may be one or more non-woven conductive strips. Busbars and / or electrodes may be made of the same material as the heating layer. The busbar and / or electrode is preferably made of a carbon material, a polymer material, a metal coated material, or a combination of a plurality of materials forming a conductive medium through which power is passed through the heater. For example, the bus bar and / or electrode may be multiple nylon fibers coated with nickel or silver, and the coated nylon fibers may be joined together by a binder to form a non-woven material that transfers power to the heating layer. .. Busbars and / or electrodes can be attached to the heating layer using any of the materials and / or methods described herein for one or more of the wires described above. The bus bar and / or electrode, one or more heating wires, or a combination thereof, is preferably connected to the heating layer using an adhesive cloth. It is more preferable that each power application portion includes a non-woven conductive material connected to the heat generating layer by the adhesive layer and two or more wires.

The adhesive layer may be any adhesive sheet as long as it forms a connection by heating. The adhesive layer may be any of the adhesive layers described in the present specification. The adhesive layer may be polyamide. The adhesive layer is preferably a non-woven material. The adhesive layer is composed of a plurality of interconnected fibers and / or fibrous adhesive particles and voids and / or pores between the plurality of interconnected fibers and / or fibrous adhesive particles. Is preferable. The adhesive layer can have multiple voids, multiple pores, or both. When the adhesive layer connects two or more conductive layers (eg, one or more power application layers, heat generating layers, or both), power passes through voids and / or pores, or electricity. The connection is maintained, or the adhesive layer does not interfere with the power supply between the two or more conductive layers, or they are combined to form a connection between the two or more layers. The adhesive layer may have a sufficient amount of voids and / or pores. The voids and / or pores of the adhesive layer correspond to an area of about 10 percent or more, about 20 percent or more, about 30 percent or more, preferably about 40 percent or more, more preferably about 45 percent or more of the total surface area of the heating layer. Can be. The voids and / or pores of the adhesive layer can correspond to about 90 percent or less, about 80 percent or less, about 70 percent or less, or about 60 percent or less of the total surface area of the heating layer. The adhesive layer may have a basic weight of about 5 g / m ² or more, about 10 g / m ² or more, or about 15 g / m ^{2 or more.} The adhesive layer may have a basic weight of about 50 g / m ² or less, about 30 g / m ² or less, or about 25 g / m ² or less (ie, about 19 g / m ^2). The adhesive layer may have an initial melting temperature of about 85 ° C. or higher, about 100 ° C. or higher, or about 110 ° C. or higher. The adhesive layer may have an initial melting temperature of about 200 ° C. or lower, about 180 ° C. or lower, or about 160 ° C. or lower (ie, about 150 ° C.). An example of an adhesive cloth that can be used is sold by Spunfab Ltd. under the trade name Spunfab®.

The power application (ie, busbar and / or electrode, one or more wires, or a combination of both) is about 1.0 x 10 ^-2 Ω / sq or less, about 5.0 x 10 ^-2 Ω / sq or less. Surface conductivity of about 1.0 × 10 ^-3 Ω / sq or less, more preferably about 5.0 × 10 ^-3 Ω / sq or less, and most preferably about 1.0 × 10 ^-4 Ω / sq or less. Any material may be used as long as it has a ratio. The power application (ie, busbar and / or electrode, one or more wires, or a combination of both) is about 1.0 x ^10-9 Ω / sq or more, about 5.0 x ^10-8 Ω / sq. Any material may be used as long as it has a surface conductivity of about 1.6 × ^{10-8 Ω / sq or more.}

