Patent Description:
Conventional resistance heaters used in vehicles include protection circuits and devices to prevent overheating and failures. Many resistance heaters are preformed, stand-alone heaters made from materials and processes that render the heaters less conducive to post-manufacturing integration into components for vehicles. For example, some conventional heaters are made from inflexible and heat intolerant materials.

Conventional composite panels, particularly those with non-planar shapes, do not include integrated heaters. Moreover, conventional resistance heaters are expensive and not conducive to integrating into or co-forming with composite or multi-ply panels. Furthermore, some temperature regulation and protection systems associated with conventional resistance heaters add too much to the weight, complexity, and cost of the heaters.

<CIT>, according to its abstract, states a capacitive sensor electrode for controlling activation and deactivation of a PTC conductive ink heater that can be deposited as part of the same layer of conductive ink used to form the open heater circuit pattern for the heater. A layer of conductive ink is deposited on an insulating substrate, with a first portion of the layer forming an open heater circuit pattern and a second portion of the layer forming a capacitive sensor electrode spaced from and electrically isolated from the first portion of the layer. A layer of positive temperature coefficient (PTC) conductive ink is deposited so as to bridge gaps between in the open heater circuit pattern while leaving the capacitive sensor electrode spaced from and electrically isolated from the layer of PTC conductive ink on the first portion of the layer of conductive ink.

<CIT> further states in par. [<NUM>] and [<NUM>] that the control circuit includes a capacitive switch incorporating the capacitive sensor electrode, and is adapted to selectively control the flow of electrical current through the first portion of the layer of conductive ink and the layer of PTC conductive ink in response to the capacitive switch. When current flows through the first portion of the layer of conductive ink and the layer of PTC conductive ink, the layer of PTC conductive ink provides resistance to the current flow and increases in temperature. Electrical power is preferably supplied to the control circuit via an electrical cord connected to an electrical outlet via a suitable step-down transformer plug, for example a 120V AC to 12V DC transformer plug. The control circuit is configured so that when an object, such as a user's hand, is moved above the capacitive sensor electrode so as to trigger the capacitive switch, electrical current is allowed to flow through the first portion of the layer of conductive ink and the layer of PTC conductive ink to heat the layer of PTC conductive ink. The control circuit may include a timer and will continue to permit electrical current to flow through the first portion of the layer of conductive ink and the layer of PTC conductive ink for a predetermined period of time after movement is detected. The timer is reset each time movement is detected so that electrical current will continue to flow through and heat the layer of PTC conductive ink as long as there is sufficiently frequent movement. If the predetermined time elapses with no movement being detected, the control circuit would then inhibit flow of electrical current through the first portion of the layer of conductive ink and the layer of PTC conductive ink, effectively turning off the heater. Also preferably, the control circuit is configured so that when it first receives power (e.g., when the plug is plugged into a wall socket), electrical current is immediately permitted to flow through the first portion of the layer of conductive ink and the layer of PTC conductive ink and the timer started, rather than waiting for movement to be detected.

<CIT> further states in par. [<NUM>] that an exemplary method s provided for making a heatable surface for a heater. A layer of conductive ink is deposited on an insulating substrate. The substrate may be, for example, a plastic sheet. A first portion of the layer of conductive ink is arranged to form an open heater circuit pattern comprising a plurality of heater conductive paths separated from one another by gaps therebetween, and a second portion of the layer of conductive ink is arranged to form a capacitive sensor electrode spaced from and electrically isolated from the first portion of the layer of conductive ink by a peripheral isolation region surrounding the capacitive sensor electrode. The first portion of the layer of conductive ink and the second portion of the layer of conductive ink are electrically isolated from one another. Preferably, the layer of conductive ink deposited includes a third portion arranged to form control circuit conductive paths for a control circuit, with the third portion of the layer of conductive ink being electrically coupled to the first portion of the layer of conductive ink and to the second portion of the layer of conductive ink so as to maintain electrical isolation therebetween. In particular, because the electrical components of the control circuit have not been attached, the control circuit conductive paths formed by the third portion of the layer of conductive ink do not form a complete circuit.

