Patent Publication Number: US-2020281046-A1

Title: Portable heating apparatus with temperature-retaining component

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional application Ser. No. 62/811,892 filed Feb. 28, 2019, the disclosure of which is hereby incorporated in its entirety by reference herein. 
    
    
     TECHNICAL FIELD 
     Embodiments relate to a portable heating apparatus, such as a heating pad or wrap, with a temperature-retaining component, such as a gel layer. 
     BACKGROUND 
     Heating pads or wraps are designed for supplying heat to various parts of the body, such as the back, arms and legs. Electric heating pads have a constant source of power for maintaining a maximum heat level, but their use is restricted to locations within reach of a power outlet. While many heating pads offer comfort and convenience to a user, often heating pads are not constructed to provide efficient and effective heat treatment of the body while also providing portability. A continuing need exists for heating pads and wraps which can meet user requirements for heat therapy while still being easy and cost-effective to manufacture. 
     SUMMARY 
     In one or more embodiments, a portable heating apparatus includes a top layer and a bottom layer connected to the top layer to form a cavity. An electric heating element is disposed within the cavity, and a temperature-retaining component, such as a gel layer, is affixed within the cavity adjacent to the electric heating element and adjacent to the top layer. A power cord is in electrical communication with the electric heating element and connectable to a power source to provide power to the electric heating element, the power cord detachable from the portable heating apparatus. The temperature-retaining component is capable of retaining heat generated by the electric heating element and creating a generally uniform distribution of heat across the top layer. 
     In one or more embodiments, a portable heating apparatus includes a top layer and a bottom layer connected to the top layer to form a cavity. An electric heating element is disposed within the cavity, a padding material is disposed within the cavity between the electric heating element and the bottom layer, and a gel layer is affixed within the cavity between the electric heating element and the top layer. A power cord is in electrical communication with the electric heating element and connectable to a power source to provide power to the electric heating element, the power cord detachable from the portable heating apparatus. The gel layer is capable of retaining heat generated by the electric heating element and creating a generally uniform distribution of heat across the top layer. 
     In one or more embodiments, a portable heating apparatus includes a main body including an outer, top layer and an inner, bottom layer connected to the top layer, the top and bottom layers forming a cavity therebetween, with a first strap and a second strap extending from the main body. An electric heating element is disposed within the cavity, and a temperature-retaining component is affixed within the cavity adjacent to the electric heating element and adjacent to the bottom layer. A power cord is in electrical communication with the electric heating element and connectable to a power source to provide power to the electric heating element, the power cord detachable from the portable heating apparatus. The temperature-retaining component is capable of retaining heat generated by the electric heating element and creating a generally uniform distribution of heat across the bottom layer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a heating pad according to an embodiment; 
         FIG. 2  is a perspective view of a heating pad according to another embodiment; 
         FIG. 3  is a top view of the heating pad of  FIG. 1  schematically illustrating the internal heating element; 
         FIG. 4  is a perspective view of the heating pad of  FIG. 1  schematically illustrating the internal temperature-retaining component; 
         FIG. 5  is a perspective view of the heating pad of  FIG. 2  schematically illustrating the internal temperature-retaining component; 
         FIG. 6  is an exploded view of a heating pad according to an embodiment; 
         FIG. 7  is a front view of a controller for a heating apparatus according to an embodiment; 
         FIG. 8  is an exploded view of a controller and related components for a heating apparatus; 
         FIG. 9  is a perspective view of a heated pillow according to an embodiment; 
         FIG. 10  is a front perspective view of a heated belt wrap according to an embodiment; 
         FIG. 11  is a rear perspective view of the heated belt wrap; 
         FIG. 12  is a front view of an inner side of the heated belt wrap schematically illustrating the internal heating element; 
         FIG. 13  is a perspective view of the heated belt wrap with an outer side removed to schematically illustrate the internal temperature-retaining component; 
         FIG. 14  is a front perspective view of a heated neck and shoulder wrap according to an embodiment; 
         FIG. 15  is a rear perspective view of the heated neck and shoulder wrap; 
         FIG. 16  is a front view of an inner side of the heated neck and shoulder wrap schematically illustrating the internal heating element; 
         FIG. 17  is a perspective view of the outer side of the heated neck and shoulder wrap schematically illustrating the internal temperature-retaining component; 
         FIG. 18  is a rear perspective view illustrating a heated neck and shoulder wrap according to another embodiment; 
         FIG. 19  is a rear perspective view of the outer side of the heated neck and shoulder wrap of  FIG. 18  schematically illustrating the internal temperature-retaining component; 
         FIG. 20  is a front view of an outer side of a heated eye wrap according to an embodiment; 
         FIG. 21  is a front view of an inner side of the heated eye wrap of  FIG. 20 ; 
         FIG. 22  is a rear perspective view of the heated eye wrap; 
         FIG. 23  is a cut away view of the connector of the heated eye wrap; 
         FIG. 24  is a rear view of the heated eye wrap schematically illustrating the internal heating element; 
         FIG. 25  is a rear view of the heated eye wrap illustrating the internal temperature-retaining component; 
         FIG. 26  is a schematic, cross-sectional illustration of the internal heating element and the internal temperature-retaining component in the heated eye wrap and its positioning with respect to a user&#39;s face; and 
         FIG. 27  is a controller for the heated eye wrap according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. 