The heater may be composed of only a heat generating layer (for example, the heater may contain only one layer). The heater preferably comprises at least three layers. However, the heater does not have to include any layer fixed on the heat generating layer. For example, the heater may include a layer that interpenetrates the heating layer to form a partial and / or complete protective layer on top of the heating layer. The heating layer may partially and / or completely incorporate the individual material (ie, the protective layer) into the heating layer so that the heating layer is protected by the protective layer. The protective layer may be a reinforcing layer. For example, the protective layer may reinforce individual fibers so that each fiber is reinforced to increase the strength characteristics of the heater (eg, tensile strength, tear strength, folding strength, etc., or a combination thereof). .. The material of the protective layer is such that the protective layer enhances the strength of the heating layer (eg, tensile strength, tear strength, folding strength, etc., or a combination thereof), the thermal insulation properties of the heating layer, or both. Any material may be used as long as it is woven into the heat generating layer. The protective layer preferably increases the strength of the heat generating layer and forms a partial dielectric film or a complete dielectric film on the heater. The protective layer may form an insulating layer on the front surface, the back surface, each side edge, or a combination thereof so that the outer heating layer has dielectric properties, flow resistance properties, or both. The protective layer may form a layer on the front side, the back side, the side edge, the upper edge, the bottom edge, or a combination thereof so that the protective layer becomes a dielectric layer on the heat generating layer. The protective layer can fill the pores and / or voids between the individual fibers of the heating layer. The protective layer fills the pores and / or voids between the individual fibers of the heating layer, but does not completely surround the individual fibers, impairing the connections and / or electrical connections between the individual fibers of the heating layer. It is preferable that there is no such thing. The heater may include one or more mounting layers. The mounting layer may be a single-sided adhesive layer. The mounting layer may be made of the same material as the adhesive layer described herein for mounting the power application. The attachment layer may be an adhesive layer (for example, glue, paste, spray adhesive, adhesive film, adhesive that can be peeled off and pasted as it is, hook-and-loop fastener, etc.). The attachment layer is preferably an adhesive film that can be peeled off and attached as it is. The mounting layer may exhibit the protective properties described herein. The heater does not have to include a mounting layer.

The heater and / or sensor described herein may include one or more or two or more heating layers for heat generation and / or sensing. For example, two substantially mirror image heaters / sensors may be created and juxtaposed in the apparatus so that each heater generates heat and each heater senses. When a plurality of heaters are used, the total area of a single heater may be approximately the same as the total area of the plurality of heaters. When a plurality of heaters are used, the plurality of heaters may be used simultaneously, individually, alternately, or in a combination thereof. For example, when two heaters / sensors are provided on the steering wheel, one heater / sensor may generate heat and the other sensor / heater may detect a state such as a hand. The heater / sensor may then be alternated so that the presence of the occupant's hand can almost always be determined. In another example, if two or more heaters / sensors are attached to the steering wheel, each sensor can sense half or a quarter of the steering wheel, so it can sense multiple hands as well as specific hands. Can sense the position.

The heaters described herein can be made using a single process. This process may include one or more of the following steps in virtually any order. A plurality of fibers described herein can be obtained. The fibers described herein are coated with a metal, cut to a desired length and refined to flatten the fibers, or refined to have an oval shape. These combinations can be made. These fibers can be mixed with any of the binders described herein, coated with this binder, contacted with this binder, or combined. These fibers may be placed in a container so that the fibers are randomly arranged. These fibers can be extruded with or without a binder to form a non-woven sheet. These fibers may be entangled with hydroentanglement. These fibers may be sprayed with the binder, immersed in the binder, coated by the binder, or a combination thereof. Attach one or more power application parts to the heating layer. Attaching one or more wires, one or more non-woven conductive strips, one or more electrodes, and / or multiple busbars, or one or more pre-assembled power application parts, or these Combination of. Pre-assembled to heat a heating layer, one or more wires, one or more non-woven conductive strips, one or more electrodes and / or busbars, or to form an electrical connection to the heating layer. Attach one or more power application parts, or a combination thereof. One or more wires, one or more so that when the adhesive layer is placed on the heater and heated, the adhesive layer connects the pre-assembled power application to the heating layer to form an electrical connection. Non-woven conductive strips, one or more adhesive layers, one or more busbars, and / or electrodes, or a combination thereof to produce a pre-assembled power application. Connecting one or more power sources to a power source, a wire, or both. The shrink tube is connected to one or more power application units, the power supply, so that the contraction tube contracts during the heating step and the power supply, wire, or both are electrically and physically connected. , Line, or a combination of these. A front coating layer, a back coating layer, a connecting layer (eg, an adhesive layer, a mechanical mounting layer, or both), or a combination thereof, is provided in the heat generating layer. Excision of the heating layer so that the heating layer contains through holes, notches, or both. A flame-retardant material, a flame-resistant material, a water-resistant material, a dielectric layer, or a combination thereof shall be provided in the heat generating layer. Attach the temperature sensor to the heating layer, heater, or both. Electrically connect the temperature sensor to the power supply. Connecting the heating layer to the controller, the control module, or both (eg, physically and / or electrically). Connecting heaters to vehicle seats, floors, steering wheels, mirrors, inserts, or combinations thereof.