<CIT> further states in pars. [<NUM>] and [<NUM>] that the layer of conductive ink deposited may include a third portion arranged to form control circuit conductive paths for a control circuit, electrical components are electrically coupled to the third portion of the layer of conductive ink to form a control circuit. The control circuit includes a capacitive switch incorporating the capacitive sensor electrode and is adapted to selectively control flow of electrical current through the first portion of the layer of conductive ink and the layer of PTC conductive ink in response to the capacitive switch. With the control circuit complete, the first portion of the layer of conductive ink and the second portion of the layer of conductive ink are in electrical communication with one another only through the control circuit. After electrically coupling the electrical components to the third portion of the layer of conductive ink, the third portion of the layer of conductive ink may be sealed.

<CIT> further states in pars. [<NUM>] and [<NUM>] that at least one sealing layer is disposed over the layer of conductive ink, other than the third portion thereof, and the layer of PTC conductive ink, so that the layer of conductive ink, other than the third portion thereof, and the layer of PTC conductive ink are disposed between the substrate and the sealing layer(s). The sealing layer(s) may comprise one or more coatings of sealant over the substrate, the layer of conductive ink other than the third portion thereof, and the layer of PTC conductive ink, or may comprise a sheet adhered over the substrate, the layer of conductive ink other than the third portion thereof, and the layer of PTC conductive ink. The sealing layer does not cover the third portion of the layer of conductive ink, so as to facilitate connection of the electronic components making up the control circuit to the control circuit conductive paths. Equivalently, the sealing layer may cover part of the third portion of the layer of conductive ink, but be omitted from the component connection regions; i.e. the parts of the control circuit conductive paths where circuit components are to be connected. Also equivalently, the sealing layer, or a separate sealing layer, may be applied to the third portion of the layer of conductive ink after the electronic components have been connected to the control circuit conductive paths.

The subject matter of the presently claimed subject-matter relates to a cured composite panel with an integrated heater system, the system itself, and an associated method for manufacturing, that overcome the above-discussed shortcomings of prior art techniques. The subject matter of the presently claimed subject-matter has been developed in response to the present state of the art, and in particular, in response to shortcomings of conventional composite panels for vehicles and conventional resistance heaters.

According to the presently claimed subject-matter, a composite panel includes a first layer made from an electrically non-conductive material. The composite panel also includes a resistance heater printed onto the first layer and a capacitive sensor applied onto the first layer. The capacitive sensor is operably coupled with the resistance heater. The composite panel additionally includes a second layer adjacent the resistance heater and the capacitive sensor. The resistance heater and the capacitive sensor are positioned between the first layer and the second layer. Furthermore, the second layer is made from an electrically non-conductive material. The resistance heater is configured to generate heat at least partially in response to input sensed by the capacitive sensor.

The resistance heater can include a first ink layer printed onto the first layer and a second ink layer printed onto the first ink layer. The first ink layer is made from a first ink and the second ink layer is made from a second ink different than the first ink. The first ink can be an electrically conductive ink and the second ink can be a switching-type positive temperature coefficient ink.

The first layer, resistance heater, capacitive sensor, and second layer can together form a sandwich panel. The sandwich panel can have a non-planar shape.

The first layer, resistance heater, capacitive sensor, and second layer can be flexible.

The composite panel can further include a heater control module applied onto the first layer. The heater control module is preferably configured to vary a voltage to the resistance heater at least partially in response to the input sensed by the capacitive sensor. The second layer is adjacent the heater control module, which is positioned between the first layer and the second layer.

The presently claimed subject-matter also relates to a system including a composite panel, preferably the composite panel referred to above. The composite panel includes a first layer made from an electrically non-conductive material, a resistance heater printed onto the first layer, and a heater control module applied onto the first layer. The heater control module is operable to vary a voltage to the resistance heater. The composite panel further includes a second layer adjacent the resistance heater and the heater control module. The resistance heater and the heater control module are positioned between the first layer and the second layer, which is made from an electrically non-conductive material. The resistance heater is configured to generate heat in response to the voltage. The system additionally includes a system control module that is external to the composite panel and operatively coupled with the heater control module to at least partially control operation of the heater control module.

The system control module is preferably wirelessly coupled with the heater control module.

