CN104488098B - 分布式热电加热和冷却的医疗、上层、无线宠物和自动化生产 - Google Patents
分布式热电加热和冷却的医疗、上层、无线宠物和自动化生产 Download PDFInfo
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Abstract
一种热电装置,包括由热绝缘材料形成的伸长板,以及具有多个热电元件,其包括位于所述绝缘材料内部的紧压导体和位于绝缘材料外部的扩展导体,该热电元件与其它层结合,用于泄漏电流拦截、体液吸收,以及保存压力重新分布的柱。该热电装置可集成到需要加热或冷却的多种表面或外壳中,并使用早已存在的自动设备所生产。
Description
在我们先前于2011年5月4日递交的美国专利申请号为13/101,015和于2012年3月5日递交的美国专利申请号为13/394.288的美国专利申请,以及于2011年9月12日递交的PCT申请号为PCT/US11/51227和于2012年7月3日递交的PCT申请号为PCT/US12/45443中的PCT专利申请中,我们描述了热电加热和冷却系统,其包括机织到或塞进或层叠到绝缘板中的热电元件的连接线,其可由柔软材料,像泡沫、记忆泡沫、绳套或天然纤维组成。导体材料在所述板的两侧扩展,以在一侧上散发热量,并在另一侧上冷却。利用热电加热和冷却升级的材料或表面这样被称为分布式热电板。在我们先前的申请中,还描述了绝缘板在床垫、椅子和毛毯内的集成。最终的结果是床上用品、座椅、毛毯和其它产品的成本相对较低,均匀分布地增加了加热和冷却。
本发明提供了加热和冷却的产品相对于现有技术的各种增强和改进,还提供了热电加热和冷却板与座垫、轮椅、病床、床顶以及宠物床的集成。此外,本发明提供了对用于各种这些和其它产品中的分布式热电板的部件生产的增强和改进。最后,本发明提供了对分布式热电系统的功率输送的改进,以用于增加的移动性。
更具体地说,根据本发明,我们提供了用于病床和轮椅的分布式热电加热和冷却板,其可实现低泄漏电流,与失禁垫兼容,以及保存下面支撑表面的压力分布。我们提供了利用可扩展绞线和柔性电路配置用于分布式热电产品所需的部件自动化生产的过程。我们提供了加热和冷却的座椅上层,其维持了座垫的原始及任意形状。最后,我们提供了给动物使用且具备加热和冷却的升高的宠物床。
本发明进一步的特征和优点将通过下面的详细说明并结合附图看出,其中相同的数字表示相同的部分,其中
图1示意性地示出了具有低泄漏电流的病床;
图2示意性地示出了与失禁垫兼容的病床;
图3示意性地示出了保持压力重新分布的病床;
图4示出了用于图1-3中的病床的热电板的电子控制和风扇的壳体;
图5示意性地示出了用于生产热电线和板的自动化处理,其中所述线使用绞线;
图6示意性地示出了用于生产热电线的自动过程,其中所述线使用柔性电路材料;
图7示意性地示出了功率如何可无线地传递到热电板用于增加的移动性;
图8示意性地示出功率如何通过可移动触点可传递到热电板用于增加的移动性;
图9A和9B示意性地示出了热电板如何可集成到座椅垫或床顶上;
图10示意性示出了热电板如何可集成到供动物使用的升高的宠物床上。
图1示出了由分布式热电线组成的病床,该分布式热电线包括扩展连接线101、热电元件103和扩展环线102。流经热电元件103的电流引起热量转移到床面或从床面转移,这取决于电流的方向。除了所述线之外,绝缘泡沫105包括热电板,这也是该床面的顶层。下方的隔网层106提供了用于风扇112的多孔通道,以将空气从入口109转移至出口110,这样空气流过环线102以分别从环境中消除热量或将热量释放到环境中。该热电板和空气流动层都位于由框架115支撑的标准病床垫114的顶部。容纳电子设备、控制系统、电源和风扇112的盒子111通过狭槽116连接到隔网上。