     With reference first to  FIGS. 1-6 , a heating pad  10  with a temperature-retaining component is illustrated. In one or more embodiments, the heating pad  10  may be substantially rectangular and have dimensions, for example, of approximately 12 inches by 15 inches ( FIG. 1 ), or approximately 12 inches by 24 inches ( FIG. 2 ), or any other suitable size. Of course, other shapes and sizes are also fully contemplated, as described further below. 
       FIG. 3  is a top view of the heating pad  10  of  FIG. 1  schematically illustrating the internal electric heating element  12 .  FIGS. 4 and 5  schematically illustrate an internal temperature-retaining component  14  affixed within the heating pad embodiments of  FIG. 1  and  FIG. 2 , respectively, generally adjacent to the heating element  12 . The temperature-retaining component  14  functions to efficiently retain heat generated by the heating element  12  for continued use of the heating pad  10  for a period of time if the heating element  12  is no longer powered. This configuration provides heat therapy while allowing portability of the heating apparatus and user mobility. The temperature-retaining component  14  may alternatively function to maintain colder temperatures if the heating pad  10  is chilled for cold therapy use. 
     As depicted in  FIG. 3 , the heating element  12  may have a sinusoidal or serpentine configuration. The electric heating element  12  may be formed by a thermally conductive wire coated with any heat resistant substance, such as a heat resistant polymer. In one embodiment, the electric heating element  12  includes a heating wire made of a positive temperature coefficient (PTC) material with negative temperature coefficient (NTC) insulation. 
     The temperature-retaining component  14  may include any fluid or solid heat-retaining material, which in one or more embodiments includes a gel material or layer. The gel material may also function as a cold-retaining material. The temperature-retaining component  14  allows heat to be more efficiently retained within the heating pad  10  for continued use of the heating pad  10  after power has been disconnected. In one non-limiting embodiment, the thermal storage capability of the temperature-retaining component  14  allows heat to be delivered for two to three hours after the power is disconnected from the heating pad  10 . The temperature-retaining component  14  also serves to further facilitate and even out the distribution of heat to the user&#39;s body. Still further, the temperature-retaining component  14  provides a cushioning interface for additional comfort to the user of the heating pad  10 . 
     With reference to  FIG. 5 , depending on the dimensions of the heating apparatus, the temperature-retaining component  14  may be divided into a plurality of separate segments  16 . These segments  16  may enhance the flexibility of the temperature-retaining component  14  and facilitate a more uniform distribution of the material (e.g. gel) contained therein within the volume of the heating apparatus, preventing disproportionate pooling in some areas and voids in other areas, especially when under pressure against a user&#39;s body. 
       FIG. 6  is an exploded view of a heating pad  10  according to one or more embodiments. The heating pad  10  has a multi-layered construction and may include a top layer  18  and the temperature-retaining component  14  positioned adjacent to the top layer  18 . The electrical heating element  12  may be positioned adjacent to the temperature-retaining component  14 , followed by a non-woven scrim material layer  20 , a batting material layer  22 , and a bottom layer  24 . In addition, if desired, a cloth outer covering (not shown) may be provided that encloses the entire heating pad  10 . 