The system can also include a passenger input receiver. The heater control module may be operable to vary the voltage to the resistance heater at least partially in response to input provided by a passenger via the passenger input receiver. The passenger input receiver can include a capacitive sensor applied onto the first layer and communicatively coupled with the heater control module to communicate the input provided by the passenger via the capacitive sensor to the heater control module. The capacitive sensor is positioned between the first layer and the second layer of the composite panel.

The passenger input receiver can alternatively, or additionally, include a passenger mobile device communicatively coupled with the system control module to communicate input provided by the passenger via the passenger mobile device to the heater control module. The system control module can be configured to determine whether a temperature condition threshold has been reached and prevent the heater control module from varying the voltage to the resistance heater in response to input provided by the passenger via the passenger input receiver when the system control module determines the temperature condition threshold has been reached.

The heater control module is preferably configured to monitor a health condition of the resistance heater and communicate the health condition to the system control module.

The presently claimed subject-matter also relates to a method of making a composite panel, preferably the hereto before referred to composite panel, which method includes providing a first electrically non-conductive layer. The method also includes applying a heater control module onto the first electrically non-conductive layer, applying a capacitive sensor onto the first electrically non-conductive layer, printing a resistance heater onto the first electrically non-conductive layer, and applying a second electrically non-conductive layer onto the heater control module, capacitive sensor, and resistance heater to form the composite panel.

Printing the resistance heater onto the first electrically non-conductive layer can include printing an electrically conductive layer onto the first electrically non-conductive layer using a conductive ink, and printing a heater layer onto the electrically conductive layer using a switching-type positive temperature coefficient ink. Applying the capacitive sensor onto the first electrically non-conductive layer can include printing the capacitive sensor onto the first electrically non-conductive layer. Printing the capacitive sensor and the resistance heater onto the first electrically non-conductive layer can include at least one of screen printing, inkjet printing, rotary screen printing, gravure printing, and atomized jetted depositing the capacitive sensor and the resistance heater onto the first electrically non-conductive layer.

Applying the heater control module onto the first electrically non-conductive layer can include printing the heater control module onto the first electrically non-conductive layer.

The method can also include shaping the composite panel into a non-planar shape. The method can further include at least one of hardening and curing the composite panel in the non-planar shape.

The features and advantages of the presently claimed subject-matter will become more fully apparent from the following description and appended claims.

The presently claimed subject-matter will be described and explained with additional specificity and detail through the use of the drawings, in which:.

As shown in <FIG>, a temperature control system <NUM> of a structure, such as a mobile structure (e.g., a vehicle) or a non-mobile structure (e.g., building), includes a system control module <NUM> and an integrated heater system <NUM> operably coupled with the system control module <NUM>. The integrated heater system <NUM> is integrated (e.g., embedded) into a composite (e.g., multi-layer or multi-ply) panel of the structure. The integrated heater system <NUM> includes a heater <NUM>, a capacitive sensor <NUM>, and a heater control module <NUM>. The heater control module <NUM> includes hardware (e.g., circuits, relays, switches, digital I/O connectors, and the like) and logic that controls operation of the heater control module. The heater control module <NUM> can be a thin-film flexible microchip, including, for example, a plurality of transistors printed onto a flexible substrate. Generally, the heater control module <NUM> supplies electrical power to the heater <NUM>, which can be a resistance heater that converts the electrical power into heat. The heat generated by the heater <NUM> can vary in response to the voltage of the electrical power supplied from the heater control module <NUM>. Accordingly, a power module <NUM> of the heater control module <NUM> is configured to regulate (e.g., vary or modulate) the heat generated by the heater <NUM> by regulating the voltage of the electrical power supplied to the heater <NUM>. The operations of the power module <NUM>, and other operations of the heater control module <NUM>, can be commanded via digital signals, such as pulse width modulation signals.

The power module <NUM> of the heater control module <NUM> regulates the voltage of the electrical power supplied to the heater <NUM> at least partially in response to input provided by a passenger input receiver. The passenger input receiver can be
one or more of the capacitive sensor <NUM> of the integrated heater system <NUM> or a passenger mobile device <NUM> (or other device external to the integrated heater system <NUM>).

The capacitive sensor <NUM> can be any of various capacitive sensors or touch sensors configured to take the capacitance of the human body as input to the sensor. Generally, a capacitive sensor includes a grid or pattern of electrodes that detect changes in capacitance of the electrodes when a portion of a human body touches or is in close proximity to the electrodes.

