US 20060137099 A1
A cushion that is heated convectively using a positive coefficient of resistance type resistive heating element that is provided with heat exchanging surfaces, includes a mattress pad, seat or the like with a bottom surface secured around its perimeter to an air permeable top surface, forming a plenum and containing tubular spacer material therein. The plenum is connected to a power unit housing a blower, a heating module and a controller unit. The heating module preferably includes a PTC type heating element in conduction with a base plate and a number of heat exchanger fins. Preferably the heating element is sandwiched between a pair of the base plates and the heat exchanger fins, and there is a seal between the base plates to minimize air flow from the blower from passing there between. A remote control for the user's convenience may be provided, and a foldable antenna attachable to the convective unit facilitates wireless communication between the remote control and controller unit. The user resting atop the cushion is able to control the blower and heating module to deliver air of a desired temperature and quantity to the cushion and through the top surface. The invention advantageously replaces the current carrying, conductive wires and insulation found inside prior art heated mattresses, enhancing safety and performance while at the same time offering a cooled or ventilated capability.
1. A selectively-controlled convective cushion comprising:
a plenum defined by a bottom surface secured around its perimeter to a generally air permeable top surface and containing tubular spacer material therein;
a power unit located remote from the plenum but in fluid communication with the plenum, and housing a blower in fluid communication with a heating module;
a controller unit in communication with the blower and the heating element;
whereby a user resting atop the cushion is able to control the blower and heating module to deliver air of a desired temperature and quantity to the cushion and through the top surface.
2. The selectively-controlled convective cushion of
3. The selectively-controlled convective cushion of
4. The selectively-controlled convective cushion of
5. The selectively-controlled convective cushion of
6. The selectively-controlled convective cushion of
7. The selectively-controlled convective cushion of
8. The selectively-controlled convective cushion of
9. The selectively-controlled convective cushion of
10. The selectively-controlled convective cushion of
11. The selectively-controlled convective cushion of
12. The selectively-controlled convective cushion of
13. The selectively-controlled convective cushion of
14. A convective mattress pad comprising:
a plenum defined by a bottom surface secured around its perimeter to a generally air permeable top surface, the plenum containing an air flow structure and having an opening at one end;
an air duct with one end sized to be received into the opening and a second end extending outside the plenum;
a power unit housing a blower in fluid communication with a heating module and connected to the second end of the air duct;
a controller unit in communication with the blower and the heating element; and,
wherein the heating module comprises a PTC type heating element in conduction with a base plate and a plurality of heat exchanging fins.
15. The mattress pad of
16. The mattress pad of
17. The mattress pad of
18. The mattress pad of
19. The mattress pad of
20. The mattress pad of
21. The mattress pad of
22. The mattress pad of
This application is continuation-in-part of utility patent application Ser. No. 11/024,073 (filed Dec. 27, 2004) entitled “Variable Temperature Cushion And Heat Pump.”
1. Field of the Invention
The present invention relates to temperature controlled mattress pads, seats or other cushions, and more particularly to such a cushion that is heated by a positive temperature coefficient (PTC) element and ventilated as well.
2. Description of the Related Art
Resistance wires oftentimes with PTC resistive elements are the conventional way of heating a cushion by conduction. This suffers from certain disadvantages, however, including that the electrical conductors are located within the cushion itself. Over time, the wires, carbon fiber strips or the like being subject to repeated weight loads and mechanical stresses may become physically damaged causing sparks from short circuits, and an occasional fire. Voltages as low as 6V can produce noticeable sparking, even at current levels in the 1-200 milliamp range.
Insulation is commonly used in the prior art, not only to limit peak heating at the conductor but also to spread the heating effect out (or average it) over the surface to be heated. The disadvantage here is that it takes longer to reach an adequate heating level, because of the drop in heating efficiency caused by the insulation. The overall efficiency of the heating apparatus is compromised as the insulation slows the heating of the outer surface of the cushion.
Additionally, resistance heated type, prior art mattress pads don't offer cooling or ventilation. This is a major disadvantage in many parts of the world where the population lacks means such that air-conditioning is unavailable and a substantial portion of the year relaxing or sleeping is uncomfortable due to very warm ambient air conditions.
