Patent Publication Number: US-2015083709-A1

Title: Shapeable heating panel system

Description:
FIELD OF THE APPLICATION 
     The present application relates to a shapeable heating panel system for producing heat, for use in heating applications requiring some panels, for instance in the automotive industry, in construction, furniture, among numerous other possibilities. 
     BACKGROUND OF THE ART 
     It is commonly known to heat surface by passing an electric current through a circuit within surface. However, existing heated surfaces typically comprise wires arranged in coil configurations, to produce the heat. The presence of such wires therefore has a negative impact on the practicality of heating surfaces, for instance by fragility of heating wires and/or the substantial amount of time required for installation thereof. 
     SUMMARY OF THE APPLICATION 
     It is therefore an aim of the present disclosure to provide a shapeable heating panel system for producing heat that addresses issues associated with the prior art. 
     Therefore, in accordance with the present application, there is provided a heating panel system for producing heat, comprising: a heating panel comprising: a layer of heating textile, the heating textile layer being made of a non-woven three-dimensional network of non-woven non-electrically conductive synthetic fibers and electrically conductive strands of synthetic fibers or fine metal wires consolidated therewith; at least one shapeable structural layer laminated to the heating textile layer; and electrodes conductively secured to the heating textile layer at opposite ends, the wires being adapted to be connected to a power source to form a circuit with the panel of heating circuit to circulate electric power within the heating textile layer. 
     Further in accordance with the present disclosure, the electrodes are elongated electrodes and extend along opposite side edges of the layer of heating textile. 
     Still further in accordance with the present disclosure, each said electrode is made of a conductive wire. 
     Still further in accordance with the present disclosure, the conductive wire of each said electrode is arranged in at least two elongated passes. 
     Still further in accordance with the present disclosure, each said electrode comprises at least one copper wire. 
     Still further in accordance with the present disclosure, each said electrode is sewn to the layer of heating textile with a conductive thread. 
     Still further in accordance with the present disclosure, sheathed wires are connected to the electrodes and adapted to be connected to the power source. 
     Still further in accordance with the present disclosure, a power source connector is at the free end of the sheathed wires, the power source connector adapted to be releasably connected to the power source. 
     Still further in accordance with the present disclosure, tacks are secured to the layer of heating textile at ends of the electrodes connected to said sheathed wires. 
     Still further in accordance with the present disclosure, the layer of heating textile has an intrinsic resistivity ranging from 0.05 to 5.0 Ωm 2 /kg. 
     Still further in accordance with the present disclosure, the strands have a length ranging between 2.5 cm and 15.3 cm. 
     Still further in accordance with the present disclosure, the shapeable structural layer is made of a thermoplastic having a shaping temperature about a maximum temperature of operation of the layer of heating textile. 
     Still further in accordance with the present disclosure, an insulation layer is positioned between the layer of heating textile and the shapeable structural layer and laminated therewith. 
     Still further in accordance with the present disclosure, the insulation layer is a foam polymer. 
     Still further in accordance with the present disclosure, a functional layer is on a side of the layer of heating textile opposite that of the shapeable structural layer, the functional layer being laminated therewith. 
     Still further in accordance with the present disclosure, the functional layer is a decorative fabric or cloth. 
     Still further in accordance with the present disclosure, the heating panel has a planar geometry resulting from lamination, and has a post-lamination thermo-shaped geometry. 
     Further in accordance with the present disclosure, there is provided a method for thermo-shaping a heating panel comprising: obtaining a laminated heating panel comprising at least a layer of heating textile, the heating textile layer being made of a non-woven three-dimensional network of non-woven non-electrically conductive synthetic fibers and electrically conductive strands of synthetic fibers or fine metal wires consolidated therewith, at least one shapeable structural layer laminated to the heating textile layer, and means for circulating electric power in the layer of heating textile to generate heat; maintaining the laminated in a planar state at ambient temperature; heating the laminated heating panel above a predetermined thermo-shaping temperature to thermo-shape the at least one shapeable structural layer to a selected non-planar geometry; and cooling down the laminated heating panel to maintain same in the selected non-planar geometry. 
     Still further in accordance with the present disclosure, the heating textile layer is connected to a power source and circulating electric power therein to generate heat to a maximum temperature of operation below the thermo-shaping temperature. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram of a shapeable heating panel system for producing heat in accordance with an embodiment of the present disclosure; 
         FIG. 2  is a schematic view of a heating textile of the textile system of  FIG. 1 ; and 
         FIG. 3  is a sectional view of a shapeable heating panel of the heating panel system of  FIG. 1 . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIGS. 1 and 2 , there is illustrated a heating panel system for producing heat at  10 . The heating panel system  10  comprises a shapeable heating panel  12  comprising a layer  12 A of heating textile. The heating textile layer  12 A of the shapeable heating panel  12  is of the type receiving an electric current to produce heat. 