当可位于各个位置的不安全状态达到时,温度传感器或过温开关113或其它装置关闭电源或促进关闭电源。这些传感器也可用于控制该床面至恒定温度用于恒温控制。不限于此,所述热电元件103的分布可具有不同的密度,或布置在具有单独或共同的温度控制的区域中,以优化用于患者的系统。因为对于患者可能在医院的故障条件下经历非常低泄漏电流的需求,所以将导电片108设置于患者和热电线之间。此导电片将优先转移任意电流并使剩余的电流最小化,该剩余电流在防水罩107可能损害时流经患者。该导电片优选是金属化织物,其在所有四个横向方向上伸展以符合躺在床上的患者的身体轮廓。具有这些属性的导电片可从Less EMF公司和其它供应商处获得。不限于此,其它的导电片也可以用于此目的,例如幕、金属网、金属化网和其它含金属或碳的材料。
图2示出了图1的病床如何与失禁垫201相配。为了实现希望的皮肤冷却,以防止褥疮和出汗,隔离患者身体与热电连接线101的层应尽可能地薄。在医院使用的标准失禁垫具有厚的用于体液的吸收材料。图2中的失禁垫201具有布置在热电连接线之间的厚区域202。这些厚区域充当储液罐并允许失禁垫201在连接线101顶部的部分薄得多。不限于此,这些厚存储区可在位于遍及床的适当部分的阵列或平行槽中。
许多病床具有压力重新分布特性,以防止或减少褥疮的发病率。一些这样的床在两组或多组支撑区域之间交替压力,以防止身体的任何部分遭受太久的高压。其它床具有一排蘑菇状的泡沫以尽可能多分布压力。还有其它床具有一排气囊,其中空气可一个气囊流到另一个来平衡压力分布。皮肤冷却已显示出进一步防止或减少了褥疮的发病率,超出了单独的压力重新分布的益处。因此,需要提供冷却层,其保留了下层表面的压力分布特性。
图3示出了热电板105如何安装在间隔开的支撑岛301的矩阵上。这些岛能够相互独立的上下位移。即使岛301的材料是硬的,但它们的小尺寸和独立移动允许保留压力分布。岛302之间的空间允许气流从入口109流到出口110。这些岛可由隔网、闭孔泡沫、开孔泡沫、橡胶、塑料、气球、流体囊、凝胶或任何其它合适的材料组成。在囊的情况下,该流体可以是凝胶、油、油脂、蜡、水、空气或其它合适的液体或气体。具有包括支柱301的空气流层的热电板105布置在现有压力重新分布表面302的顶部。不限于此,压力重新分布表面302可由成型泡沫、蜂窝状凝胶、交变压力机构、气囊阵列、粘性流体袋或任何其它表面组成。这些表面可从Roho、Hill-Rom、Stryker、Sunrise、Pride Mobility和其它处获得,并适用于座椅和床上用品,包括轮椅、病床和手术台。
图4示出了热电板操作所需的机电组件如何可容纳在单独的盒子111中。该盒子111具有容纳电源403、风扇112和电子控制设备402的空间。电子控制设备402提供了打开和关闭的功能404,选择温度或冷却功率电平的功能405,具有灯光的表示冷却强度或温度的功能406以及表示故障状态的功能407,例如温度过高或部件故障。该盒子具有用于隔网的狭槽116,不限于此,或用于气流和悬挂所述盒子的钩401的其它通道。
对于由目前可用的各热电芯片所提供的冷却功率来说,通常在加热和冷却的产物中需要成百上千这样的芯片。热电线也需要成百上千个可扩展的导体部分例如绞线以及成百上千的应变消除所构成。单独地插入各热电偶接点需要成百上千个进入到该绝缘和气流层的插入点。因此,需要使制造热电线和将所述线插入到绝缘体中制作热电板的过程自动化。
图5示出了如何利用目前已有的三个共同自动化机器实现热电板的制造。第一机器501切割绞线的长度并在每个端部上卷曲套圈。该机器的输出是带有明确端部的绞线段。这种类型的机器可从Schluniger和其它处获得。