The passenger mobile device <NUM> can be any of various mobile computing devices, such as mobile phones, laptops, tablets, watches, and the like. Passenger input received by the passenger mobile device <NUM>, such as via an application running on the passenger mobile device, is communicated to the heater control module <NUM> via a passenger control module <NUM> of the system control module <NUM>. More specifically, the passenger mobile device <NUM> may communicate passenger input, such as via a wired or wireless connection, to the passenger control module <NUM> of the system control module <NUM>, which in turn communicates the passenger input, such as via a wired or wireless connection, to the communications module <NUM> of the heater control module <NUM>. The passenger mobile device <NUM> can be configured to sync with the passenger control module <NUM> and associate the seat in which a passenger using the passenger mobile device <NUM> is assigned with the heaters <NUM> in the area of the assigned seat. In this manner, a passenger can automatically control the temperature proximate his seat by linking his mobile device with his seat.

The communications module <NUM> can include hardware, such as antenna, transceivers, network interface controllers, and the like, for facilitating the receipt and transmission of electronic data communications. The system control module <NUM> may also be configured to supply electrical power to the power module <NUM> of the heater control module <NUM>.

The system control module <NUM> may also include an override module <NUM> configured to override the control of the heater <NUM> by the passenger input receiver or disables control of the heater <NUM> by passengers. More specifically, under certain circumstances, the override module <NUM> is configured to prevent the passenger input receiver from controlling the heater <NUM> by preventing the heater control module <NUM> from varying the voltage to the heater <NUM> in response to the passenger input received from the passenger input receiver. The override module <NUM> can monitor one or more temperature conditions of the structure and overrides the control of the heater <NUM> by the passenger input receiver when one or more of the temperature conditions meets a threshold. For example, the override module <NUM> can monitor an ambient temperature of an interior of the structure and, if the ambient temperature exceeds a maximum allowable temperature of the interior of the structure, the override module <NUM> overrides the control of the heater <NUM> by the passenger input receiver. The override module <NUM> can monitor the difference between the ambient temperature of an interior of the structure and a temperature of the composite panel and, if the difference exceeds a maximum allowable temperature difference, the override module <NUM> overrides the control of the heater <NUM> by the passenger input receiver.

The heater control module <NUM> can further include a health module <NUM> that monitors one or more health conditions of the integrated heater system <NUM>, including the heater <NUM>, and communicates the monitored health condition(s) to the system control module <NUM> via the communications module <NUM>. The health module <NUM> may continuously communicate health conditions to the system control module <NUM>. Alternatively, the health module <NUM> may communicate health conditions to the system control module <NUM> only when the health conditions meet a threshold. In response to the monitored health conditions, such as when a health condition meets a threshold, the system control module <NUM> may permanently or temporarily disable operation of the integrated heater system <NUM>. The health condition(s) monitored by the health module <NUM> may be any of various conditions related to the performance, function, and/or safety of the heater <NUM>. For example, the health condition can be a temperature of the heater <NUM> and the threshold can be a maximum allowable temperature of the heater <NUM>. The health condition can be a capacitance reading from the capacitive sensor <NUM> and the threshold can be a maximum normal operating capacitance of the capacitive sensor <NUM>. Monitored health conditions may or may not be communicated to the system control module <NUM> and the heater control module <NUM> is operable to disable operation of the integrated heater system <NUM> when a health condition meets a threshold.

The system control module <NUM> can form part of an electronic control unit (ECU) of a vehicle. Moreover, the system control module <NUM> is positioned in a part of the vehicle (e.g., flight deck of an aircraft) remote from or distanced from the part of the vehicle in which the integrated heater system <NUM> is located (e.g., a passenger compartment of the aircraft).

Although the temperature control system <NUM> is shown to include a system control module <NUM>, in some embodiments, the temperature control system <NUM> does not include a system control module <NUM> and utilizes only the integrated heater system <NUM> to control temperature.