As described herein, by incorporating a heater into this other component during the construction of another component, the heater and this other component may form a single component. Good. For example, when the article is a molded part, by adding a heating medium forming a heating layer in the mold, when the final article is manufactured, the heater layer extends over the entire article and electricity is applied. The entire article may be warmed up. The heat generating medium may be a plurality of individual fibers. The heat generating medium may be a sheet. The heating medium may be scattered in the mold, cut and placed as a sheet in the mold, mixed with the molding material and added to the mold together, or a combination thereof.

The heaters described herein can be controlled using any of the methods described herein. The heater preferably includes a negative coefficient temperature sensor or thermistor that measures the temperature of the heater and the controller controls the temperature of the heater, ventilation system, air conditioning system, or both, based on the measured temperature. The heater, air conditioning system, ventilation system, or both can be controlled by pulse width modulation.

The heater may include a sensor. It is preferable that the heater can be a sensor. The sensing part of the heater can be used at the same time as heat generation, during heat generation cycles, during heat generation cycles, or in combination thereof. It is preferable that the heat generation cycle and the sensing cycle alternate. The sensor may detect the presence of an occupant, the occupant's contact with a component, the mass of the occupant, any other sensing function described herein, or a combination thereof. The sensing portion of the heater may include only the heater (ie, a power applying portion, one or more power connecting portions, a continuous heating layer). The sensing unit may function when the signal reaches the heater via one or more busbars.

The signal may be any signal that detects the occupant, the contact by the occupant, the presence of the occupant, or a combination thereof. The signal may be an analog signal, a digital signal, or a combination of both. The signal has a frequency, and the frequency of the signal may be a predetermined frequency. As the signal passes through the heater, the frequency of the signal can be constant. The frequency of the signal can shift when the occupant comes into contact with the component, including the heater, or when the occupant is in close proximity to the component and / or the heater, or both. The frequency change may be any frequency deviation that is sufficient to be caused by the occupant (eg, millihertz, microseconds, etc., or a combination thereof). For example, the frequency deviation (if any) that can occur when the bag is placed on the seat is not sufficient to start the sensor and send a signal compared to the frequency deviation by the occupant. The frequency deviation may be any frequency deviation as long as it is associated with a change in capacitance. The capacitance may be one or more, but is preferably a plurality of capacitances. The capacitance may be the measured capacitance, the calculated capacitance, or both. The capacitance may be the average capacitance. The capacitance may be the average of a plurality of measured capacitances, a plurality of calculated capacitances, or both. The average capacitance may be about 3 or more, 5 or more, or about 10 or more calculated capacitance, measured capacitance, or an average of both. The measured capacitance, the calculated capacitance, or both of the system may be about 50 pF or higher, about 75 pF or higher, or about 100 pF or higher. The measured capacitance, the calculated capacitance, or both of the system may be about 500 pF or less, about 400 pF or less, about 300 pF or less, or about 200 pF or less. The frequency deviation is preferably associated with a change in capacitance between about 100 pF and about 200 pF, a measured capacitance, a calculated capacitance, or a combination thereof. For example, this signal may be measured when a signal of a certain frequency enters the heater and exits the heater. When the occupant is in contact with the heater, the frequency of the signal can shift, so that the frequency of the signal when the signal is output is delayed as compared with the signal when the occupant is not in contact with the heater. In another example, the capacitance of the system was measured and the measured value of the system in the absence of an occupant was 0 pF, measured and / or calculated when the occupant was in contact with the heater and / or sensor. The capacitance of the system may be set relative to the measured capacitance of the system so that the capacitance of the system is about 100 pF.

