Abstract:
The present inventive concept relates to electrically-powered, thermally-regulated apparel or heated garments and a controller and related methods of operation thereof. The thermally-regulated apparel item can include one or more heating elements that can be mounted at spaced locations about the body of the apparel item, such as being received in pockets, or by being attached to the body by releasable fasteners. The heating elements also can be connected together is series to form a combined or composite heating element assembly for the apparel item having a user selected or defined configuration and coverage along the body of the apparel item.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure generally relates to thermally regulated and/or heated apparel and/or hand held heated devices, and in particular to A system and method for configuring and mounting one or more heating elements at desired locations about an item of apparel or other heated device with the heating elements being linked in a replaceable/reconfigurable arrangement or array adapted to fit desired user or wearer preferences. 
       BACKGROUND OF THE INVENTION 
       [0002]    Heated clothing, such as jackets, pants, boots, gloves, socks, and other apparel items have been developed in recent years to provide supplemental heating or warmth for provide protection against harsh weather conditions such as extreme cold. In particular, heated clothing having electrically powered heating pads has been developed, such as disclosed in U.S. Patent Application Publication No. 2008/0223844. Such heated garments include electrically powered heating elements formed or sewn onto a pad that can be integrated into a garment or inserted into pockets thereof, and which further are connected to an electrical power source such as a battery pack for heating the garment. 
         [0003]    One problem that has been found to exist with many conventional heated garments has been that the heating elements in many cases have been integrated or sewn directly into the clothing. Thus, wearers or users of such heated garments generally cannot easily or readily configure their garments according to their particular preferences as to where they want additional warmth to be applied as well as how much additional heat or warmth is to be applied. In addition, manufacturing heated garments to allow for a substantial variety of different size, type and/or arrangements of heating elements to be used also generally requires additional steps or operations that consequently can increase the cost of such garments, as well as potentially limit production rates. Still further, the use of multiple heating elements or pads within the garment also generally requires additional wire connections to connect each heating element to the power source. Such wires, especially to the extent that thicker, heavier wires are needed to conduct higher levels of power to multiple heating elements in the garment, often can be noticeably seen or felt within the garment, and thus can detract from the look and feel of the garment, as well as the comfort to the wearer. 
         [0004]    Accordingly, it can be seen that a need exists for thermally regulated or heated apparel or other articles, and a system and method of forming such apparel or other articles, which enables replacement and/or reconfiguration of heating elements, and their placement at varying locations, according to user preferences and without adversely affecting the look, fit and/or comfort of the apparel to the wearer, and which addresses the foregoing and other related and unrelated problems in the art. 
       SUMMARY OF THE INVENTION 
       [0005]    Briefly described, the present invention generally is directed to thermally regulated and/or heated apparel items or garments and other heated devices, including a replaceable/configurable heating system, and a method of manufacturing such thermally regulated and/or heated apparel items or garments and other heated devices or articles. The heating system can comprise an array of heating elements or pads removably mounted at varying locations about the body of the heated garment or device in accordance with user or wearer preferences. In one embodiment, the system and method of the present invention enables users to selectively design and configure a heating system for a heated garment or other apparel item, wherein the user can select one or more heating elements or pads of varying sizes, configurations, and/or thermal applications or outputs, to form the heating system for their garment according to their specific user preferences. 
         [0006]    According to one aspect of the present disclosure, the heating elements can be formed as pads, and can be mounted and/or connected or arranged in an array or series at varying selected locations about the body of the garment. Each heating element further generally will be replaceably mounted within/to the garment body to enable removal and reconfiguration of the heating elements as needed in response to changing user/wearer preferences and/or environmental conditions. For example, as a wearer travels to different environments or is exposed to changing temperatures, they can change the configuration of their garment heating system, such as by removing and replacing one or more existing heating elements of the garment with heating elements of other, varying sizes, configurations and/or thermal applications or outputs/intensities. The wearer also can remove and/or add additional heating elements or pads at other locations about the body of the garment to provide greater or lesser coverage throughout the body of the garment as needed or desired. 
         [0007]    In one embodiment, the body of the garment can be formed with a series of pockets. The pockets can be formed at various locations about the garment, and in varying sizes as needed. In some embodiments, a series of pockets can be provided in adjacent or closely spaced alignments, to enable a desired spacing and/or positioning of the heating elements with respect to one another. The pockets also can be sized and/or configured to receive heating elements, such as heating pads, of a selected size and/or configuration; or alternatively, can be configured/provided with partitions, connectors, or other features that enable the sectioning of the pockets to form different size enclosures therein, and/or for securing the heating elements in desired orientations or alignments within the pockets. 