Referring to <FIG>, and a vehicle <NUM> can include a plurality of structures, such as a sidewall <NUM>, floor <NUM>, and seat <NUM>. Each of the structures may include one or more composite panels. As defined herein, a composite panel is a structure with at least two adjacent plies or layers each made from different materials. The adjacent plies are coupled to each other using any of various coupling techniques, such as fastening, bonding, adhesion, welding, and molding. Each layer may include separate sub-layers coupled together in the same or similar manner. The layers, and sub-layers, of a composite panel each has a thickness that is substantially greater than a length and width. Accordingly, the layers of a composite panel can be considered sheet-like. A composite panel can be a sandwich panel with a core layer sandwiched between first and second adjacent layers. One of the adjacent layers may be defined as an external layer and the other may be defined as an internal layer. One or more of the external and internal layers can be a decorative layer or decorative laminate ply.

The sidewall <NUM> of the vehicle <NUM>, which can be an aircraft as depicted, can include a composite panel <NUM>. The composite panel <NUM> includes the integrated heater system <NUM>, which includes the resistance heater <NUM> or heater layer, positioned between first and second layers <NUM>, <NUM>, respectively. The integrated heater system <NUM> can be one ply of a plurality of plies forming a composite stackup or laminate of the composite panel <NUM>. Because the integrated heater system <NUM> is one ply of a plurality of plies of the composite panel <NUM>, and sandwiched between adjacent plies, the heater system is defined as an integrated heater system or a heater system integrated into the composite panel <NUM>.

The first layer <NUM> is depicted as an internal layer facing an interior <NUM> of the vehicle <NUM>, and the second layer <NUM> is depicted as an external layer facing an exterior <NUM> of the vehicle. Moreover, the first layer <NUM> can define an internal façade or decorative laminate ply of the sidewall <NUM>. For example, as shown, the temperature control system <NUM> includes indicia <NUM> on an interior surface <NUM> of the first layer <NUM> over the capacitive sensor <NUM> of the integrated heater system <NUM>. The indicia <NUM> indicating a location on the interior surface <NUM> that a passenger may touch to provide corresponding input to the capacitive sensor <NUM> under the first layer <NUM>. Although in the illustrated example, the indicia <NUM> includes an indicium "-" indicating a reduction in heat and indicium "+" indicating an increase in heat, any of various other indicia corresponding to the configuration and location of the capacitive sensor <NUM> can be used. The first layer <NUM> can include decorative non-planar features. Although the first layer <NUM> is depicted as an internal layer and the second layer <NUM> is depicted as an external layer, the composite panel <NUM> may include one or more additional layers internally of the first layer <NUM> and/or externally of the second layer <NUM>. Coupled to the integrated heater system <NUM> is a set <NUM> of electrical terminals or contacts configured to supply electrical signals, such as power and communication signals, to the integrated heater system <NUM> from an electrical power source <NUM>, which may be controlled by the system control module <NUM> as described above to supply power and communications to the integrated heater system <NUM> and/or receive communications from the integrated heater system <NUM>.

The composite panel <NUM> forms a portion of the sidewall <NUM> including planar and non-planar sections of the sidewall <NUM>. As defined herein, a composite panel <NUM> has a non-planar shape when the broad-faced surfaces of the layers of the panel perpendicular to the thicknesses of the layers are non-planar (e.g., contoured or curved). For example, the composite panel <NUM> is formed into a non-planar or <NUM>-dimenionsal shape defining a contoured or curved portion <NUM> of the sidewall <NUM>.

Similar to the sidewall <NUM>, the floor <NUM> of the vehicle <NUM> may also include a composite panel <NUM>. The composite panel <NUM> of the floor <NUM>, like the composite panel <NUM>, includes a resistance heater <NUM> positioned between first and second layers <NUM>, <NUM>, respectively, and thus integrated into the composite panel <NUM>. The resistance heater <NUM> in the floor <NUM> forms part of the integrated heater system <NUM>. More specifically, the integrated heater system <NUM> can include multiple heaters <NUM> with each one being controlled by a single or multiple heater control modules <NUM> of the integrated heater system <NUM>.