图5中的第二机器502是制作电路板的机器。该机器502能分配胶水、分配焊料、自动布置芯片和其它电子组件,然后利用受控的温度曲线使焊料在烘箱中流动。为了制作热电线,执行这些功能以产生热电偶接点103的条带504。绞线连接101从条带504布置到另一条带504,并且绞线环线102布置在条带504的外侧上。不限于此,该连接线101组和环线102组可手动或自动布置在具有梳状槽的载体上,以便连接线的端部与条带504上的焊垫对齐。连接线101、环线102和条带504的组合被移动通过回流炉熔化,然后硬化该焊料。在将条带504分割(singulating)为连接的但是单独的热电偶接点103之后就产生了热电线。
图5中的第三机器包括一列尖管503,其能够同时在绝缘层中穿透许多孔。该机器还具有在顶部和底部的一列通孔504,以引导所述管并将绝缘材料保持在适当的地方,以及气动或其它系统来产生完全穿透和插入所需要的力。一旦成列的管已完全穿透所述绝缘材料,热电线的环线102端手动或自动布置在所述管中。然后,成列的管在与其插入的相反方向上去除。完整的热电板在所有的插入同时完成时产生。
图6示出了用于自动化生产热电带条的另一种方法。在这种情况下,柔性电路材料601用来代替图5的绞线与刚性条带。图6中所示方法的目的之一是不需要铜的蚀刻或基板的图案化。图6的步骤1是柔性电路材料601,例如镀在聚酰亚胺基板上的铜的片材。不限于此,柔性层可以是聚酯、聚酯薄膜或其它合适的材料。图6的步骤2示出了在压力机或其它合适的机器中冲压孔602、603和604之后的柔性材料601。每个角上的孔602用于板材在固定装置中的套准和安装,便于布置和对齐。孔603去除了在后面的步骤中布置的芯片端部之间的电连接。孔604用于安装和夹持应变消除,防止损坏芯片的大的力干扰。图6的步骤3示出了由布置在柔性电路材料的背面上的环氧树脂或其它硬的或硬化材料制成的应变消除605。这种应变消除605可进一步形成或插入到所述夹持孔604中,用于额外的应变缓解强度。图6的步骤4示出了在铜垫上布置焊锡膏605,为在后面的步骤中布置热电芯片作准备。图6的步骤5示出了以交替的方式在柔性电路材料上并邻近所述焊锡膏布置606来布置n型热电芯片607和p型热电芯片608。然后,图6的步骤5是在焊料回流炉中处理装配,其中焊锡膏形成了与芯片端部和铜垫的硬共晶键。不限于此,在步骤3中布置的环氧树脂或其它胶可在步骤5之后在相同的回流炉中进行固化。图6的步骤6示出了条带中的最终切口609,其代表二维的热电带条,如图6的步骤7所示准备用于插入到105中。插入过程实现了n型和p型热电芯片607和608的背靠背布置。现在,图6的步骤7的热电板类似于分布式热电板,可用于座垫、床面、冰箱壁、饮料包装或其它需要加热或冷却和/或能彼此切换的产品。
使用本发明和同一发明人的其它发明的分布式热电板能够增加对任何座位或床表面的加热与冷却。然而,许多这样的表面需要移动性,例如带轮子的办公椅。这些产品需要使用不抑制或限制移动性的无线或其他装置将电力输送到所述热电板。图7示出了一个结构,其中无线电力输送到椅子707内部的热电板。无线电力装置购自Powermat、Qualcomm、WiTricity和其它提供无线电力到移动设备,例如手机和汽车的公司。这些无线电力发射器701和702提供电力到移动设备703内部的对应无线接收器。热电板所需的功率电平大于用于手机的701,但小于在汽车中用于电池充电的702。因此可以预期,例如任一设备可根据需要来驱动办公椅707。
图8示出了另一实施方式,以允许含热电板产品的移动性。在这种情况下,导电刷804滑动接触下层垫801,其含有用于电源电压的交替导电电极802和接地电极803。不限于此,多个刷子804安装在三脚架806的端部上或在含有分布式热电板的任何移动设备的轮上。只要至少一个刷子804接触所述电源电压电极802,并且至少另一刷子接触接地电极803,可利用图8中的二极管阵列电路将电源输入电压805输送到椅子中的热电板。所有的电极802和803电连接到所述二极管阵列802的两端,并且所述二极管的整流功能确保了电源输入电压805从电力供给源流到接地中。