The capacitance of the system can be calculated using the RC series circuit equation. The capacitance of the system can be calculated using the equation τ = RC. In the equation, R is the resistance of the reference resistor, C is the capacitance of the capacitor to be monitored, and τ is the time constant. The time constant (τ) during discharge may be the amount of time required to drop about 36.8 percent from the voltage applied across the circuit. Since the reference resistor has a known value, the capacitance can be calculated to obtain the capacitance of the system by obtaining the time constant. Capacitance can be discharged to about 36.8 percent after τ and basically completely discharged after about 5τ (0.7 percent). Alternatively, the charging time constant (τ) may be the time required for the voltage to reach about 63.2 percent of the voltage applied across the circuit. Capacitance can basically be fully charged after about 5τ (99.3 percent). The signal may be monitored continuously, intermittently, or both. The capacitance of the system can be measured and / or calculated using the RC series circuit equation described herein and / or using the capacitive voltage divider technique.

The capacitive voltage divider technique can work to divide the voltage into a measured voltage and a reference voltage. The capacitance of the system can be determined by comparing the reference voltage with the measured voltage. An example of a voltage divider technique that can be used with the teachings herein is DS01478B, a method of obtaining a sensing solution by Burke Davison of Microchip, entitled Capacitive Voltage Divider ( It is described on pages 1-25 of the paper entitled "mTouch ^{TM Sensing Solution Acquisition Methods Capacitive Voltage Divider)".} This teaching is expressly incorporated herein by reference for all purposes. The capacitive voltage divider method can be used to measure the capacitance of the heater / sensor instead of or in addition to the RC series circuit equation.

In the monitoring step, the signal, signal frequency, signal capacitance, voltage, time constant, or a combination thereof (hereinafter referred to as the measurement signal) is used to determine the presence of the occupant, the contact of the occupant, or both. It may be compared with a lookup table. The measurement signal may be filtered through a resistor before the measurement signal reaches the signal controller. The resistor may serve to assist the system in determining the presence of the occupant, the contact of the occupant, or both. The resistor may function to protect the measurement node of the system, to protect the microprocessor, or both. The measurement signal may be compared to a look-up table to determine occupant status. The measurement signal can determine whether the occupant is present, whether the occupant is in contact with the component, or both. The measurement signal is constant when the occupant is in contact with the component including the heater, and the change in the measurement signal is other than the predetermined measurement signal (for example, the occupant has not been in contact with the heater for a predetermined time for a predetermined time). If so, it can provoke a given response. A predetermined response can occur after a measurement signal other than the predetermined measurement signal exists for about 1 second or longer, about 2 seconds or longer, about 3 seconds or longer, or about 5 seconds or longer. This predetermined response can occur after a measurement signal other than the predetermined signal has been present for about 30 seconds or less, preferably about 20 seconds or less, more preferably about 10 seconds or less. For example, if the driver releases the steering wheel, the car will not take over until it is released for a longer period of time. The heat generation function may include one control device to supply electric power to the heater so that the heater generates heat, and the sensing function may include another control device to perform sensing, and the heat generation function and the sensing function may be included. May be operated by the same controller.

Power, current, voltage, or a combination thereof may be applied continuously, intermittently, varied, or combined so that the heater heats up. It is preferable that the control device can control the heater, adjust the temperature of the heater, or both by using pulse width modulation (PWM). Depending on the desired temperature of the heater, the PWM signal that supplies power can be longer or shorter. Therefore, power is applied or not applied (ie, turned on or off), and the power application time is adjusted. For example, when the heater is on the medium, PWM can provide a signal between about 60 percent and about 80 percent. Therefore, the heater is off for about 40 percent and 20 percent of that time. The sensing signal may interrupt the heating signal and / or the heating voltage so that one or more, preferably multiple, measurement signals are taken while the heating is temporarily stopped. For example, heat generation can be interrupted for about 500 ms so that one or more signals are taken. This process can be repeated intermittently so that the occupants are detected. The sensor may provide sensing function when the heater is off and / or when no power is applied to heat the heater.

The signal can be supplied to the heater at any time so that the heater is used for sensing. It is preferable that a signal is applied to the heater when no power is applied (ie, when the heater is "off"). During the application of the sensing signal, one or more transistors may disconnect the heater from the power supply, disconnect the heater from the ground, or both. During the application of the sensing signal, the power controller, the heat generation function, or both may be disconnected. This signal may be any signal as long as it has a frequency. This signal may be any signal as long as it is a signal that shifts due to a change in capacitance.