The first layer <NUM> is depicted as an internal layer facing an interior <NUM> of the vehicle <NUM>, and the second layer <NUM> is depicted as an external layer facing an exterior <NUM> of the vehicle. Although the first layer <NUM> is depicted as an internal layer and the second layer <NUM> is depicted as an external layer, the composite panel <NUM> may include one or more additional layers internally of the first layer <NUM> and/or externally of the second layer <NUM>. The first layer <NUM> can define a floor panel on which another layer, such as a carpet layer, is applied. The first layer <NUM> can be a carpet layer with the resistance heater <NUM> being applied (e.g., bonded) directly to the carpet layer. The same set <NUM> of electrical terminals or contacts for supplying electrical power to the resistance heater <NUM> of the composite panel <NUM>, or a different set <NUM> of electrical terminals or contacts, is electrically coupled to the resistance heater <NUM> of the composite panel <NUM>.

As with the sidewall <NUM> and the floor <NUM>, an interior structure, such as the seat <NUM>, may also include a composite panel <NUM>. The composite panel <NUM> of the seat <NUM> includes a resistance heater <NUM> positioned between first and second layers <NUM>, <NUM>, respectively, and thus integrated into the composite panel. The resistance heater <NUM> in the seat <NUM> forms part of the integrated heater system <NUM>. Accordingly, a single heater control module <NUM> can be configured to individually or independently control the operation of multiple heaters <NUM> in different locations of the vehicle <NUM>. Such control can be at least partially responsive to input, provided by a passenger input receiver, corresponding to a particular one or more of the multiple heaters <NUM>. The capacitive sensor <NUM> can be configured to receive separate inputs for separately selecting desired heating characteristics of the multiple heaters <NUM>. The indicia <NUM> may have indicium associated with heating controls of the heater <NUM> in the sidewall <NUM>, indicium associated with heating controls of the heater <NUM> in the floor <NUM>, and indicium associated with heating controls of the heater <NUM> in the floor <NUM>. The passenger mobile device <NUM> may be configured to provide an interface for receiving separate inputs each associated with controlling the heating characteristics of one of the multiple heaters <NUM>.

The first layer <NUM> of the seat <NUM> is depicted as an outward layer of the seat <NUM>, and the second layer <NUM> is depicted as an inward layer of the seat. The composite panel <NUM> may include a third layer <NUM> coupled to the first layer <NUM>. The third layer <NUM> can be considered a second outward layer of the seat <NUM>. The third layer <NUM> may include a cushion and/or surface upon which a user may sit. It is recognized that the composite panel <NUM> of the seat <NUM> may include one or more additional outward layers coupled to and positioned outwardly of the third layer <NUM>. The first layer <NUM> may include a cushion and/or surface upon which a user may sit, and the resistance heater <NUM> may be bonded directly to the cushion and/or surface. Although the second layer <NUM> is depicted as the only inward layer, the composite panel <NUM> may include one or more additional inward layers inwardly of the second layer <NUM>. The same set <NUM> of electrical terminals or contacts for supplying electrical power to one or both of the resistance heaters <NUM> of the composite panels <NUM>, <NUM>, or a different set <NUM> of electrical terminals or contacts, is electrically coupled to the resistance heater <NUM> of the composite panel <NUM>.

Although the vehicle <NUM> is depicted as an aircraft, and the sidewall <NUM>, floor <NUM>, and seat <NUM> of the vehicle are depicted as having a composite panel, it is recognized that the vehicle can be any of various other vehicles or mobile structures, such as automobiles, boats, spacecraft, and the like, and other structures of the vehicle can include a composite panel. Moreover, as mentioned above, the composite panels of the presently claimed subject-matter can be used to form part of non-mobile structures, such as buildings and bridges. Also, although a limited number of layers of the composite panels of the vehicle <NUM> are shown, the composite panels of the vehicle can include any additional number of layers, and the vehicle can include any number of additional features, structures, layers, etc. coupled to the composite panels. Additionally, it is recognized that the size, including the thickness, of the composite panels relative to the size of the vehicle is illustrated for clarity in showing the features of the composite panels and is not drawn to scale.