         [0008]    In additional embodiments, the garment body can be provided with a liner that can be removable or which can be opened, such as via a zipper, snaps, hook and loop fasteners, or other, similar resealable fasteners, to enable the placement of the heating elements between a shell or outer body of the garment and the liner or inner shell thereof, thus further insulating the heating elements from direct contact with the wearer. Still further, in addition to or as an alternative to the use of pockets being, a series of releasable fasteners, such as zippers, hook and loop fasteners, snaps, clips, and/or other, similar releasable fasteners located at a series of spaced locations about the garment body, by which the heating elements, can be releasably mounted about the garment body. Such releasable connectors or fasteners also can be used to connect multiple heating elements together in series, so as to form a composite heating element array or configuration for the heating system of the garment. 
         [0009]    Each of the heating elements generally will include a conductive material, such as conductive micro/nano-wire that can be applied and attached to a substrate, via embroidery or other sewing operations. Each heating element also can include a connector or plug, such as a flat wire connector, adapted to engage and interconnect with a power transmission line or conduit connected to a power source for the garment. The power transmission line can include a single wire or cable with a series of corresponding connectors for linking with the heating elements or can include a series of wires or cables, each associated with one of the heating elements to be connected thereto and with the wires being arranged/combined in a bundle. 
         [0010]    The power transmission line(s) for the garments of the present invention will be arranged so as to extend along and be incorporated into the seams joining each body section of the garment. During formation of the garment, as the various body sections such as the chest portions are connected to the back or rear section, the power transmission lines can be applied and sewn/integrated into the seams connecting such body sections together. As a result, the power transmission lines can be substantially hidden within and aligned with or otherwise follow the seams of the garment. Additionally, different gauge conductive wires can be used for the power transmission lines, with thinner, lighter micro/nano-wire connections provided for and between the heating elements and the power transmission lines, without substantially adversely affecting the appearance or feel of the garment or the range of movement of the wearer. One or more connectors further can be provided for connecting the power transmission lines to a power source, such as one or more replaceable battery packs. 
         [0011]    Various objects, features and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detailed description, when taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a plan view illustrating one embodiment of the replaceable/reconfigurable heating system for garments according to the principles of the present invention. 
           [0013]      FIGS. 2A and 2B  illustrate front and back views of the garment of  FIG. 1 . 
           [0014]      FIGS. 3A and 3B  illustrate a garment incorporating the replaceable/reconfigurable heating element system according to the principles of the present invention, illustrating the formation of pockets at different areas or sections of the garment body. 
           [0015]      FIG. 4  illustrates example configuration of heating elements for use in the replaceable/reconfigurable heating element system as illustrated in  FIGS. 1-3B . 
           [0016]      FIGS. 5A-5C  illustrate embodiments of the replaceable/reconfigurable heating element system, as generally shown in  FIGS. 1-4 , showing the heating elements formed as pads mountable within pockets of a garment and connectable together in series. 
           [0017]      FIG. 6  illustrates an embodiment of a snap connector system for the heating elements as generally illustrated in  FIGS. 1 and 5B-5C . 
           [0018]      FIG. 7  illustrates an embodiment of a hook and loop fastener type connection system for the heating elements as generally illustrated in  FIGS. 1-4 and 5B-5C . 
           [0019]      FIG. 8  illustrates an embodiment of a zipper type connection system for the heating elements as generally illustrated in  FIGS. 1-4 and 5B-5C . 
       
    
    
       [0020]    Those skilled in the art will appreciate and understand that, according to common practice, the various features of the drawings discussed below are not necessarily drawn to scale, and that the dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention as described herein. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    Referring now to the drawings in which like numerals indicate like parts throughout the several views,  FIGS. 1-8  illustrate various example embodiments of a thermally regulated or heated garment including a replaceable/configurable heating system for such garments or other, similar items of apparel and/or heated devices. In one example embodiment,  FIGS. 1-4  illustrate a thermally regulated or heated garment  10  having a replaceable/configurable heating system  11  according to the principles of the present invention, wherein the garment  10  can be provided with a series of heating elements  12 , here shown as pads  13 , that can be replaceably mounted or attached about the body  14  of the garment in varying configurations, arrangements or arrays and which can enable the selection and use of heating elements  12  of varying sizes, shapes and/or thermal outputs, with the location and selection of the heating elements about the garment being in accordance with user or wearer preferences. Thus, the replaceable/configurable heating system  11  enables the user or wearer to substantially customize their heated garments or other apparel items or heated devices, including the selection, placement and removal and/or replacement of heating elements so as to create heating element arrays or composite heating assemblies for their garment as needed to match personal preferences and/or changing environmental conditions. 
