JP6375416B2 - Conductive heater with sensing function - Google Patents

Description

  The present teachings generally relate to a device that includes both a fever function and a sensing function such that the entire or part of the occupant is sensed and heated.

  The present teachings are based on providing an improved heater, more preferably an improved heater for a vehicle. Generally, a heater includes a single line formed in a pattern. When electricity is applied to this line, it generates heat. In some cases, the wire is disposed in the carbonaceous material, and as the wire generates heat, the heat is diffused into the carbonaceous material to heat a larger 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. Furthermore, 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 positive temperature coefficient material such that heat is generated by conduction of electricity from one electrode to the other through the positive temperature coefficient material. The other plurality of heaters have a woven fabric shape in which a plurality of long materials are interwoven. Because these materials can cause current drift along a single line, these heaters can cause hot spots along one or more of these materials.

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

  Several examples of heaters can be found in US Pat. All of these documents are hereby incorporated by reference for all purposes. Several examples of sensors and heaters can be found in US Pat.

  It would be attractive to have a heater and sensor that does not include multiple individual components. It would be attractive to have a heater that functions 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, a space where high flexibility is required, or both, It is a flexible heater that can also be used as a sensor.

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

  The present teachings include an improved heater and sensor comprising (a) a heat generating layer, a sensing layer, or both, and (b) one or more power applicators, one or more sensing units, or both. The heat generating layer and the sensing layer are arranged in the same plane, and the heat generating layer is composed of a plurality of metal-coated fibers arranged at random so that the heat generating layer supplies heat when electric power is applied. Satisfy one or more (if not all) current requirements by providing a device formed by a formed nonwoven layer.

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

  The teaching of the present specification is that (a) a heater / sensor is installed in a vehicle component, and (b) power is supplied to the heater / sensor so that the heat generation layer of the heater / sensor generates heat. (C) providing a signal to the heater / sensor so that the sensing layer of the heater / sensor generates a signal to determine the presence of the occupant, contact between the occupant and the vehicle component, or both And (d) monitoring this signal for the occupant, the absence of the occupant, the lack of contact between the component and the occupant, or a combination thereof.

  The teachings herein surprisingly solve one or more of the above problems by providing a heater and sensor that does not include discrete components. The teachings herein provide a heater that functions as a sensor without adding any additional sensing elements. The teachings herein provide a sensor that provides good heating performance so that the heater / sensor can be installed in a compact space, a space where high flexibility is required, or both. A flexible heater that can also be used.

Figure 5 shows an infrared image of a heater according to the teachings of the present application. Fig. 4 illustrates a heater / sensor according to the teachings herein. FIG. 3 shows a close-up view of the power application unit of FIG. 2. FIG. 4 shows a close-up view of an alternative power application section in accordance with the teachings herein. Sectional drawing of a 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. Fig. 3 shows a heater / sensor having a plurality of parts each including an individual power application unit. 2 shows a heater / sensor having a plurality of portions in which a plurality of power application units are electrically connected to each other. 2 shows a heater / sensor including a plurality of longitudinal power application units. FIG. 6B shows the heater / sensor of FIG. 6A disposed on the steering wheel. Fig. 3 shows a heater / sensor including a plurality of individual power application sections for power supply extending along the length of the heater / sensor. 2 shows two individual heaters / sensors each including a longitudinal power application. 8B shows the two individual heaters / sensors of FIG. 8A disposed on the surface of the steering wheel. Fig. 3 shows a heater / sensor including a plurality of individual power application sections for power supply extending along the length of the heater / sensor. 2 shows an example of an electrical configuration for a heater / sensor. Another example of the electrical configuration is shown. An example of a heater / sensor in which both ends are adjacently arranged without opening a gap between the ends of the heater / sensor is shown. An example of a heater / sensor having an individual power application unit for power application and an individual power application unit for signal application is shown. Fig. 4 illustrates a sensing circuit in accordance with the teachings herein. An example of a heat generation and sensing circuit is shown. An example of the electric power and signal which are applied to a heater is shown.

  The description and figures presented herein are intended to inform other persons skilled in the art of the invention, its principles, and its practical application. Those skilled in the art can adapt and apply the present teachings in many forms to best suit the requirements of a particular application. Accordingly, the specific embodiments of the present teachings that are described are not intended to be exhaustive or limiting of the present teachings. Accordingly, the scope of the present teachings should not be determined with reference to the above description, but should be determined with reference to the appended claims along with the full scope of equivalents to which such claims are entitled. Should be determined. The disclosures of all articles and references are incorporated by reference for all purposes, including patent applications and publications. Other combinations are possible as found from the appended claims, and these combinations are also incorporated into this description by reference.

  This teaching claims priority to US Provisional Application No. 61 / 823,642, filed May 15, 2013, the entire teachings of which are incorporated herein by reference for all purposes. . The apparatus taught herein can be useful as a heater and / or can be incorporated into another apparatus. In the latter case, this alternative device can be used as a heater. The apparatus taught herein can be used for any known heating application. For example, the heater may be used for heating a bed, heating a plant, or a treatment heater for heating a vehicle seat, steering wheel, mirror, glass, flooring, door panel, armrest, headliner, etc., or a combination thereof. Can be used for. Preferably, the apparatus taught herein can be connected to, incorporated into, or both of a vehicle seat, a steering wheel, or both. The heater described herein is overlaid on the cushion of the vehicle seat (ie, van or back) and then a trim cover is placed over the heater or placed around the steering wheel and then It may be an individual piece that is covered by a trim piece or both. A portion of the heater may be placed in the cushion trench so that the heater, cushion, trim cover, or combination thereof is attached to the seat frame. The heater can be saddleable, moldable, severable, or a combination thereof so that heating of the trench region of the vehicle seat by the heater can be substantially prevented. For example, a portion of the heater may be cut so that substantially only the electrodes, buses, conductors, or combinations thereof extend into the trench in the vehicle seat. The trim cover may have mounting features that extend through the heater such that the heater is connected to the trim cover and vehicle components.