Referring to <FIG>, a composite panel <NUM> includes a first layer <NUM> and a resistance heater <NUM> printed onto the first layer <NUM> and integrated into the composite panel. The first layer <NUM> or first ply is made from an electrically non-conductive material, such as, for example, fiberglass, plastic, ceramic, silicone, fabric, and the like. The first layer <NUM> can be a thin film with a thickness in the range of between a nanometer and several micrometers. The first layer <NUM> can have a thickness greater than several micrometers. As shown, in a first configuration, the first layer <NUM> has a substantially planar shape. The first layer <NUM> may be substantially rigid or non-flexible such that the first layer <NUM> can remain in the first configuration or is not configurable into a second configuration (see, e.g., <FIG>). However, the first layer <NUM> can be made from a non-rigid flexible material such that it can be flexed or moved into a non-planar shape to configure the first layer <NUM> into a second configuration. For example, as explained below in more detail with reference to <FIG>, the first layer <NUM>, as well as the resistance heater <NUM>, heater control module <NUM>, and capacitive sensor <NUM>, can be flexed from the first configuration into the second configuration using a die system <NUM>, which shapes and cures the composite panel <NUM> in the second configuration.

The resistance heater <NUM> includes a first ink layer <NUM> printed onto the first layer <NUM> and a second ink layer <NUM> printed onto the first ink layer <NUM>. The first and second ink layers <NUM>, <NUM> of the resistance heater <NUM> can have a substantially planar shape. The first ink layer <NUM> is made from a first ink and the second ink layer <NUM> is made from a second ink. The first ink is different than the second ink. For example, the first ink is an electrically conductive ink and the second ink is a switching-type positive temperature coefficient (PTC) ink. Each of the first and second ink layers <NUM>, <NUM> is a thin film made from the hardened first and second inks, respectively.

Like conventional printing inks, the first and second inks are liquid or semi-viscous in a pre-printing state and are solid in a post-printing state following printing and drying of the ink on a substrate. Each of the first and second inks includes a solvent with additives that contribute to the electrical conductivity and thermal properties of the inks.

The first ink includes additives that promote the electrical conductivity of the first ink, and by extension, the first ink layer <NUM>. The additives of the first ink can include electrically conductive fibers or filaments each made from an electrically conductive material, such as silver, carbon, and the like.

The second ink can include additives that promote the thermally self-regulating properties of the second ink, and by extension, the second ink layer <NUM>. More specifically, the additives of the second ink are made from materials that collectively make the second ink have a switching-type positive temperature coefficient (PTC). The switching-type PTC ink of the second ink layer <NUM> is made from poly-crystalline ceramic materials, such as barium carbonate and titanium oxide, that are highly electrically resistive in an original state, but are made semi-conductive by the addition of dopants, such as tantalum, silica, and manganese. Accordingly, the switching-type PTC ink of the second ink layer <NUM> may include a combination of poly-crystalline ceramic materials and conductive dopants. The switching-type PTC ink of the second ink layer <NUM> can be made from an electrically non-conductive plastic material with embedded conductive grains, such as carbon grains.

Generally, the switching-type PTC ink of the second ink layer <NUM> self-regulates or self-limits the temperature of the second ink layer by increasing the electrical resistance of the switching-type PTC ink as the temperature of the switching-type PTC ink increases. As the temperature approaches an equilibrium temperature, which can be defined as a maximum, transition, or Curie temperature of the PTC ink, the electrical resistance of the PTC ink "switches" to rapidly increases toward infinite resistance. The equilibrium temperature can be defined as the temperature at which the electrical resistance of the PTC ink is about twice the resistance as a minimum electrical resistance of the PTC ink. The rapid increase in the electrical resistance at the equilibrium temperature rapidly reduces the electrical current allowed to flow through the PTC ink. With less current flowing through the PTC ink, the temperature of the PTC ink correspondingly drops below the equilibrium temperature, which results in a corresponding drop in the electrical resistance of the PTC ink and an increase in the current allowed through the PTC ink. The increase in current contributes to an increase in the temperature of the PTC ink until the equilibrium temperature is again established and the cycle of rapidly increasing the electrical resistance, rapidly decreasing the current, and decreasing the temperature of the PTC ink is continued.

In the above manner, with the supply of electrical power from an electrical power source at a constant (e.g., unchanging) voltage above an equilibrium voltage, the unique properties of the PTC ink allow the PTC ink to self-limit its temperature to increase up to but not exceed an equilibrium temperature. Furthermore, because the PTC ink self-regulates its temperature, extraneous components and systems for regulating the temperature of resistance heater <NUM> are not necessary. Although the second ink of the second ink layer <NUM> has been described as being a PTC ink, in other embodiments, the second ink can be made from any of various other electrically-conductive inks.