Accordingly, it is an object of the present invention to construct a temperature-controlled cushion that is heated without the conventional resistance wires or PTC resistive elements in conductive mode within the cushion itself,
It is a further object of the present invention to construct such a cushion while minimizing the use of insulation.
It is a still further object of the present invention to provide such a cushion that also includes a cooled or ventilated mode.
It is a still further object of the present invention to provide such a cushion that includes convenient controls for the user.
It is a still further object of the present invention to provide such a cushion that is simple and relatively inexpensive to manufacture.
It is a still further object of the present invention to provide an accompanying power unit that is quiet and compact, and located remote from the cushion;
These and other objects of the present invention will become apparent upon reference to the following detailed description and accompanying drawings.
Disclosed is a new approach for a cushion that is heated convectively using a positive coefficient of resistance type resistive heating element that is provided with heat exchanging surfaces, or alternatively a thermoelectric device with heat exchanging surfaces, or a Stirling Cycle heat pump with PTC heater mounted on the cold head and heat exchanging surfaces attached to the PTC heater and/or cold head.
The present invention includes a mattress pad, seat or other cushion with a bottom surface secured around its perimeter to an air permeable top surface (forming a plenum or air-flow structure) and containing tubular spacer material or equivalent therein. The plenum has an opening for a (preferably insulated) air duct which leads to a power unit housing a blower, a heating module and a controller unit. Besides obvious uses in the home or an automobile, the invention as disclosed herein may also be used for patient warming in medical and surgical settings.
The heating module preferably includes a PTC type heating element in conduction with a base plate and a number of heat exchanger fins. Preferably the heating element is sandwiched between a pair of the base plates and the heat exchanger fins, and there is a seal between the base plates to minimize air flow from the blower from passing there between. A remote control for the user's convenience may be provided and a foldable antenna attachable to the convective unit facilitates wireless communication between the remote control and controller unit, although corded remote control may also be utilized or the controls located on the power unit itself. The power unit may include multiple PTC elements including of varying capability to allow the user to more precisely control the output temperature of the air, and may include a speed control for the blower.
The user resting atop the cushion is able to control the blower and heating module to deliver air of a desired temperature and quantity to the cushion and through the top surface. The advantages of the subject invention over the prior art in heating mode for mattress pads, seats and other cushions are substantial. Since there are no current conducting wires or carbon fiber strips within the cushion structure, the convective cushion is much safer than the prior art when used as a mattress pad. This is because the PTC heating element is located remotely from the cushion and is connected to the cushion only with an air duct hose, eliminating all mechanical stress to any electrical wires from weight applied to the sleeping or seating surface. Because the heating medium is air, and not hot current conductor wires, it isn't necessary to use insulation to spread the heating effect over the entire surface of the cushion. By using air, the heating effect is gentle and effective without the need for insulation, so the overall heating mode efficiency is higher and more evenly distributed over the heated surface.
The present invention, besides replacing basic electric resistance wire heated mattress pads as well as other resistance element heated cushions, also offers a feature that the prior art cannot using the same equipment and that is a ventilation mode for warm weather. By causing ambient air to move within the air flow structure (which is much more efficiently done with tubular spacer fabric as described elsewhere herein, and in U.S. Pat. Nos. 6,263,530 and 6,085,369, but can be done less efficiently with other air flow structure materials), a meaningful percentage of excess body heat can be removed during warm weather while the user is seated on or sleeping on the cushion of the subject invention.
As long as ambient temperature is below the user's body skin temperature (which averages out to approximately 96 degrees Fahrenheit over much of the body), there must (according to Newton's Law of thermal transfer), be a thermal exchange between the source of heat at a higher temperature (body skin surface), and a heat sink at a lower temperature, by ambient air under forced convection (macrocosmically) and free convection, (microcosmically). The terms macrocosm and microcosm simply refer to the relatively large bulk air flow (or forced convection), produced through the cushion air flow structure by the blower and the relatively very small air convection movement (free convection), produced at the microcosmic level by the delta T or difference in the relatively warm air nearest the user's skin and the relatively cool air brought into close proximity via forced convection. The microcosmic level is that level within the padding and textiles which is the interface between the user and the air flowing through the cushion.