     According to an embodiment, the heating textile layer  12 A is in accordance with the fabric described in U.S. Pat. No. 7,994,080, incorporated herewith by reference, or in accordance with any other suitable configuration. Therefore, the heating textile layer  12 A may be an electrically conductive non-woven fabric comprising a three-dimensional network of non-woven non-electrically conductive synthetic fibers and electrically conductive strands of synthetic fibers or fine metal wires consolidated therewith. The conductive strands may have a length ranging between 1 to 6 inches (2.5 cm to 15.3 cm), although the conductive strands may be longer. According to an embodiment, the non-electrically conductive synthetic fibers occupying a mass ranging between 50% to 98% of the fabric such that the fabric has an intrinsic resistivity in the range of from about 0.05 to 5 Ω m 2 kg. In this embodiment, the electric current is conducted through the panel of heating textile layer  12 A without a circuit of wires all over the textile layer  12 A. In other words, the heating textile layer  12 A is the link between electrodes  14 A and  14 B, as described hereinafter. Accordingly, the properties of the heating textile layer  12 A are similar to that of more conventional fabrics in terms of lightness and flexibility, thereby facilitating their lamination structural layers. 
     Referring to  FIGS. 1 and 3 , the shapeable heating panel  12  may comprise at least one structural layer  12 B. An additional layer is illustrated at  12 C, thereby sandwiching the heating textile layer  12 A between structural layers  12 B and  12 C. The layers  12 A,  12 B,  12 C and/or  12 D are therefore laminated together to form the shapeable heating panel  12 , shown as thermo-shaped by 12′ in  FIG. 3 . 
     At least one of the structural layers  12 B and  12 C are made of a thermoplastic shapeable material such as polymers, composite materials, metals, etc, upon reaching a given specific heating temperature but maintaining its thermoformed shape at ambient temperatures. The specific heating temperature is thus selected to be below the temperature reached by the powering of the heating textile layer  12 A, such that the heating textile layer  12 A may generate heat without risking to deform the structural layer  12 B, unless a suitable insulation layer is provided as described below. According to an embodiment, the material of the structural layer  12 B is selected to substantially maintain its shape when heated, thermoformed or molded, and may hence be a thermoplastic. A well-suited material to be used as structural layer  12 B is PVC, although other materials may be used as well. While the heating textile layer  12 A, the structural layers  12 B and  12 C provide a different functionality to the heating panel  12 , such as structural integrity allowing the heating panel  12  to be shaped in accordance with the expected use of the heating panel  12 . 
     It is considered for instance to position an additional insulation layer  12 D between the structural layer  12 B and the heating textile layer  12 A, such as a foam polymer. Accordingly, the laminated panel having the heating textile layer  12 A, the structural layer  12 B and the insulation layer therebetween would have structural integrity due to the presence of the structural layer  12 B giving and maintaining a shape for the assembly (e.g., by way of thermoforming), with the heat generated by the heating textile layer  12 A being shield from transferring to the structural layer  12 B by way of the insulation material  12 D. Additional layers may also be used. For instance, the layer  12 C may consist of an insulation material (e.g., foam polymers, such as EPP, EPE, EPS) for heat generated by the layer  12 A to warm up the structural layer  12 B and/or a cushioning material. The layer  12 C may otherwise be provided to protect the heating textile layer  12 A, and provide a given finish to the heating panel  12 , such as leather, vinyl, leather cloth, fabrics, or other decorative cloth layers. 
     The structural layers  12 B,  12 C and/or  12 D may be laminated to the heating textile layer  12 A by any appropriate means and/or process. For instance, an adhesive may be used. The layers may be fused to one another by heating any one of the layers to a sufficient temperature. The layers may be molded to one another, thermoformed into the panel  12 , etc. 
     Hence, the heating panel  12  is thermo-shapeable and is typically provided as a planar panel that may readily be shaped to the appropriate geometry in a post-lamination thermoforming or thermo-shaping. The configuration of the heating textile panel  12 A, namely an electrically conductive non-woven fabric comprising a three-dimensional network of non-woven non-electrically conductive synthetic fibers and electrically conductive strands of synthetic fibers or fine metal wires consolidated therewith, is well suited to be a part of the laminated heating panel  12  due to its non woven nature. Indeed, as opposed to woven fabrics, or metallic mesh, a non-woven fabric is more compliant during the post-lamination thermo-shaping process. 