         [0022]    In one example embodiment, the thermally regulated garment  10  is shown in  FIGS. 1-3B  as a jacket  15 , the body  14  of which can generally include a back or rear portion  16 , first and second or right and left side chest/front portions  17 A/ 17 B attached to the back portion, a waist portion or area  18 , a collar  19  circumscribed about a neck opening  21 , and sleeves  22 A/ 22 B. It further will be understood by those skilled in the art that the thermally regulated garment  10  alternatively could include a variety of different types of garments or items of apparel, including vests, shirts, pants, socks, hats, gloves or other, similar items, and still further that the replaceable/configurable heating system  11  also can be applied to other heated devices, such as vehicle seats, hand warmers, blankets, cushions and/or other, similar devices. 
         [0023]    Each body section  16 - 22 B generally will be sewn or otherwise attached to adjacent body sections by seams  23 . Still further, those with skill in the art also will understand that the chest portions  17 A/B of the jacket  15 , or other similar garment, can generally be releasably connectable by a closure along the side edges  23 A thereof, such as a zipper  24 , as shown in  FIGS. 2A and 2B , (snaps, clips, or other closures also can be used), and also could include removable sleeves  22 A/ 22 B for conversion of the jacket to a vest. In addition, the body  14  of the thermally regulated or heated garment  10  can be formed with multiple layers or plies, including an inner liner  26 A ( FIG. 1 ) and an outer shell  26 B ( FIGS. 2A-3B ). In one example embodiment, the inner liner can be made of a material having a softer or cushioned feel, while the outer layer can include a weather-resistant or more durable material, such as used for ski jackets, motorcycle jackets, or other, similar thermally insulated clothing. 
         [0024]    As  FIGS. 1-3B  illustrate, the body sections of the garment  10  will be provided with a series of heating elements  12  that can be arranged at spaced locations thereabout. In one example embodiment, each of the heating elements  12  can comprise a pad  13  or similar device including a substrate or carrier  30  to which an electrically conductive material will be applied. The electrically conductive material generally can comprise a thin, flexible metal micro-wire or nano-wire, or filaments of a known conductive material, or can include various conductive threads or filaments, yarns made from, for example, nylon, polyester, cotton or blends thereof, and which have been impregnated or bonded with electrically conductive materials such as silver, copper, annealed copper, gold, aluminum, rhodium, tungsten, zinc, cobalt, cadmium, nickel, lithium, iron, platinum, palladium, or other known conductive or semi-conductive materials. 
         [0025]    The conductive micro/nano-wires, yarns or threads  31  generally will be applied to the carrier, typically being embroidered, stitched or otherwise bonded thereto, in a desired pattern  32 , which can include a series of crisscrossing or intersecting wire segments so as to form a resistive heating element as indicated in  FIGS. 1-4 , and with the ends of the wires terminating at a flat, micro/nano-wire connections  33  ( FIG. 4 ), e.g., formed as flat wire connections, which further can connect to leads  34 , as indicated in  FIGS. 5A-5C . The conductive wire, yarn or thread materials  31  of the heating elements further can be selected and arranged in a heating pattern  32  based upon a predetermined resistance per unit length thereof to provide a desired level of thermal of heat output based upon a selected voltage and/or current draw. The heating pads  13  further can be formed in varying sizes and/or configurations, including substantially square or rectangular, as illustrated in  FIGS. 1-4 , although it will be understood by those skilled in the art that other, varying configurations or designs also can be used. For example, as indicated in  FIG. 2B , a single large heating pad  13  having an expanded shape or configuration substantially matching its corresponding garment body section can be applied, i.e., across the back portion thereof, or multiple pads can be used. 