  One or more heaters may be attached to a vehicle seat and / or steering wheel by mechanical fasteners, adhesives, pressure from one or more adjacent layers, welding, heat staking, ultrasonic welding, brazing, or combinations thereof It can stick to. For example, the heater may be secured to the trim layer, the support, or both by a thread of the same material as the heater so that the heater is secured within the component. Adhesive can be adhesively peelable to the heater, or adhesive that can be permanently bonded to the heater, pressure sensitive adhesive, glue, hook-and-loop fastener, spray adhesive, adhesive that can be peeled off, or A combination of these may also be used. The heater may be secured directly to the trim layer, or directly to the seat cushion (ie, van, back, or both), or directly to the steering wheel, or They may be combined. A mechanical fastener extends through, connects to, or attaches to the heater so that the heater can be secured in the seat, in the steering wheel, or both, Or these may be combined. The mechanical fastener may be a hog ring or a metal bar that extends over a portion of the heater and pulls the heater and trim layer to the closest distance of the cushion, part of the heater, part of the trim layer, Alternatively, it may be a plastic tag that penetrates both, or a combination thereof. A heater according to the teachings herein may be used 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 combinations thereof may be connected to the heater so that a signal is created when signal, power, or both are applied. The sensor may be any type of passenger sensor that senses the presence of a passenger, contact with a heater, adjacent contact to the 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 capacitive sensor, pressure sensor, membrane sensor, infrared, passive and / or active ultrasonic sensor, mass sensor, or a combination thereof. This sensor detects a system that activates an alarm when the user is not touching the steering wheel, or a system that turns on the vehicle guidance system when the user is not touching the steering wheel, It may be connected to a system that issues an alarm when the passenger is not wearing a seat belt, or a system that turns off the airbag when an underweight passenger is in the seat, or a combination thereof. The heater and passenger sensor may be used in conjunction with an active cooling system, an active heating system, a ventilated system, or a combination thereof.

  The heater may be used in conjunction 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 has one or more porous layers covering the heater so that air passes directly through the heater and one or more layers (eg, fleece layer, adhesive layer, protective coating layer, or combinations thereof) that cover the heater. Layers can be included. The heater may include one or more barrier layers that completely and / or partially cover the heater. This barrier layer facilitates directing fluid flow to the heater area 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 substantially prevent the passage of fluid by making the central “U” portion of the heater substantially porous so that the fluid to be moved is directed to the contact area. You may provide in the area | region which surrounds. The heater may include one or more through holes so that air passes through the heater. The heater may include a fan and / or blower and / or be adjacent to the blower and / or fan, which may be in fluid communication with the fan and / or blower, so as to pass fluid into and / or around the heater. The heater, fan, blower, or combination thereof may include Peltier devices, thermoelectric devices, or both, to move hot and / or cold air (ie, conditioned air) toward the occupant. The heater may be indirectly connected to a fan, blower, or both, including Peltier devices, thermoelectric devices, or both.

  The heater may be connected to an insert (ie, a bag) that facilitates distributing conditioned air toward the occupant. The heater may have one or more holes that are mirror images of the insert holes. The heater may be provided with no holes, and the air from the bag may pass directly through the heater toward the passenger. 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 fed into the insert is directed to a predetermined area. The insert may include one or more spacer materials. The heater taught herein may function as a portion of the spacer layer and / or spacer material that forms an open space within the insert. Additional aspects of the insert and its various layers and materials are described in US Pat. No. 7,083,227, column 1, row 45 to column 3, row 67, column 4 and are incorporated herein by reference. , Row 54 to column 6, row 32, and FIGS. 2-3, column 3, row 34 to column 10, row 2, column 11, row 4 to column 13, row 18 of US Pat. No. 7,735,932, And can be found from the teachings herein, including the teachings of FIGS. 1, 4, 15A, and 15B. These patent documents show 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 herein is preferably a nonwoven sheet. For example, the heat generating layer taught herein may be composed of a plurality of individual fibers that may be cut into a predetermined length and randomly arranged to form a heater. The heater can be adapted to virtually any shape. For example, the heater can be wrapped around a circular object such that a circular object (eg, a steering wheel) is heated. The heater may include a plurality of fibers that form a heat generating layer. The heat generating layer can be comprised 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. The heat generating layer can be comprised 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 heat generating layer may be comprised of no more than about 99 weight percent, no more than about 98 weight percent, or no more than about 97 weight percent fibers. The heat generating layer may comprise about 50 weight percent to 99 weight percent fiber, preferably about 70 weight percent to about 99 weight percent fiber, more preferably about 80 weight percent to about 99 weight percent (ie, about 80 weight percent). Up to about 90 weight percent).

  The plurality of fibers are preferably randomly dispersed throughout the heat generating layer. More preferably, the fibers have a short average fiber length so that the heat generating layer has a non-woven structure when the fibers are combined and the fibers are not woven together by a mechanical device. More preferably, the average fiber length and arrangement of these fibers causes the heater to have a substantially constant thermal gradient, a substantially constant heat density, or both when power is applied. The fiber array causes the power to move and spread across 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 heat generating layer taught herein has almost no fiber alignment such that the heat generating layer does not have a machine direction, a cross direction, or both. The heat generation layer may not include a plurality of individual heat generation lines, heat generation yarns, or both, and heat generation may occur through a plurality of randomly arranged fibers. As used herein, the expression randomly arranged is about 60 percent or less of these fibers, about 50 percent or less, preferably about 40 percent or less, more preferably about 30 percent or less, more preferably About 20 percent or less means aligned in the same direction. Average fiber length can affect fiber alignment.

  The average fiber length is any length where a nonwoven sheet is formed and the sheet has sufficient strength for bending, folding, cutting, power transmission, pushing into a trench, pulling, or a combination thereof. It may be length. The average fiber length is such that when power is applied, the power moves from fiber to fiber and the heater has a substantially uniform temperature gradient (ie, the temperature when measured randomly 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 less, or about ± 2 ° C. or less. 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, about 50 mm or less. The average fiber length is preferably relatively short. Accordingly, 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, and even 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, further preferably about ± 1 mm or less, and most preferably about ± 0.5 mm or less. Standard deviation. 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, even more preferably about 100 mm or less, and most preferably about 50 mm or less.