     The top layer  18  and the bottom layer  24  may be constructed of any suitable material such as, but not limited to, polyester. In one embodiment, the top layer  18  and bottom layer  24  are constructed from a micromink material and each may have a thickness of approximately 1 mm, although other thicknesses are also contemplated. The top layer  18  and the bottom layer  24  are secured together, such as along their edges, to form an inner cavity for receiving the various internal layers of the heating pad  10 . 
     In one embodiment, the temperature-retaining component  14  is positioned adjacent an inner surface of the top layer  18 . In an alternative embodiment, the temperature-retaining component  14  could form an exterior portion of the heating pad  10 , without the top layer  18 , such that temperature-retaining component  14  would be in direct contact with the user&#39;s body. In one non-limiting example, the temperature-retaining component  14  may be approximately 8 mm thick. The temperature-retaining component  14  may be constructed from spaced sheets of a flexible, liquid-impermeable, plastic material which are secured together to contain the gel material therein. The heating element  12  is substantially uniformly distributed within the heating pad  10  and arranged to effectively and efficiently distribute heat to the temperature-retaining component  14  and the top layer  18  of the heating pad  10 . 
     Padding material is positioned between the electric heating element  12  and the bottom layer  24 , and may include a non-woven scrim material layer  20  and a layer of batting material  22  as shown in  FIG. 6 . The electric heating element  12  may be attached to the scrim material layer  20 , where the scrim material layer  20  may be constructed from polyester with a thickness of approximately 0.1 mm, although this dimension is not intended to be limiting. The batting material layer  22  provides a layer of insulation between the electric heating element  12  and the bottom layer  24  of the heating pad  10 . The batting material layer  22  may be constructed from any suitable insulative material, such as polyester and, in one non-limiting example, may have a thickness of approximately 1.5 mm. In addition to insulation, the padding material provides additional cushioning and comfort for the user. 
     The various layers of the heating pad  10  can be manufactured separately and then assembled. After manufacture, the layers of the heating pad  10  are secured together, such as by sewing their edges together. In an alternative embodiment, the top layer  18  and the bottom layer  24  can be constructed from a continuous sheet which may be folded around the internal layers and then secured to assemble the heating pad  10 . An edging belt  26  may be sewn or otherwise secured around the edge of the assembled heating pad  10 , where the edging belt  26  may be constructed from a polyester material. The multi-layered design of the heating pad  10  provides manufacturing efficiency and flexibility in that the multiple layers of the heating pad  10  can be manufactured at separate times and in separate locations before being assembled into the finished product. 
     Referring to  FIGS. 7 and 8 , a controller  28  is in electrical communication with the electric heating element  12 . The controller  28  includes a printed circuit board  30  and a housing  32  via which the user may select from various settings to regulate the power supplied to (adjust the temperature of) the electric heating element  12  and thus the temperature of the temperature-retaining component  14  and the heat output of the heating pad  10 . In one or more embodiments, the controller  28  includes various user interface features including an LED indicator  34 , such as a 2-hour auto-off indicator. The controller  28  also includes a digital display  36  which may indicate the current heat setting, a power button  38 , and + and − buttons  40  to toggle the heat setting up and down. The electric heating element  12  and the controller  28  are in electrical communication with a power source, such as a power cord  42  which may receive power from a wall outlet. In one embodiment, the power cord  42  may be detachable from the heating pad  10  to allow for greater portability. The heating pad  10  may, alternatively, include a detachable battery pack (not shown). 
     The description provided herein for the heating pad  10  embodiment may also be applicable to other heated devices such as, but not limited to, heated blankets, wraps, throws, cushions, and pillows, as described further below. 
     As a first example,  FIG. 9  illustrates a heated pillow  44  according to an embodiment. As shown, the heated pillow  44  may have a relatively smaller, more rounded appearance than the heating pad  10 , and may also include an increased thickness of the padding material, if desired. The construction and features of the heating pad  10  may be equally applicable to the heated pillow  44 . 