         [0026]    As further illustrated in  FIGS. 1-5A , the replaceable heating elements  12  can be selectively mounted about the body of the heated garment, the mounting of the heating elements being substantially in accordance with user preferences or desires as to the areas of coverage and amount of coverage of the heating elements being applied through their garment. In one embodiment, the heating elements  12  can be replaceably mounted within a series of pockets  40  that pockets  40  can be formed along and/or in the body sections  16 - 22 B ( FIG. 1 ) of the garment  10 . By way of example, as indicated in  FIGS. 1, 2A and 3A-4 , the series of pockets  40  can be formed in and/or along one or more of the body sections, typically at spaced locations to provide expanded or wider areas of coverage. The pockets typically can be formed within and/or along the inner portion or along the inner liner of the heated garment  10 , although it further will be possible to provide exteriorly located or accessible pockets along an outer portion or shell of the garment as well. 
         [0027]    As a further alternative, for garments having an inner liner  26 A ( FIG. 1 ), the inner liner can be releaseably attached, along at least a portion thereof, to an outer shell  26 B ( FIGS. 2-3B ) of the garment so as to enable separation and access to the area between the inner liner and outer shell of the garment, in which the pockets  40  can be formed. The inner surface of the outer shell could be provided with pockets, while the outer surface of the inner liner likewise could be provided with pockets, or one or both of the inner and outer liners can be provided with a series of spaced pockets or similar receptacles. As still another alternative, the pockets  40  can be separately formed and can be releasably attached or mounted to the body sections of the garment by releasable fasteners, such as zippers, snaps, clips, hook and loop fasteners, or other, similar connectors. 
         [0028]    As further illustrated in  FIGS. 4-5A , a heating element  12 , such as a pad  13 , can be inserted through an inlet opening  41  formed along each pocket  40 , with the wire connections  33 , or connecting leads  34  ( FIG. 5A ) thereof of each heating element/heating pad being received and fed through a smaller connector opening  42  formed along the body of the pocket. For example, as shown in  FIG. 5A , the pockets  40  can include a slit or smaller opening  42  formed along one side thereof, such as adjacent a bottom or lower portion of the pocket, through which the flat wire connections  33  of the heating element  12  is received and passed. Alternatively, as indicated in, for example,  FIG. 4 , the pockets can be provided with passages  43  through which wire connections  33 , or connecting leads  34  ( FIGS. 5A-5C ) thereof, of the heating elements  12  can be fed/guided for connection to power transmission lines  45  of the heated garment. 
         [0029]    In one embodiment, the pockets  40  in which the heating elements/pads are received generally can be sized and/or configured to substantially match or fit a heating element or pad of a prescribed size and/or configuration (as shown in  FIG. 4 ) so as to provide a substantially secure mounting of the heating elements or heating pads therein to avoid bunching, shifting or other undesired movements of the heating elements or pads. It will be understood, however, that the pockets  40  also can be formed in other sizes or configurations, including sizes and/or configurations larger and/or different than the pads received therein. For example, as shown in  FIG. 2B , pockets  40 ′ can be formed with a size that is larger than a typical heating element or heating pad to be received therein, such as being formed of a size sufficient to accommodate a largest size heating pad to be received therein, but alternatively also can receive multiple heating elements or heating pads therein. In such an embodiment, as illustrated in  FIG. 2B , a series of heating elements  12  can be mounted within the pocket  40 ′. These heating elements further can be connected together (such as shown in  FIGS. 5B-5C ) to define a composite pad or an array of individual heating elements or heating pads placed and secured at desired locations within a pocket using fasteners such as hook and loop fasteners, snaps, zippers, clips, releasable adhesive materials or other connections. Still further, the pockets themselves also can be provided with partitions, and/or closure elements, as indicated by phantom lines  44  in  FIG. 2B , including various releasable fasteners, such as snaps, clips, hook and look fasteners, zippers, tacky/releasable adhesive strips, etc., to enable the expansion or reduction of the size of the pocket as needed to fit desired size heating elements or pads received therein. 
         [0030]    As illustrated in  FIGS. 1, 2A and 4 , each of the heating elements  12  will be coupled via their wire connections  33 , such as flat micro/nano-wire connectors, to a power transmission line  45  that generally will be connectable to a power source such as a replaceable battery pack or other power source via a plug-in connector  46  ( FIG. 4 ). The power transmission lines will be arranged along the seams  23  formed between the body sections of the garment  10  and/or along the side edges thereof, such as extending along or adjacent the edges  23 A of the chest sections of the garment along which zipper  24  or similar closure is attached, as illustrated in  FIG. 1 . For example, during manufacture/formation of the garment, as the body sections are assembled, the power transmission lines  45  can be applied in registration with the mating side edges of the body sections as the body sections are attached together so as to be integrated into the seams  23  formed as the body sections are sewn, or otherwise attached together, the power transmission lines thus being secured to and substantially hidden within the garments. 