  The heat generating layer may be made of any non-woven material that generates heat through electricity. The heat generating layer is a non-woven material that can be cut, bent, folded, punched, or a combination thereof, and can be made of any non-woven material that can generate heat when power is applied. Also good. The heat generating layer may be made of a material that can be manufactured using a spunlace method (eg, hydroentanglement), a needle punch method, or a combination of both. The heat generating layer may include carbon, metal coated carbon, polymer, metal coated polymer, binder, or combinations thereof. The heat generating layer preferably includes 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 formation of the layer, or one or more coatings may be applied to the fibers when the fibers are a layer (eg, fiber mat or fiber sheet), Alternatively, a first coating may be applied to these fibers and then a second coating may be applied to the fibers when they are part of the layer, or a combination thereof. In one example, a nylon mat may be formed, and then the nylon mat may be coated with copper and then coated with nickel so that the nickel prevents copper corrosion and / or oxidation. The polymer that can constitute the fiber is nylon, polyester, polyurethane, polyamide, aramid, para-aramid, meta-aramid, vinyl alcohol, thermoplastic urethane, urethane, polyimide, carbon, carbon fiber, 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 combinations thereof is there. In one preferred embodiment, the plurality of fibers are made only of carbon. In another preferred embodiment, the 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 heat generating layer. The percentage of the coating with respect 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. Preferably, the percentage of the coating in the total weight of the heat generating layer can be a sufficient amount so that the heat generating layer generates heat to a temperature from about 80 ° C. to about 110 ° C. upon application of power. The percentage of the coating in the total weight of the heat generating layer can be sufficient such that the resistivity of the heat generating layer is from about 1Ω to about 5Ω, preferably from about 1.5Ω to about 2.5Ω. The coating may comprise about 5 percent or more, about 10 percent or more, preferably about 15 percent or more of the total weight of the heat generating layer. The coating may comprise no more than about 50 percent, no more than about 40 percent, or no more than about 30 percent (ie, from about 20 percent to about 25 percent of the total weight) of the total weight of the heat generating layer. An example of a metal-coated nylon nonwoven fleece is sold by YSShield under the trade name HNV80. Some examples of some carbon nonwoven fabrics are sold by Marktek Inc. under the trade names C10001xxxT series, NC10004xxxT series, C100040xxxT series. Another example of a non-woven fabric is from Nickel Nanostrands, Nickel CVD coated carbon fiber, or Nickel CVD coated non-woven carbon fiber (Nickel CVD) from Conductive Composites. Coated nonwoven carbon fiber). The plurality of fibers described herein can be held together by a binder.

  The heat generating layer is a non-woven material. It is preferable that the heat generating layer has a felt shape (that is, a flat homogeneous nonwoven structure). More preferably, the heat generating layer may be a non-woven material having a microstructure arranged at random. The heater may not have a hole. The heater may include a plurality of holes. These holes can be any shape that generates heat and heats adjacent surfaces, people, items, devices, or combinations thereof. These holes may be circular, oval, square, cross, elongated, symmetric, asymmetric, geometric, non-geometric, or combinations thereof. The heater may include a side cutout. The heater preferably does not include a side notch. The heater may have a meandering shape. The heater is preferably not meandering. The microstructure of the heat generating layer may include a plurality of pores, a plurality of voids, or both. The voids and pores described herein are part of the microstructure of the heat generating layer, and the through holes and notches are larger spaces from which material has been removed, for example. The heat generating layer may include a sufficient amount of voids and / or pores so that air from the air mover can pass through the heat generating layer, or the fibers of the heat generating layer are randomly arranged, or the power is randomly distributed throughout the heat generating layer. It can be distributed, or the protective layer can penetrate the heating layer, or a combination thereof. The voids and / or pores of the exothermic layer are in an area of about 10 percent or more, about 15 percent or more, about 20 percent or more, about 25 percent or more, about 30 percent or more, or about 40 percent or more of the total surface area of the heating layer. It may correspond. 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 heat generating layer is sufficient to allow one or more other layers to be connected to the heat generating layer, or to allow the protective layer to form a flat surface on the heat generating 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 include any additional conductive layers (eg, buses, electrodes, terminals, traces, branches, branches, or combinations thereof). The heater preferably includes a plurality of buses, electrodes, or both (e.g., power applicators) that extend substantially along the length and / or width of the heater to assist in applying power to the heater. More preferably, the heat generating layer does not include a terminal for connecting the power source to the heater (ie, a single power application point). The heat generating layer may not include gold, silver, copper, or a combination thereof. The heater may include a positive temperature coefficient (PTC) material. The exothermic layer may not include additional conductive layers, positive temperature coefficient layers, adjuncts, or combinations thereof that are added to the exothermic layer in a separate step to help generate heat, generate signals, or both Good. The heating layer may not include a stabilizing material, a soft filler material, an impregnated filler material, or a combination thereof. For example, the heat generating layer does not include stabilizing materials, soft filler materials, impregnated fillers, or combinations thereof that are added to the heater to help transfer power between the fibers. More preferably, the heat generating layer may be only a heater portion necessary for heat generation. For example, the heat generating layer may not be a substrate, and the heat generating layer may include one or more materials disposed or printed on the surface thereof to form the heat generating layer, a material woven into the material, or a combination thereof. It does not have to be included. The configuration of the heat generating layer can be used to change the resistivity, surface power density, or both of the heat generating layer.

  The heat generating layer described in the present specification has a resistivity and a surface output density. The resistivity and surface power density of the heat generating layer can be determined by changing the size and shape of the heat generating layer, or by changing the material composition of the front cover layer, the back cover layer, or both, or the voltage applied to the heat generating layer. It can be changed by changing the amount, by changing the amperage applied to the heat generating layer, or by combining them. For example, the resistivity and surface power density of the heat generating layer can be varied by removing material from the heat generating layer (eg, by adding notches, through holes, slits, or combinations thereof). In another example, material can be effectively removed from the heat generating layer such that the resistivity of the heater is increased. The resistivity of the heat generating layer may be about 1.0Ω or more, preferably about 1.5Ω or more, more preferably about 1.8Ω or more. The resistivity of the heat generating 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 power density of the heat generating layer. It is preferable that the resistivity is inversely proportional to the surface output density of the heat generating layer. Thereby, when the resistivity increases, the surface output density decreases.

The surface power 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 basis weight of the heat generating layer, the basis weight, or both, can affect the resistivity, surface power density, or both.