用于加热和冷却座位的应用是座位垫或靠背垫,其尺寸与这些现成垫是同等的,并使用电源线或电池供电。图9A和9B示出了这样的垫子。进气口109在座椅底垫的前面或在座椅靠背垫的顶部。不限于此,该进气口可以部分或全部是罩107的分布孔。热电板105布置在隔网气流层102的顶部。鼓风机904位于座椅底垫的背部或座椅靠背垫的下端。空气从入口109通过鼓风机吹入,并从空气出口110排出。取决于座垫的安排,排气口110的优选方向可能被阻塞,所以可增加替代的出口901,其具有不同的气流方向。罩107将座椅表面与热电板的连接线101分隔开。为了舒适和性能,罩107可包括软的但导热的材料,例如碳纤维、甘油、凝胶或未膨胀的聚氨酯。整个加热和冷却系统可包含在传统的座垫尺寸和形状之内。
图10示出了用于宠物或其它动物在室内或室外舒适的加热和冷却床。许多现有的宠物床升高以从下方提供通风。在图10中,保留了升高的支撑层952和框架953和954。热电线101放在支持层952的顶部或从下方保持良好的接触。空气入口109可以是隔网106的部分或全部边界,利用风扇904将空气从这些入口吹到出口110。罩951将宠物和热电板的电线101分隔开。
可做出各种改变而不脱离本发明的精神和范围。
Claims (15)
1.热电装置,包括由电绝缘的基板材料形成的板,并具有多个热电元件,所述热电元件包括至少部分的位于所述基板材料内部的紧压导体和至少部分的位于所述基板材料外部的扩展导体,其中所述板由转移泄漏电流的导电片材覆盖,其中所述导电片材由防水罩覆盖,且其中所述导电片材配置为在防水罩损害时转移泄漏电流。
2.根据权利要求1所述的装置,其中,所述导电片材包括幕、隔网或织物,其中所述幕、隔网或织物是金属化的或由金属或碳组成。
3.根据权利要求1所述的装置,其中,基板材料或导电片材在一个或多个方向上是可拉伸的。
4.根据权利要求1所述的装置,其安装在床顶或床框架、座椅或座椅框架、病床或病床架、轮椅垫或轮椅框架或手术台上,并且进一步包括具有布置在扩展导体之间用于积累体液的储液槽的顶垫。
5.根据权利要求4所述的装置,还包括气流层,所述气流层包括支撑柱矩阵,所述支撑柱独立地在竖直方向上移动以重新分布压力,其中所述支撑柱是由塑料、隔网、闭孔泡沫、开孔泡沫或含流体的气球组成。
6.根据权利要求5所述的装置,其中,所述流体包括空气、水、凝胶、膏、油或蜡。
7.根据权利要求4所述的装置,其中所述板布置在交变压力表面、压力重新分布表面、手术台或其它治疗性表面的顶部或集成到其中。
8.根据权利要求1所述的装置,还包括无线功率发射器和接收器,用于为所述装置供电,其中所述无线功率发射器和接收器采用共振磁场或电磁波。
9.根据权利要求1所述的装置,还包括移动导电刷,所述移动导电刷与连接到电源的电极接触,所述电极形成一固定阵列,所述电源为该装置供电。
10.根据权利要求9所述的装置,还包括以下的一个或多个特征:
(a)还包括一列固定式电极,每个连接到电源或接地电压,并适于与移动导电刷接触;
(b)还包括二极管或整流器,用于选择其接触提供电源电压和接地电压的电极和所述装置;以及
(c)其中所述导电刷安装在轮椅、滚动床或滚动座椅的轮子上或其附近。
11. 用于形成根据权利要求1所述的热电装置的方法,该装置包括由电绝缘的基板材料形成的板,并具有多个热电元件,所述热电元件包括至少部分的位于所述基板材料内部的紧压导体和至少部分的位于绝缘材料外部的扩展导体,其中所述板由转移泄漏电流的导电片材覆盖,且其中所述板是由执行以下一个或多个操作的机器以自动方式生产的:
(a)电火花线切割、电线卷曲、镀锡、挑选和布置热电元件、分配或模印焊料或焊锡膏、焊料回流、分离以及利用一列空心针刺穿绝缘层;或
(b)通过蚀刻或冲压形成柔性电路、自动挑选和布置热电元件、分配焊料或焊锡膏,焊料回流以及利用空心针刺穿绝缘层。
12.根据权利要求11所述的方法,其中,所述热电元件首先布置在成盘带条中以便于自动挑选,并且其中所述焊料或焊锡膏是由锡、铋、锑、铜、锡合金、铋合金、锑合金、或铜合金组成。
13.一种垫,包括安装在与鼓风机结合的气流层顶上的热电板,其中来自风扇的空气来源于所述垫的侧面、边缘或罩,并在多个方向排出,其中所述罩具有分布孔,其中所述热电板由转移泄漏电流的导电片材覆盖,其中所述导电片材由所述罩覆盖,且其中所述导电片材配置为在所述罩损害时转移泄漏电流。
14.根据权利要求13所述的垫,还包括下列一个或多个特征:
(a)其中所述垫定位为座椅底部或座椅靠背;
(b)还包括电池;
(c)其中所述垫安装在升高的床底下;
(d)其中所述热电板包括沿着床表面定位的扩展导体,以及通过该表面中的孔的紧压导体;以及
(e)其中所述罩由导热材料制成,所述导热材料包括碳纤维、凝胶、甘油、金属颗粒或聚氨酯。
15.一种系统,其包含多个板,所述板设置成可有选择地开启和关闭,以提供响应于局部压力、局部温度、局部身体灵敏度或其组合的或多或少的冷却或加热,其中所述多个板中的每个板由电绝缘的基板材料形成,并具有多个热电元件,所述热电元件包括至少部分的位于所述基板材料内部的紧压导体和至少部分的位于所述基板材料外部的扩展导体,其中所述多个板中的每个板由转移泄漏电流的导电片材覆盖,其中所述导电片材由防水罩覆盖,且其中所述导电片材配置为在防水罩损害时转移泄漏电流。
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- 2013-07-12 JP JP2015526547A patent/JP6261584B2/ja active Active
- 2013-07-12 WO PCT/US2013/050378 patent/WO2014025495A1/en active Application Filing
- 2013-07-12 CN CN201380037835.8A patent/CN104488098B/zh active Active
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2017
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Also Published As
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BR112015002707A2 (pt) | 2017-09-19 |
CN104488098A (zh) | 2015-04-01 |
JP6261584B2 (ja) | 2018-01-17 |
US20170261241A1 (en) | 2017-09-14 |
JP2015532000A (ja) | 2015-11-05 |
KR20150042157A (ko) | 2015-04-20 |
EP2883250A1 (en) | 2015-06-17 |
WO2014025495A1 (en) | 2014-02-13 |
EP2883250A4 (en) | 2016-06-15 |
US20140041396A1 (en) | 2014-02-13 |
US9638442B2 (en) | 2017-05-02 |
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