Initially referring to
Inside the plenum 12 is tubular spacer material 18 or equivalent. U.S. Pat. Nos. 6,085,369 and 6,263,530 pioneered the use of such tubular spacer fabric 18 as an air flow structure for seats, mattresses, mattress pads, and other articles of furniture that can be sat on or laid down upon. Although the preferred embodiment of this invention utilizes the same tubular spacer fabric 18 as described in the issued Feher '369 and '530 patents, it is possible to utilize other air flow structures such as Muller Textile's 3 Mesh or Strahle and Hess' assembled woven tube fabric, as well as any other air flow structure; however there may be substantially reduced levels of performance when compared to tubular spacer material 18 as disclosed in the above U.S. Pat. Nos. and herein.
Also shown in
The box 24 may optionally include a Triac or other semiconductor power control for the PTC heating elements to enable the PTC elements to operate below their switch temperature design point. The PTC element switch temperature is the temperature at which the resistance starts to rise exponentially. The elements 36 are called Positive Temperature Coefficient because, unlike NTC, or Negative Temperature Coefficient type materials, the electrical resistivity rises with increasing temperature, instead of dropping with increasing temperature. Most materials exhibit PTC characteristics because increasing temperature causes more ionic movement, crystal lattice vibration, and/or molecular motion, any of which can interfere with electron mobility. The switch temperature of ceramic PTC devices is determined by the amount of doping with certain elements, such as strontium, for example, before firing.
In order to operate the PTC heating elements 36 below their design point switch temperature it is necessary to either increase the heat load beyond the capabilities or rating of the elements, by increasing air flow beyond the design point for example, or by reducing voltage to the elements, which reduces the power rating of the elements relative to the load. For a mattress pad application of the convective cushion 10 it may be more desirable to use a power reduction instead of an air flow increase, in order to maintain a very low noise level for a comfortable sleeping environment.
The PTC heating module assembly 30 can be made with a single heat exchanger 32; however such an arrangement would not be as efficient from a thermal point of view. The heat exchangers 32 are preferably made of copper, although aluminum or any other thermally and electrically conductive material can also be used. Although solder can be used to bond the PTC heating elements 36 to the heat exchanger base plates 18, a flexible adhesive with good thermal and electrical conductivity is preferred to prevent excessive stress buildup and possible PTC element 36 cracking due to differences in coefficient of thermal expansion (CTE) between the PTC heating element 36 material and the heat exchanger 32 material, which can be substantial, for example, approximately 10:1 for the PTC elements 36 and copper.
Referring back to
The solution of
This is one way of making an insulated air duct hose 40 for the preferred embodiment 10 that remains flexible and non-bulky while enabling higher performance and efficiency for the subject cushion or mattress pad in heating mode under cold ambient air temperature conditions. However it is configured, an insulated air duct hose 40 is important for best cold weather heating mode performance, especially because the air delta T in heating mode is substantially higher than in ventilation mode, in which there is no delta T because ambient air is being used for ventilation. If a source of air cooled below ambient is used, then the insulated air duct 40 will improve efficiency, however, not to the same extent, as active cooling mode delta T will still usually be less than half that of heating mode delta T. For example, heating mode may easily entail an air delta T of 45+ deg. F., while active cooling mode with thermoelectric or Stirling Cycle devised as disclosed in some of my other patents, will generally not exceed 20-30 deg. F.
Note the airflow direction through the cushion 130 varies depending upon where the power unit 150 is placed, with the air primarily exiting the cushion 130 remote from the power unit 150. The set up with the power unit 150 forward the seat rest 132 is advantageous for ease of control in that the power unit 150 controls could be located directly on the unit 150 and easily accessible between the user's legs when seated on the cushion 130. When the power unit 150 is located aft of the user, a wired control extends to the user or to a location accessible to the user or a remote wireless control could be used.
The present invention has been described in connection with preferred and alternate embodiments, but it is understood that modifications will occur to those skilled in the appertaining arts that are within the spirit of the invention disclosed and within the scope of the claims.