The heat generating layer can be characterized by a basis weight (ie, weight per unit area of the 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, most preferably about 100 g / m. ^It 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, 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 that the fibers of the heat generating layer have is density. The density of the fiber 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 density of the fibers 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 density of the fiber 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 a diameter. The fiber diameter can be about 0.0001 mm or more, preferably about 0.001 mm or more, preferably about 0.005 mm or more, and most preferably about 0.0065 or more. The diameter of the fiber 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, and most preferably about 0.008 or less (ie, about Between 0.007 and about 0.006 mm). The diameter of the fiber 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 heat generating 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 reducing the thickness of the heat generating layer sufficiently, the resistivity is 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 the heat generating layer taught herein. The heat generation performance of the heat generation layer may be improved compared to the low heat generation 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, more preferably about 1.0 mm or less. The thickness of the heat generating 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 heat generating layer has a basis weight. The base 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 heat generating layer may have a basis 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 heat generating 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 between about 1.0 W / m * k and about 0.001 W / m * k, preferably from about 0.5 W / m * k It may be up to 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 between about 1.5 W / m * k and about 0.001 W / m * k, preferably from about 0.7 W / m * k It may 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 includes specific heat. 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 *. 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. 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. 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 heat generating layer has a specific heat measured at 600 ° C. using ASTM STP1426 or ASTM STP1320, between about 10.0 W * sec / g * K and about 0.01 W * sec / g * K, preferably about 5 W *. having 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 heat generating layer includes a tensile strength at break. The tensile strength at break can be about 1 N / cm or more, about 1.5 N / cm or more, or preferably about 2 N / cm. The tensile strength at break may be about 100 N / cm or less, about 80 N / cm or less, or about 60 N / cm or less. The heat-breaking point tensile strength of the heat generating layer is about 0.5 N / cm to 100 N / cm, preferably about 1.0 N / cm to 80 N / cm, more preferably about 1.5 N / cm to 60 N / cm. Can be.

  The material of the heat generating 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 heat generating layer may have good strong acid resistance. The material of the heat generating layer can have excellent weak acid resistance. The material of the heat generating layer may have weak strong base resistance. The material of the heat generating layer can have good weak base resistance. The material of the heat generating layer can have excellent chemical resistance to organic solvents. The material of the heat generating layer may exhibit a low modulus of elasticity (ie, the material does not stretch), abrasion resistance, non-curing, self-sliding, or a combination thereof.

  The heat generating layer can be formed by mixing one or more of the compositions described herein. The mixed composition can be extruded to form fibers, sheets, mats, yarns, or combinations thereof. A heat generating layer can be formed by injecting the composition into a mold. The heat generating layer can be formed by mixing a plurality of fibers to form a mat. These materials can form a first material that can exhibit the exothermic properties described herein. These materials may be subjected to secondary treatment.

  Since the heat generating layer can be attached to one or more terminals, the heat generating layer generates heat upon application of electricity (for example, electric power). The heat generating 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 signals. The power application line may be connected to a power source, a microprocessor, a processor, a computer, or a combination thereof. The heat generation layer uses two or more, three or more, or four or more terminals and / or power application to apply power and / or signals to the power application unit to cause heat generation and / or sensing using the heater / sensor. Can be connected to a line. For example, the heat generating layer can include positive and negative lines connected to each end of the heat generating layer such that a total of four lines are connected to the heat generating layer. When connected to one or more positive power sources and one or more negative power sources (ie, a power application layer or a power application material), the heat generation layer may generate heat and / or be used for sensing. The heat generating layer preferably does not include a terminal for connecting the bus and / or the electrode to the heat generating layer. For example, the bus and / or electrode may be connected to the heat generating layer, and the bus and / or electrode may be connected to a power source. The terminal may be directly and / or indirectly attached to the heat generating layer using any device, and electricity may enter the heat generating layer from this terminal to cause the heat generating layer to generate heat. The terminal may be pressure-bonded to the heat generating layer. For example, the power application unit may include a plurality of terminals that connect the power source to the power application unit. The terminals may be connected to the heat generation layer, each power application layer, or both by gluing, bonding, mechanical fasteners, or a combination thereof. The heat generating layer preferably does not include a plurality of terminals attached directly to the heat generating layer (ie, a single power application point). The heater may not include a mechanical fastener that attaches a power source to the heater. For example, the heat generating layer may not include a mechanical attachment device that holds the heat generating layer and fixes one or more wires to the heater. The heat generating layer may include two or more power application units that help supply power to the heat generating layer.

  Two or more power application units may be arranged at any position on the heater. The two or more power application units are preferably separated from each other. Two or more power application units may be sufficiently separated so that the heater is partially and / or completely energized by application of power. More preferably, the two or more power application units 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 is second from the first edge. The electric power may pass through the heater when moving to the end edge. The power application section may extend along the side edge (eg, width) of the heater or along the longitudinal edge (eg, length) of the heater. The length of the power application line can be inversely proportional to the conductivity of the heater / sensor. Thus, for example, the longer the wire, the lower the heater / sensor conductivity. More specifically, a heater / sensor having a longitudinal power application section may be manufactured only from a carbon material. In another example, the power application section extending along the side portion or the edge may be connected to a heater having metal-coated fibers having a higher conductivity than that of a carbon material heater. The heater may include more than two power application units. For example, the heater may be connected to a power application unit provided substantially at the center of the heater and a central power application unit so that power and / or signals move from the central power application unit to both edges or vice versa. And 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 sections extending from each edge to the opposite edge. The two opposing power application units terminate before the power application units are connected so that there is a gap between the power application units. This gap can electrically insulate the sides / edges of the heater / sensor. Both sides of the heater / sensor so that this gap and / or insulation is not present between the sides / edges of the heater / sensor, or the heater / sensor is not shorted, or both. Parts / edges may be of the same polarity. Accordingly, each heater may include two or more, three or more, or four or more power application units for applying heat and / or power. These power applicators may be arranged in the heater / sensor so that the opposing sides / edges of the power applicators contain similar polarities. For example, the negative polarity, the positive polarity, or both may be arranged on opposite edges so that when the heater / sensor is wound around the core, the positive polarity or the negative polarity are in close proximity. In another example, the positive polarity is placed on both sides / edges that are in close proximity when wrapped, and the negative polarity is placed midway between them.

  Each power application unit may include one or more portions for applying power, signals, or both. In one preferred example, each power application unit consists of two individual bus bars, electrodes, wires, or combinations thereof connected to each other, each two bus bars, electrodes, wires, or combinations thereof to the heat generating layer. Help to supply power. These power application units may apply signals, power, or both. The heater / sensor may include two power application units adjacent to each other, one power application unit supplying power, and the other power application unit supplying signals. As described herein, these power applicators may apply signals, power, or both. However, in order to apply only a signal or only power, a plurality of individual power application units and a plurality of lines associated therewith may be used. In order to determine whether the user is in contact with the heater / sensor, a separate sensing power applicator may be connected directly to the microprocessor or processor. The bus bars, electrodes, wires, or combinations thereof may be made of the same material, different materials, or combinations thereof.