The teachings herein provide fever and sensing methods. The method comprises one or more of the steps described herein in substantially any order. Electric power can be applied to the heater so that the heater heats up. A signal can be applied to the heater so that the heater becomes a sensor. Power, signals, or both can be applied alternately or simultaneously. The power can be turned off intermittently so that the sensing signal is applied. The controller may measure the capacitance deviation of the system, the frequency deviation of the measurement signal, or both. One or more transistors may turn on and / or off the heating part of the circuit (eg, ground, power supply, or both).

FIG. 1 shows an infrared image of the steering wheel 2 when the heater 10 and the sensor 20 are on. The heater 10 / sensor 20 includes a power application unit 12 at each end, and these power application units are connected to a power line so that the heater 10 / sensor 20 provides heat generation and sensing functions. As shown, the heat of the heater 10 is uniform around the steering wheel 2.

FIG. 2 shows the heater 10 / sensor 20. The power application units 12 are arranged at both ends so that the heater 10 generates heat when power is applied and the sensor 20 senses it.

FIG. 3A shows a close-up view of the power application unit 12 of FIG. The power application unit 12 includes a power application line 14, and the power application line 14 is covered with a power application material 16 connected via an adhesive (not shown).

FIG. 3B shows a close-up view of a power application unit 12 that includes a power application line 14 needle punched into the heater 10 / sensor 20 that forms electrodes for supplying power and / or signals.

FIG. 4 shows a cross section of the steering wheel 2. The steering wheel 2 includes a core 4. The heater 10 / sensor 20 winds around the core 4. The heater 10 / sensor 20 is covered by the trim layer 6.

FIG. 5A shows heaters / sensors 10 and 20 having three power application units 12. As shown in the figure, the central power application unit 12 is a positive power application unit, and negative power application units 12 are at both ends. The central power application unit 12 may be located at substantially any position between the two terminal power application units 12, but is preferably located substantially in the center. The positive power application line 14 extends to and contacts the central power application unit 12, and each terminal power application unit 12 is connected to another negative power application line 14.

FIG. 5B shows two individual heaters / sensors 10 and 20 that are combined to form one heater / sensor. Each of the individual heaters / sensors 10 and 20 includes a positive power application unit 12 and a negative power application unit 12 connected to the individual power application lines 14, respectively. As shown, the positive power application units 12 are close to each other and the negative power application units 12 are located outside the heaters / sensors 10 and 20. As shown, each sensor 20 can individually sense the occupant's hand (not shown) so that the sensor 20 is in the sensing mode whether one or more occupant's hands are in contact with, for example, the steering wheel. I can sense it.

FIG. 5C shows two individual heaters / sensors 10 and 20 electrically connected to each other via a common positive power application line 14 and a negative power application line 14. As shown, the negative power application line 14 is connected to the outer ends of the heaters / sensors 10 and 20, and the positive power application part is at the ends of the heaters / sensors 10 and 20 opposite to the negative power application part 12. Close to each other. As shown, each sensor 20 can individually determine contact with the occupant, so that the sensor can determine whether one or more body parts of the occupant are in contact with the sensor 20 during the sensing phase.

FIG. 6A shows the heaters / sensors 10 and 20 having a plurality of power application portions 12 in the longitudinal direction extending along the lengths of the heaters / sensors 10 and 20. The power application portions 12 in the longitudinal direction extend substantially in parallel along both side edges of the heaters / sensors 10 and 20. In the meantime, the material of the heater / sensor extends, and the two opposing power application units 12 are electrically connected to each other.

FIG. 6B shows the heaters / sensors 10 and 20 of FIG. 6A connected to the steering wheel 2. The heaters / sensors 10 and 20 have a plurality of power application units 12 wound around the core 4 (not shown) so that the power application units 12 are substantially close to each other, and power application extending from each power application unit 12. Includes line 14 and. As shown in the figure, an insulating layer 50 that does not insulate in the materials of the heaters / sensors 10 and 20 but electrically insulates the two power application parts 12 from each other is arranged between the power application parts 12, so that the power is one side. Since it is necessary to move from the power application unit 12 to the second power application unit 12 via the materials of the heaters / sensors 10 and 20, heat is generated.