     Wires  13 A and  13 B are part of a circuit that will supply electric current to the heating textile layer  12 A. As shown in  FIG. 2 , a portion of the wires  13 A and  13 B are fixed directly to the heating textile layer  12 A, at opposed ends of the panel, and hence form electrodes  14 A and  14 B for the heating textile layer  12 A. The electrodes  14 A and  14 B are for instance sewn to the heating textile layer  12 A in the illustrated elongated pattern. In an embodiment, a conductive sewing thread (e.g., silver or the like) is used to attach the electrodes  14 A and  14 B to the heating textile layer  12 A. The electrodes  14 A and  14 B may consist of any suitable conducting material, such as a copper wire, and may be arranged in a few passes (two in  FIG. 2 ) to have suitable conducting surface with the heating textile layer  12 A. The spacing between the electrodes  14 A and  14 B causes the electric current to pass through the heating textile layer  12 A when the circuit is closed. The resistivity of the heating textile layer  12 A will cause same to heat up when electric current passes through it. In parallel, the layers  12 B and  12 C may be selected with insulating properties to ensure that the current remains in the heating textile layer  12 A. 
     As shown in  FIG. 2 , tacks  15 A and  15 B may respectively be provided in the wires  14 A and  14 B, to secure wires  14 A and  14 B to the heating textile layer  12 A. The electrodes  14 A and  14 B may be directly linked to the panel of heating textile layer  12 A. The tacks  15  are patches of material sewn to the heating textile layer  12 A, to reinforce the joint between the electrodes  14 A and  14 B and the heating textile layer  12 A. The wires  13 A and  13 B may be sheathed from the tacks  15 A and  15 B to a power source  16 . The electrodes  14 A and  14 B may be directly linked to the panel of heating textile layer  12 A, and may also be covered by a strip of sheathing, or encapsulated for instance by folded edges of the heating textile layer  12 A. 
     Referring to  FIG. 1 , a power source  16  is in the circuit of the system  10 . Considering that the textile system  10  is used in heating applications of various apparatuses, the power source  16  may be associated with the apparatus hosting the heating panel  12 . For instance, when the heating panel  12  is part of a vehicle (e.g., car, snowmobile, plane), the power source  16  is typically that of the vehicle. In appliances, such as a coffee machine, the power source  16  is typically that of the appliance. Appropriate connectors and signal treating components may provided as a function of the type of battery used. It is also considered to provide the system  10  with a connector plug, such as car lighter connector. A controller  18  may be provided to adjust the level of current fed to the circuit. In its basic configuration, the controller  18  is an on/off switch to open and close the circuit. The controller  18  may be a rheostat, and may include a digital-display thermostat and thermocouple to control the temperature of the heating textile layer  12 A. The controller  18  may be that of the apparatus, with an appropriate application in the controller  18  to control the amount of heat produced by the heating panel  12 . 
     The shapeable heating panel  12  may be used in any application requiring a heating panel. The shapeable heating panel  12  may be part of the body of a vehicle (e.g., aircraft, truck, car, train), and may be used to remove ice or snow buildups. In such a case, the heating panel  12  may be connected to the power source from the vehicle. Other automotive applications are considered, for instance, such as heated car mats or heated seating. Moreover, some components of the motor group may be warmed up in cold weather using the heating panel  12 . 
     According to another application, the shapeable heating panel  12  is used as a building material. For instance, the heating panel  12  may be used in roofing, and hence as a de-icing component of the roof. The heating panel  12  may also be part of a radiant heated floor. 
     According to yet another application, the shapeable heating panel  12  is a part of a mold, with the heating used in the ejection of the molded part after the molding process. 
     According to yet another application, the shapeable heating panel  12  is a part of dishes that may be heated to keep foodstuff warm. 
     Hence, a method of operation would go as follows. The heating panel  12  is in a planar state at ambient temperature, following lamination. The laminated heating panel is then heated post-lamination above a predetermined thermo-shaping temperature to thermo-shape the structural layer  12 B and other thermo-shapeable layers to a selected non-planar geometry. Other steps including cutting, painting, coloring, etc, the panel beforehand or after thermo-shaping. Once, thermo-shaped, the laminated heating panel is cooled down to maintain same in the selected non-planar geometry. The heating panel  12  may be connect to a power source, for electric power to circulate therein to generate heat. However, the heating panel  12  must have a maximum temperature of operation below the thermo-shaping temperature.