  Each bus bar and / or electrode of a single power application section is preferably made of two or more different materials. The power application unit may include one or more lines, but may preferably include two or more lines interwoven with each other. The one or more lines may be needle punched into the heater so that a power application portion is formed at one or both ends of the heater. The needle punched wire may be connected to a heater and directly connected to a power source. The line to be needle punched may be a line coated with a silver film, a copper film, or both. The needle punched line may be made of substantially the same material as the heater. However, the needle punched line can have a longer fiber length than the fibers in the heater. These wires may be made of any conductive material that helps transfer power to the heat generating layer to generate heat. The resistivity of each line may be about 5 Ω * m or less, about 2 Ω * m or less, or about 1 Ω * m or less. The resistivity of each line may be about 0.01Ω * m or more, about 0.05Ω * m or more, or about 0.01Ω * m or more (ie, 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 or more). mm). In a preferred embodiment, each line is a composite where multiple lines are braided together to form a single line. For example, each line may be composed 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. The wires are made of copper, silver, gold, nickel, or combinations thereof and / or coated with copper, silver, gold, nickel, or combinations thereof so that power is transferred to the heat generating layer, It is preferable. To connect the one or more wires to the heat generating 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 heat generating layer. May be. Some examples of attachment devices and / or methods that may be used include gluing, gluing (eg, using conductive or non-conductive glue), joining, knitting, stapling, or combinations thereof. The one or more lines are preferably connected to the heat generating layer using an adhesive layer. An adhesive layer that secures one or more wires to the heat generating layer can also be used to connect a second bus bar and / or electrode to the heat generating layer.

  The power application unit may be made of any material as long as it is a material that assists the transmission of power to the heat generating layer by applying power so that the heat generating layer is warmed. The power application unit may be made of any material as long as the heat generation layer senses the state when the sensor signal is applied. The power applicator may include bus bars and / or electrodes that are disposed below one or more lines, preferably above one or more lines, or a combination of both. The power application unit may not include a wire, and may be made of only the nonwoven material described in the present specification. For example, a clip that provides an electrical connection for supplying power to the heat generating layer may be attached directly to the nonwoven. The bus bar and / or the electrode may be a non-woven material having conductivity. The bus bar and / or electrode may be one or more non-woven conductive strips. The bus bar and / or electrode may be made of the same material as the heat generating layer. Preferably, the bus bar and / or electrode can be made of a carbon material, a polymeric material, a metallized material, or a combination of materials that form a conductive medium that passes power through the heater. For example, the bus bar and / or electrode may be a plurality of nylon fibers coated with nickel or silver, and the coated nylon fibers may be joined together by a binder to form a nonwoven material that transfers power to the heat generating layer. . The bus bar and / or electrode may be attached to the heat generating 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 of both are preferably connected to the heating layer using an adhesive cloth. More preferably, each power application unit includes a non-woven conductive material connected to the heat generating layer by an adhesive layer and two or more wires.

The adhesive layer may be any adhesive sheet that forms a connection by heating. The adhesive layer may be any adhesive layer described in this 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 sticky particles and voids and / or pores between the interconnected fibers and / or fibrous sticky particles. Is preferred. The adhesive layer can have a plurality of voids, a plurality of pores, or both. When the adhesive layer connects two or more conductive layers (eg, one or more power application layers, heat generation layers, or both), power passes through the voids and / or pores, or electricity Such that the electrical 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 can 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 heat generating layer. Can do. The voids and / or pores of the adhesive layer may 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 heat generating layer. The adhesive layer may have a basis 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 basis 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 less, about 180 ° C. or less, or about 160 ° C. or less (ie, about 150 ° C.). An example of an adhesive fabric that can be used is sold by Spunfab Ltd. under the trade name Spunfab®.

The power application unit (that is, bus bar and / or electrode, one or more lines, or a combination of both) is about 1.0 × 10 ⁻² Ω / sq or less, about 5.0 × 10 ⁻² Ω / sq or less. , Preferably 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 having a rate may be used. The power application section (ie, bus bar and / or electrode, one or more wires, or a combination of both) is about 1.0 × 10 ⁻⁹ Ω / sq or more, about 5.0 × 10 ⁻⁸ Ω / sq The material may be made of any material 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, one layer may be included in the heater). The heater preferably includes at least three layers. However, the heater may not include any layer fixed on the heat generating layer. For example, the heater may include a layer that interpenetrates the heat generating layer to form a partial and / or complete protective layer on the heat generating layer. The heat generating layer may partially and / or fully incorporate the individual material (ie, the protective layer) into the heat generating layer so that the heat generating 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 properties of the heater (eg, tensile strength, tear strength, folding strength, etc., or combinations thereof). . The material of the protective layer is such that the protective layer enhances the heat generating layer strength (eg, tensile strength, tear strength, folding strength, etc., or a combination thereof), the heat insulating properties of the heat generating layer, or both Any material may be used as long as the material is woven into the heat generating layer. The protective layer preferably increases the strength of the heat generating layer, and a partial dielectric film or a complete dielectric film is preferably formed 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, such that the outer heat generating layer has dielectric properties, flow resistance properties, or both. The protective layer may form a layer on the front side, back side, side edge, top edge, 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 heat generating layer. The protective layer fills the pores and / or voids between the individual fibers of the heat generating layer, but does not completely surround the individual fibers and impairs the connection and / or electrical connection between the individual fibers of the heat generating layer. Preferably not. The heater may include one or more attachment layers. The attachment layer may be a single-sided adhesive layer. The attachment layer may be made of the same material as the adhesive layer described herein for attaching the power applicator. The attachment layer may be an adhesive layer (for example, glue, paste, spray adhesive, adhesive film, adhesive that can be peeled off and applied as it is, surface fastener, etc.). The attachment layer is preferably an adhesive film that can be peeled off and attached as it is. The attachment layer can exhibit the protective properties described herein. The heater may not include an attachment layer.