     Turning to  FIGS. 10-13 , a heated belt wrap  46  is illustrated. In addition to the construction and features described above for the heating pad  10 , the heated belt wrap  46  includes an elongated main body  48  with an adjustable strap  50  extending therefrom. The strap  50  can be adjusted in length to fit the size of the user&#39;s desired body treatment area, and in one non-limiting embodiment may be constructed from an elastic material. A releasable closure  52  is disposed on the strap  50  to secure it to the main body  48  at desired position, wherein the releasable closure  52  may comprise a fastener, such as a hook and loop material (e.g. Velcro®). 
     The heating element  12  and the temperature-retaining component  14  may be sized to substantially fill the area of the main body  48 . As with the heating pad  10 , the temperature-retaining component  14  may be adjacent the top layer  18 . In one embodiment, the heated belt wrap  46  may be reversible, such that the top layer  18  may be placed in contact with the user&#39;s body part. This arrangement may be especially beneficial if the temperature-retaining component  14  is chilled and used for cold therapy. As illustrated in  FIG. 13 , optionally a portion of the top layer could be removable to allow for direct contact of the temperature-retaining component  14  with the user&#39;s skin. 
       FIGS. 14-17  illustrate a first embodiment of a heated neck and shoulder wrap  54  having a back portion  56 .  FIGS. 18 and 19  show a heated neck and shoulder wrap  54  according to another embodiment, wherein a larger back portion  56  is utilized and contains a temperature-retaining component  14  with a plurality of segments  16 . In one non-limiting embodiment, the heating element  12  may span substantially an entire area of the neck and shoulder wrap  54 , whereas the temperature-retaining component  14  may be disposed only in the back portion  56 . In one embodiment, the heated neck and shoulder wrap  54  may be reversible, such that the top layer  18  may be placed in contact with the user&#39;s body part. This arrangement may be especially beneficial if the temperature-retaining component  14  is chilled and used for cold therapy. Again, the construction and features of the heating pad  10  may be equally applicable to the heated neck and shoulder wrap  54 . 
     Turning to  FIGS. 20-25 , a heated eye wrap  58  is illustrated according to an embodiment. In addition to the construction and features described above for the heating pad  10 , the heated eye wrap  58  includes a main body  60  with a first strap  62  and a second strap  64  extending therefrom. The main body  60  may have an elongated configuration which generally resembles goggles, with two eye portions  66  sized to cover each of a user&#39;s eyes and an indentation  68  therebetween sized to accommodate a user&#39;s nose. According to one embodiment, at least one of the first strap  62  and the second strap  64  may be constructed from an elastic material (i.e. shown as the first strap  62  in  FIGS. 20-22 ) to provide universal adjustability around a user&#39;s head. The first and second straps  62 ,  64  each have a releasable closure  70  which may comprise a fastener, such as a hook and loop material (e.g. Velcro®). When secured to the user&#39;s head, the first and second straps  62 ,  64  may be sized to be disposed above the top of a user&#39;s ears, preventing uncomfortable chafing and muffling of sound. 
     As shown in  FIGS. 22 and 23 , a power adapter port  72  may be provided on the bottom layer  24  of the main body  60 , and may be covered with fabric (e.g. micromink) for comfort. The port  72  may be configured to removably receive a connector  74  for a power line or a controller  76 , such as shown in  FIG. 27 . The controller  76  may include a translucent power icon  78  which indicates the heat level, and an audible indicator that emits different tones depending on heat level, allowing for blindfolded use. 
     As shown in  FIGS. 24 and 25 , the heating element  12  and the temperature-retaining component  14  may be sized to substantially fill the area of the main body  60 . Although not shown, it is understood that the temperature-retaining component  14  could be configured with a plurality of segments  16 , such as one segment  16  in each eye portion  66  of the main body  60 . With reference to  FIG. 26 , the heated eye wrap  58  may have a configuration where the temperature-retaining component  14  is adjacent the inner or bottom layer  24 , closer to the user&#39;s eyes and face compared with the heating element  12 . In operation, the heating element  12  heats up the temperature-retaining component  14 , providing uniform, diffused soothing heat to the eye region of the user which can be retained for extended periods of time. When the eye wrap  58  is chilled prior to use, the temperature-retaining component functions to cool the bottom layer  24  against the user&#39;s skin. Alternatively, the temperature-retaining component  14  may be adjacent the outer or top layer  18 , and the eye wrap  58  could also be reversible. 
     While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.