         [0031]    The power transmission lines  45  can include one or more conductive wires or filaments, and can be of a heavier or thicker gauge material sufficient to carry and distribute power to each of the heating elements  12  connected thereto, substantially equally. The wire connections  33 , and/or the connecting leads thereof, for each of the heating elements can connect to associated ones of the power transmission lines  45  via clamping, pin or plug-in type connections  47  ( FIG. 4 ), or similar releasable couplings/connectors. In another alternative embodiment, a series of power transmission lines  45  can be provided, each connectable to an associated or corresponding one of the heating elements or a series of heating elements connected together, and with the power transmission lines being arranged in a bundle extending along the seams between the interconnected body sections of the garment. 
         [0032]      FIGS. 5B and 5C  illustrate alternative example embodiments of the connection of one or more of the heating elements  12  can be connected to a single power transmission line  45 . As indicated in  FIG. 5B , in one embodiment, the wire connectors  33  of each of the heating elements  12  can be connected to a splitter  48  that can be connected or integrated with a single power transmission line. As illustrated in  FIG. 5C , a series of heating elements also can be connected together via wire connections  33 ′, with one of the heating elements having a wire connection or a connecting lead  34  that connects directly to the power transmission line  45 , with the power thus being provided through each of the heating elements in series. 
         [0033]    As further illustrated in  FIG. 4 , the garment body sections also can be provided with a series of inner channels  49  along the seams  23 /side edges  23 A ( FIG. 1 ) of the garment  10  to enable insertion and/or replacement of the power transmission lines  45  and for helping to hide the interconnections between the power transmission lines and the wire connectors of the heating elements. As an example, as shown in  FIG. 4 , a heating element  12 ′ can be provided within or as a part of a collar  19  of the heated garment  10 , with the collar further including an inner channel adjacent the seam between the collar and a chest portion of the garment. Additional channels can be formed along the sides of the body portions as needed. 
         [0034]    By extending the power transmission lines along or adjacent the seams formed between the interconnected body sections of the garment, the power transmission lines can be substantially effectively hidden therein. Thus, the power transmission lines can be located in areas of the garments where they will be far less noticeable both from an appearance or look, as well as being felt by the wearer, and which placement further can help minimize possible restrictions on movement of the wearer due to such power transmission lines being run through the garments. In addition, the heating elements can be formed in smaller or thinner sizes with multiple heating elements being connectable to the power transmission lines such as through the use of splitters or other, similar connections as illustrated in  FIGS. 5B and 5C . This can further enable reductions in weight and increased flexibility, coupled with the ability to configure the garment as needed, including the expansion, configuration and replacement/reconfiguration of heating elements within the garment in order to suit a wearer/user&#39;s desired preferences and/or needs based on their particular desires or preferences, changes in environmental conditions, etc. 
         [0035]      FIGS. 6-8  illustrate further, additional embodiments for connection of the heating elements to the body sections of the heated or thermally regulated garment and/or to each other. For example,  FIG. 6  illustrates the use of snap type connectors or clips by which the heating elements, here shown as elongated heating pads  13 , can be connected to the garment body by engagement of a series of spaced snap connectors  51  with corresponding snap or clip connectors applied to the body sections. In another alternative embodiment,  FIG. 7  illustrates the use of hook and loop type fasteners  52  including a series of strips or pads  53  with hooks or loops formed thereon which are configured to engage and attach to corresponding hook and loop fasteners applied to the garment body, or alternatively, which can engage and mount the pads directly to the material of the garment body.  FIG. 8  further illustrates a zipper connection system  54  by which the pads can be releasably mounted within the garment by zipper connection.  FIG. 8  also shows the interconnection of a pair of pads together via such a zipper connection, and it will be understood by those skilled in the art that other connections such as hook and loop fasteners, adhesives, snaps, clips or other releasable connectors can be used to attach the heating elements together in a connected series or array as needed or desired. 
         [0036]    The foregoing description generally illustrates and describes various embodiments of the present invention. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present invention without departing from the spirit and scope of the invention as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of the present invention. Accordingly, various features and characteristics of the present invention as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the invention, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present invention as set forth in the appended claims.