  The heaters and / or sensors described herein may include one or more, or two or more, heat generating layers for heat generation and / or sensing in parallel. For example, two substantially mirror image heaters / sensors may be created and arranged in parallel in the apparatus so that each heater generates heat and each heater senses. When a plurality of heaters are used, the total area of the single heater may be substantially the same as the total area of the plurality of heaters. When multiple heaters are used, the multiple heaters may be used simultaneously, individually, alternately, or 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 sense a hand or the like. Thereafter, the heater / sensor may be replaced so that the presence of the passenger's hand can be determined almost always. In another example, if more than one heater / sensor is attached to the steering wheel, each sensor can sense half or quarter of the steering wheel, so it can sense multiple hands, The position can be sensed.

  The heater described herein can be fabricated using one process. This process may include one or more of the following steps in substantially any order. Multiple fibers as described herein can be obtained. The fibers described herein are coated with metal and cut to the desired length and refined so that the fibers are flat, or refined so that the fibers have an oval shape, or These combinations can be made. These fibers can be mixed with, coated with, or contacted with any of the binders described herein, or a combination thereof. You may arrange | position these fibers in a container so that these fibers may be arranged at random. These fibers can be extruded with or without a binder to form a nonwoven sheet. These fibers may be entangled using hydroentanglement. These fibers may be sprayed with the binder, immersed in the binder, coated with the binder, or a combination thereof. At least one power application unit is attached to the heating layer. Install one or more wires, one or more non-woven conductive strips, one or more electrodes, and / or multiple bus bars, or one or more pre-assembled power applicators, or these Combination. Pre-assembled to heat the 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 Installing one or more power application units, or a combination thereof. One or more wires, one or more, such that when the adhesive layer is placed on the heater and heated, the adhesive layer connects the pre-assembled power application section to the heat generating layer to form an electrical connection Fabricating a pre-assembled power applicator by combining together non-woven conductive strips, one or more adhesive layers, one or more bus bars, and / or electrodes, or combinations thereof. Connect one or more power applicators to a power source, a line, or both. One or more power applicators, power supplies, such that the contraction tube contracts during the heat generation step so that one or more power applicators and the power source, line, or both are electrically and physically connected. , Wire, or a combination of these. Providing the heating layer with a front coating layer, a back coating layer, a connection layer (eg, an adhesive layer, a mechanical attachment layer, or both), or a combination thereof. Cutting off the heating layer so that it contains through holes, notches, or both. Provide the heat generating layer with a flame retardant material, a flame resistant material, a water resistant material, a dielectric layer, or a combination thereof. Attach the temperature sensor to the heating layer, heater, or both. Electrically connect the temperature sensor to the power supply. Connecting the heat generating layer to a control device, a control module, or both (eg, physically and / or electrically). Connect the heater to the vehicle seat, floor, steering wheel, mirror, insert, or a combination of these.

  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 part. Good. For example, if the article is a molded part, by adding a heating medium that forms a heating layer into the mold, when the final article is manufactured, the heater layer extends throughout the article and electricity is applied Alternatively, the entire article may be warmed. The heating medium may be a plurality of individual fibers. The heating 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 heater described herein can be controlled using any of the methods described herein. Preferably, the heater includes a negative coefficient temperature sensor or thermistor that measures the temperature of the heater and the controller controls the temperature of the heater, the ventilation system, the 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. Preferably, the heater can be a sensor. The heater sensing portion may be used simultaneously with heat generation, between heat generation cycles, during heat generation cycles, or a combination thereof. The exothermic cycle and the sensing cycle are preferably alternating. The sensor may detect the presence of an occupant, contact of a component by the occupant, the mass of the occupant, any other sensing function described herein, or a combination thereof. The heater sensing unit may include only the heater (ie, the power application unit, one or more power connection units, and a continuous heat generation layer). When the signal reaches the heater via one or more bus bars, the sensing unit can function.

  The signal may be any signal that detects an occupant, 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. When the occupant contacts a component that includes a heater, or when the occupant is in close proximity to the component and / or the heater, or both, the frequency of the signal can shift. The change in frequency can be any frequency shift that is a sufficient frequency shift (eg, millihertz, microseconds, etc., or a combination thereof) caused by the occupant. For example, the frequency shift that can be caused when the bag is placed on the seat (if any) is not sufficient to trigger the sensor to send a signal compared to the frequency shift caused by the occupant. The frequency shift may be any frequency shift as long as it is associated with the change in capacitance. The capacitance may be one or more capacitances, but is preferably a plurality of capacitances. The capacitance may be a measured capacitance, a calculated capacitance, or both. The capacitance may be an average capacitance. The capacitance may be an average value of a plurality of measured capacitances, a plurality of calculated capacitances, or both. The average capacitance may be an average of about 3 or more, 5 or more, or about 10 or more calculated capacitance, measured capacitance, or both. The measured capacitance, calculated capacitance, or both of the system may be about 50 pF or more, about 75 pF or more, or about 100 pF or more. The measured capacitance, 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 shift is preferably associated with a change in capacitance that is between about 100 pF and about 200 pF, a measured capacitance, a calculated capacitance, or a combination thereof. For example, a signal of a certain frequency may enter the heater and this signal may be measured when this signal exits the heater. When the occupant is in contact with the heater, the frequency of the signal can shift, so the frequency of the signal when the signal is output is delayed compared to the signal when the occupant is not in contact with the heater. In another example, the system capacitance was measured and measured and / or calculated when the occupant was in contact with the heater and / or sensor when the occupant was in contact with the heater and / or sensor. The system capacitance may be set based on the measured capacitance of the system such that the system capacitance is about 100 pF.

  The system capacitance 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 a time constant. The time constant (τ) during discharge may be the amount of time required to drop approximately 36.8 percent from the voltage applied across the circuit. Since the reference resistor has a known value, the capacitance of the system can be obtained by calculating the capacitance by obtaining the time constant. The capacitance can be discharged to about 36.8 percent after τ and can be essentially fully discharged after about 5 τ (0.7 percent). Alternatively, the time constant during charging (τ) may be the time required for the voltage to reach approximately 63.2 percent of the voltage applied across the circuit. The capacitance can be essentially fully charged after about 5τ (99.3 percent). The signal may be continuously monitored, intermittently monitored, or both. The system capacitance may be measured and / or calculated using the RC series circuit equations described herein, or using a capacitive voltage divider approach, or both.