FIG. 7 shows a heater having a power application line 14 connected to each end of the heater / sensor 10 and 20 so that the power application unit 12 in the longitudinal direction extends along the length of the heater / sensor 10 and 20. / Sensors 10 and 20 are shown. Since each power application unit 12 extends in the longitudinal direction from each end and terminates before the power application units 12 come into contact with each other so that a small gap 52 exists between each end of the power application unit 12, each power application unit 12 is terminated. The positive power application unit 12 is electrically insulated, and each negative power application unit 12 is also electrically insulated. The negative power application unit 12 and the positive power application unit 12 are electrically connected via the heaters / sensors 10 and 20.

FIG. 8A shows two individual heaters / sensors 10, 20 including positive and negative power application units 12, respectively, connected to the power application line 14. The heaters / sensors 10 and 20 individually generate heat and individually sense by passing power and / or signals from one power application unit 12 to the opposite power application unit 12 via the heater material. Since each sensor 20 can individually detect the state, it is possible to simultaneously detect a plurality of states such as two hands.

FIG. 8B shows the two individual heaters / sensors 10 and 20 of FIG. 8A wound around the steering wheel 2. The power application lines 14 are connected to each other so that power and / or signals are distributed between the heaters / sensors 10 and 20.

FIG. 9A shows heaters / sensors 10 and 20 including three longitudinal power application portions 12. As shown, the two outer power application units 12 are negative and the middle power application unit 12 is positive. Each power application unit is connected to the power application line 14 so that the power and the sensing signal are applied via the heaters / sensors 10 and 20.

FIG. 9B shows a cross-sectional view of the heaters / sensors 10 and 20 wound around the steering wheel 2. As shown, the two negative ends of the heaters / sensors 10 and 20 are placed in close proximity and even come into contact with each other, but the heaters / sensors 10 and 20 are not short-circuited.

FIG. 9C shows a cross-sectional view of another heater / sensor 10 and 20 wound around the steering wheel 2. As shown, the two positive ends of the heaters / sensors 10 and 20 are placed in close proximity and even come into contact with each other, but the heaters / sensors 10 and 20 are not short-circuited.

FIG. 9D shows heaters / sensors 10 and 20 wound around the steering wheel 2. Both ends are brought into contact with each other so that there is no gap between both ends of the heaters / sensors 10 and 20.

FIG. 10 shows heaters 10 and 20 including a power application unit 12A for applying power at each end and a power application unit 12B for signal application at each end. Each power application unit 12A for power application is connected to the power application line 14A so that power is applied to the heaters / sensors 10 and 20 to generate heat. Each power application unit 14B for signal application is connected to the power application line 14B so that a signal is applied to the heaters / sensors 10 and 20 to detect occupant contact when the heat is off. Each power application line 14B is connected to a microprocessor 60 that senses occupant contact.

FIG. 11 shows a circuit diagram during sensing. A signal is supplied from the input unit 22 and input to a heater (not shown) of the steering wheel 2. This signal is then returned to the output section 24 via the resistor 26, where it is compared to the look-up table. As shown, the steering wheel 2 forms one side of the capacitor 40 so that the frequency deviation is sensed via the output unit 24 when the occupant 100 is in contact with the steering wheel 2. It forms the other side of the capacitor 40.

FIG. 12 shows a circuit diagram including both a heating unit and a sensing unit. During the operation of the heater 10, electric power is applied from the power source 30 to the heater 10 via the second transistor 34. During sensing, a signal is sent from the input unit 22 to the heater 20, and the first transistor 32 and the second transistor 34 are turned off, so that the signal is sent to the output unit 24 via the resistor 26.

FIG. 13 shows one operation example of the heater 10 and the sensor 20. Since power is supplied to the heater 10 by pulse width modulation, the power is applied for a predetermined time, and then the power is turned off for a predetermined time. During the time the heater is off, a signal is applied to the heater so that the heater is used for sensing.