The capacitive voltage divider approach can function to divide the voltage into a measurement voltage and a reference voltage. By comparing the reference voltage with the measured voltage, the capacitance of the system can be determined. An example of a voltage divider technique that can be used in conjunction with the teachings herein is DS01478B and listed by Microchip, Burke Davison, “Method for Obtaining mTouch® Sensing Solution Capacitive Voltage Divider ( mTouch ^™ Sensing Solution Acquisition Methods Capacitive Voltage Divider) ”, pages 1-25. This teaching is expressly incorporated herein by reference for all purposes. The capacitive voltage divider approach can be used to measure the heater / sensor capacitance instead of or in addition to the RC series circuit equation.

  In the monitoring step, a signal, signal frequency, signal capacitance, voltage, time constant, or a combination thereof (hereinafter a measurement signal) is used to determine occupant presence, occupant contact, or both. It may be compared with a lookup table. The measurement signal may be filtered through a resistor before it reaches the signal controller. The resistor may function to assist the system in determining occupant presence, occupant contact, 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 the occupant status. The measurement signal may determine whether an occupant is present, whether the occupant is in contact with a 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 is not in contact with the heater for a predetermined time). In some cases, it can cause a predetermined response. The predetermined response can occur after a measurement signal other than the predetermined measurement signal exists for about 1 second or more, about 2 seconds or more, about 3 seconds or more, or about 5 seconds or more. This predetermined response can occur after a measurement signal other than the predetermined signal is 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 his hand from the steering wheel, the car will not take over until he releases his hand for a longer time. The heat generation function may include one control device for supplying power to the heater so that the heater generates heat, and the sensing function may include another control device for sensing, the heat generation function and the sensing function. May be operated by the same control device.

  Power, current, voltage, or a combination thereof may be applied continuously, intermittently, changed, or a combination so that the heater generates heat. The controller is preferably capable of adjusting the heater control, heater temperature, or both using pulse width modulation (PWM). Depending on the desired temperature of the heater, the PWM signal supplying power can be lengthened or shortened. Thus, 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 media, the PWM can provide a signal between about 60 percent and about 80 percent. Thus, the heater is turned off between 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 heat generation is temporarily stopped. For example, heat generation may be interrupted for about 500 ms so that one or more signals are taken. This process can be repeated intermittently so that an occupant is detected. The sensor may provide a sensing function when the heater is off and / or when no power is applied to heat the heater.

  Signaling to the heater can occur at any time so that the heater is used for sensing. Preferably, a signal is applied to the heater when power is not 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 source, or disconnect the heater from the ground, or both. During application of the sensing signal, the power control device, 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 shifts due to a change in capacitance.

  The teachings herein provide heat generation and sensing methods. The method includes one or more of the steps described herein in substantially any order. Electric power can be applied to the heater such that the heater generates heat. A signal can be applied to the heater so that the heater becomes a sensor. The power, signal, or both can be applied alternately or simultaneously. The power may be turned off intermittently so that a sensing signal is applied. The controller may measure the system capacitance deviation, the measurement signal frequency deviation, or both. One or more transistors may turn on and / or off the heating elements of a 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 illustrated, 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 the 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 the power applicator 12 including 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 is wound around the core 4. The heater 10 / sensor 20 is covered by the trim layer 6.

  FIG. 5A shows a heater / sensor 10, 20 having three power application units 12. As shown, the central power application unit 12 is a positive power application unit, and the negative power application unit 12 is at both ends. The central power application unit 12 may be disposed at substantially any position between the two terminal power application units 12, but is preferably disposed substantially at 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 heater / sensors 10, 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 respectively connected to the individual power application line 14. As shown in the figure, the positive power application units 12 are close to each other, and the negative power application unit 12 is disposed outside the heater / sensors 10 and 20. As shown, each sensor 20 can individually sense an occupant's hand (not shown), so that the sensor 20 is in sensing mode if one or more of the occupant's hands are in contact with the steering wheel, for example. I can sense how.

  FIG. 5C shows two individual heaters / sensors 10, 20 that are 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 end of the heater / sensor 10, 20, and the positive power application unit is at the end of the heater / sensor 10, 20 opposite the negative power application unit 12. Close to each other. As shown, each sensor 20 can individually determine contact with an 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 heater / sensor 10, 20 having a plurality of longitudinal power applicators 12 extending along the length of the heater / sensor 10, 20. These longitudinal power application sections 12 extend substantially parallel along the side edges of the heaters / sensors 10,20. In the meantime, the heater / sensor material extends to electrically connect the two opposing power application sections 12.

  FIG. 6B shows the heater / sensor 10, 20 of FIG. 6A connected to the steering wheel 2. The heaters / sensors 10 and 20 include 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. Line 14. As shown in the figure, an insulating layer 50 that is not insulated in the material of the heaters / sensors 10 and 20 but electrically insulates the two power application units 12 from each other is disposed between the power application units 12, so Since the power application unit 12 must move from the power application unit 12 to the second power application unit 12 via the material of the heater / 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, 20 such that the longitudinal power application section 12 extends along the length of the heater / sensor 10, 20. / Sensors 10 and 20 are shown. 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 there is a small gap 52 between each end of the power application unit 12. 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 heater / sensors 10, 20 each including a positive and negative power applicator 12 connected to a power application line 14, respectively. Each heater / sensor 10, 20 individually generates heat and senses individually 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 sense a state, a plurality of states such as two hands can be sensed simultaneously.

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

  FIG. 9A shows heaters / sensors 10, 20 including three longitudinal power application units 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 power and sensing signals are applied via the heater / sensors 10 and 20.

  FIG. 9B shows a cross-sectional view of the heater / sensors 10, 20 wound around the steering wheel 2. As shown, the two negative ends of the heater / sensors 10, 20 are located at a close distance and even contact each other, but the heater / sensors 10, 20 do not short circuit.

  FIG. 9C shows a cross-sectional view of another heater / sensor 10, 20 wound around the steering wheel 2. As shown, the two positive ends of the heater / sensors 10, 20 are located at a close distance and even contact each other, but the heater / sensors 10, 20 do not short circuit.

  FIG. 9D shows the heaters / sensors 10, 20 wound around the steering wheel 2. The ends are brought into contact so that there is no gap between the ends of the heater / sensor 10,20.

  FIG. 10 shows heaters / sensors 10 and 20 including a power application unit 12A for power application 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 sense a passenger contact when the heat is off. Each power application line 14B is connected to a microprocessor 60 that senses passenger 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 output 24 via resistor 26 where it is compared to a lookup table. As shown, the steering wheel 2 forms one side of the capacitor 40 so that a frequency shift is sensed via the output 24 when the occupant 100 is in contact with the steering wheel 2, The other side of the capacitor 40 is formed.

  FIG. 12 shows a circuit diagram including both the heat generating part and the sensing part. During operation of the heater 10, 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 that the heater is off, a signal is applied to the heater so that the heater is used for sensing.

  The numerical value described in this specification is any numerical value, and when the smaller value and the larger value are at least 2 units apart, from the smaller value to the larger value. Includes any value that increases by one unit. By way of example, if the amount of a component or the value of a process variable, such as temperature, pressure, time, etc. is stated to be, for example, 1 to 90, preferably 20 to 80, more preferably 30 to 70. In the present specification, values such as 15 to 85, 22 to 68, 43 to 51, and 30 to 32 are explicitly listed. For values less than 1, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 as appropriate. These are merely examples of specifically intended values and all possible combinations of numerical values between the minimum and maximum values listed are also considered explicitly stated herein. Shall be.

  Unless otherwise stated, every range includes both endpoints and any numerical value between these endpoints. As used with respect to a range, "about" or "approximately" refers to both ends of the range. Accordingly, “about 20 to 30” shall include “about 20 to about 30”, including at least the specified endpoints.

  The disclosures of all provisions and references are incorporated by reference for all purposes, including patent applications and publications. The expression “consisting essentially of” to describe a combination substantially impairs the identified elements, ingredients, components, or steps and the basic and novel properties of this combination. Other elements, components, components, or steps are not included. Where the term “comprising” or “including” is used herein to describe a combination of elements, components, components, or steps, basically these elements, Embodiments consisting of components, components, or steps are also contemplated. In this application, any attribute contained and described as "obtained" by use of the term "may be" may be used arbitrarily.

  Multiple elements, components, components, or steps may be provided by a single integrated element, component, component, or step. Alternatively, an integrated single element, component, component, or step may be divided into multiple individual elements, components, components, or steps. The disclosure of “one” or “one” to describe an element, component, component, or step does not exclude additional elements, components, components, or steps.

  It is to be understood that the above description is illustrative and not restrictive. After reading the above description, many embodiments and many applications will become apparent to those skilled in the art in addition to the examples provided. Accordingly, the scope of the present teachings should not be determined with reference to the above description, but should be determined with reference to the appended claims along with the full scope of equivalents to which such claims are entitled. Should be determined. The disclosures of all provisions and references are incorporated by reference for all purposes, including patent applications and publications. The omission in the appended claims for any aspect of the subject matter disclosed herein is not a waiver of such subject matter, but is a subject matter of the invention for which we have disclosed such subject matter. It should not be considered not to have been considered part of.

Claims (13)

A heater 10 and sensor 20 for a vehicle steering wheel or seat ,
a) a heating layer, a sensing layer, or both,
b) one or more power application units 12, one or more sensing units capable of detecting the sensing function provided by the sensing layer , or both;
With
The heat generating layer and the sensing layer are disposed in the same plane,
The heat generating layer is formed by a nonwoven layer including a plurality of metal coating fibers arranged randomly,
The heating layer and the sensing layer are the same device,
The heater and sensor can function as a sensor without adding any additional sensing elements,
The heating layer, the sensing layer, or both form one side of a sensing circuit between the heater and sensor and the ground of the vehicle;
The controller detects a frequency shift of a signal passing through the sensing circuit when an occupant is in proximity to or in contact with the heat generation layer, the sensing layer, or both.
Heater 10 and sensor 20. The heater / sensor according to claim 1, wherein the heat generating layer, the sensing layer, or both are two or more heat generating layers, the sensing layer, or both . The heater is controlled using pulse width modulation, wherein when the heater is off, in order to perform the sensing, heater and sensor according to claim 1, signals pass through the sensing layer. The heater / sensor according to any one of claims 1 to 3, wherein an occupant forms the other side of the sensing circuit. The one or more power application units 12 are conductive nonwoven fabrics fastened to the heat generation layer, the sensing layer, or both, and the one or more power application units are edge regions at both ends of the heater. heater combined sensor according to claim 1 or 3 arranged are two power application portion. A heater controller is connected to the heater to energize the heater so that the heater supplies heat, and a sensing controller is connected to the sensor to supply a signal for the sensor to sense, The sensing control device and the heater control device are connected to the heater / sensor via one or more lines, and the one or more lines are used to apply a voltage to the heater and supply a signal to the sensor. The heater / sensor according to claim 1 or 3 , wherein both are performed. The heater and sensing is covered by a trim layer disposed within a seat of the vehicle, or the heater and sensing is covered by a trim layer disposed within said steering wheel, or claim 1-3 is both The heater / sensor according to any one of the above. The two or more heating layers, sensing layers, or both are disposed within the steering wheel, each of the two or more heating layers, sensing layers, or both can sense a plurality of hands; 3. The heater and sensor according to claim 2, wherein half or quarter of the steering wheel is sensed so that a specific position of a hand can be sensed . The signal supplied by the sensing control device has a frequency, and the sensing control device is in contact with an occupant in contact with the heater / sensor, a component including the heater / sensor, or this The heater / sensor according to claim 6 , wherein the frequency shift of the signal is measured to determine whether both are present. Fever and sensing method,
a) installing the heater 10 and sensor 20 according to claim 1 on a component of an automobile;
b) supplying electric power to the heater / sensor so that the heating layer of the heater / sensor generates heat;
c) signals to the heater and sensor such that the sensing layer of the heater and sensor generates a signal to determine the presence of an occupant, contact between the occupant and the component of the vehicle, or both And supplying
d) monitoring the signal for an occupant, absence of an occupant, lack of contact between the component and the occupant, or a combination thereof;
Only including,
The power and the signal are applied to the heater and sensor via a line, and the line is the same line for both the signal and the power,
Method. The power such that the power has an on phase and an off phase is applied by pulse width modulation, the signal, when the power is of the off phase, according to claim 10 applied to the heater and sensing the method of. The signal includes a frequency, and a sensing control device determines the presence of the occupant, the contact between the occupant and the heater / sensor, or both, and the sensing controller is configured to detect the frequency, the frequency shift, and the signal static. The method according to claim 10 or 11 , wherein a capacitance, a voltage to be measured, or a combination thereof is measured. The heater 10 and sensor 20 are two heaters and sensors disposed in the steering wheel. During the heat generation and sensing, one heater and sensor and the other heater and sensor alternately heat and sense. the method according to any one of claims 10 to 12 for.