The numerical values described in the present specification are from the smaller value to the larger value when the smaller value and the larger value are separated by at least 2 units regardless of the numerical value. Includes any value that increases by one unit. As an example, if the amount of component or the value of a process variable, such as temperature, pressure, time, etc., is stated to be, for example, 1-90, preferably 20-80, more preferably 30-70. In the specification of the present application, values such as 15 to 85, 22 to 68, 43 to 51, and 30 to 32 are clearly listed. If the value is less than 1, one unit is appropriately considered to be 0.0001, 0.001, 0.01, or 0.1. These are merely examples of specifically intended values, and any possible combination of numbers between the listed minimum and maximum values is also considered to be explicitly stated herein. It shall be.

Unless otherwise stated, any range includes endpoints and any number between these endpoints. The "about" or "approximately" used with respect to a range spans both ends of the range. Therefore, "about 20 to 30" shall range from "about 20 to about 30", including at least the specified end points.

Disclosure of all provisions and references shall be incorporated by reference for any purpose, including patent application and publication. The expression "consisting essentially of" to describe a combination substantially impairs the identified element, component, component, or step and the basic and novel properties of this combination. It shall include other elements, components, components, or steps that may not be present. When the terms "comprising" or "including" are used in the specification of the present application to describe a combination of elements, components, components, or steps, these elements, Embodiments consisting of components, components, or steps are also conceivable. In the specification of the present application, by using the term "~ get / ~ may", any of the attributes included and described as "get" shall be optional.

Multiple elements, components, components, or steps can be provided by a single integrated element, component, component, or step. Alternatively, a single integrated element, component, component, or step can be divided into multiple individual elements, components, components, or steps. Disclosure of "one" or "one" to describe an element, component, component, or step does not preclude an additional element, component, component, or step.

It should be understood that the above description is for illustration purposes only and is not limited to this. After reading the above description, one of ordinary skill in the art will be aware of many embodiments as well as many applications, in addition to the plurality of examples provided. Therefore, the scope of this teaching should not be determined with reference to the above description, but with reference to the appended claims and the entire scope of equivalents covered by such claims. Should be decided. Disclosure of all provisions and references shall be incorporated by reference for any purpose, including patent application and publication. The omission in the appended claims for any aspect of the subject matter disclosed herein is not a waiver of such subject matter, but the subject matter of the invention in which the inventors disclose such subject matter. It should not be considered that it was not considered part of.

Claims (12)

A heater and sensor for the steering wheel or seat of a vehicle.
It ’s a heater,
A non-woven sheet composed of a plurality of individual fibers, 60% or less of the plurality of individual fibers are arranged in the same direction, and the heat generating layer having an average length of the plurality of individual fibers of 130 mm or less is included.
A conductive wire to which electric power is applied to generate heat in the heating layer, and a conductive wire connected to the heating layer.
And a heater with a,
A heater circuit that supplies power to the heater during the first period,
A sensing circuit for the output sensing signal to the heat generating layer during a second time period, sensing the frequency of the measurement signal on the heat generating layer in the second period,
The heater circuit controls the power output during the first period and selectively detects occupants in the vicinity of the sensing circuit in response to changes in the frequency measured during the second period. With a control device configured to
With
The first period and the second period do not overlap,
Heater and sensor. The heater and sensor according to claim 1, wherein the conductive wire includes a strand of a braided wire. The heater / sensor according to claim 2, wherein the conductive wire is made of copper. The heater / sensor according to claim 1, wherein the heat generating layer contains felt. The heater / sensor according to claim 1, wherein the first period and the second period alternate. The heater / sensor according to claim 1, wherein the heater is at least partially defined by a first conductive wire arranged on one surface portion of the heating layer. The heater / sensor according to claim 1, wherein the control device calculates a change in capacitance determined based on the change in frequency measured during the second period. The heater / sensor according to claim 1, wherein 30% or less of the plurality of individual fibers are arranged in the same direction. The heater / sensor according to claim 1, wherein 20% or less of the plurality of individual fibers are arranged in the same direction. The heater / sensor according to claim 1, wherein the average length of the plurality of individual fibers is 30 mm or less. The heater / sensor according to claim 1, wherein the average length of the plurality of individual fibers is 25 mm or less. The heater / sensor according to claim 1, wherein the temperature gradient over the heating layer is substantially uniform.

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