The heater control module <NUM> is applied onto the first layer <NUM> concurrently or non-concurrently with the printing of the resistance heater <NUM> onto the first layer <NUM>. The heater control module <NUM> can be pre-manufactured or pre-formed and mounted onto the first layer <NUM> such as via a bonding, fastening, or adhesion process. However, the heater control module <NUM> can be formed on the first layer <NUM> by printing the hardware (e.g., transistors) of the heater control module <NUM> directly onto the first layer <NUM>.

Similar to the heater control module <NUM>, the capacitive sensor <NUM> is applied onto the first layer <NUM> concurrently or non-concurrently with the printing of the resistance heater <NUM> onto the first layer <NUM>. The capacitive sensor <NUM> can be pre-manufactured or pre-formed and mounted onto the first layer <NUM> such as via a bonding, fastening, or adhesion process. However, the capacitive sensor <NUM> may be formed on the first layer <NUM> by printing the traces of the capacitive sensor <NUM> directly onto the first layer <NUM>.

The first layer <NUM> and integrated heater system <NUM>, including the resistance heater <NUM>, heater control module <NUM>, and capacitive sensor <NUM>, may together form a thin film ply that can be combined with other plies (e.g., base layer <NUM> and second layer <NUM>) to form a composite panel with minimal effect on the overall thickness and weight of the composite panel. For example, the integrated heater system <NUM> may form a relatively thin ply that is applied onto a first layer <NUM>, which is bonded to an optional base layer <NUM>, which can be a relatively thick ply made of a core material, such as a honeycomb structure, that provides a comparatively higher portion of the strength of the composite panel <NUM> than the first layer <NUM> and the integrated heater system <NUM>. The first layer <NUM> (along with a sandwiching second layer <NUM>) and integrated heater system <NUM> can form the entirety of the composite panel <NUM> and the first layer <NUM> may be substantially thicker than a thin film.

Electrical power is supplied to the heater control module <NUM> via the set <NUM> of electrical terminals <NUM>, <NUM> or traces, which receive electrical power from an electrical power source (e.g., electrical power source <NUM>). Each of the electrical terminals <NUM>, <NUM> can be electrically coupled to a respective one of a positive and negative terminal of a power source, such as a battery supplying a DC power signal. The electrical terminals <NUM>, <NUM> can be made from an electrically conductive ink, such as the same ink as the first ink layer <NUM> of the resistance heater <NUM>, and be co-formed with the first ink layer <NUM>, such as via an ink printing process. Alternatively, the electrical terminals <NUM>, <NUM> can be formed separately from the first ink layer <NUM> and coupled to the first layer <NUM> using any of various coupling techniques.

The heater control module <NUM> supplies electrical power to the capacitive sensor <NUM> via electrical terminals <NUM>, <NUM> or traces, and supplies electrical power to the first ink layer <NUM> of the resistance heater <NUM> via electrical terminals <NUM>, <NUM> or traces. The electrical terminals <NUM>, <NUM> can be applied or coupled to the first layer <NUM> in a manner similar to the electrical terminals <NUM>, <NUM>. The heater control module <NUM> passively supplies electrical power to the capacitive sensor <NUM>. However, the capacitive sensor <NUM> can receive electrical power directly from the electrical terminals <NUM>, <NUM> without the electrical power being routed first through the heater control module <NUM>. The heater control module <NUM> actively and dynamically controls the transmission of electrical power to the first ink layer <NUM> of the resistance heater <NUM> via input (e.g., passenger input and/or system input) received from one or both of the capacitive sensor <NUM> (e.g., via communication line <NUM>) and the system control module <NUM> (e.g., via communication line <NUM>, which is optionally included in embodiments where the system control module <NUM> may control operation of the heater <NUM>). The communication lines <NUM>, <NUM> can be configured and formed similarly to the electrical terminals <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, except communication lines <NUM>, <NUM> transmit communication signals, as opposed to power signals.

Electrical power is supplied to the second ink layer <NUM> of the resistance heater <NUM>, to heat the second ink layer <NUM>, via the first ink layer <NUM> of the resistance heater <NUM>. More specifically, electrical power supplied to the first ink layer <NUM> is transmitted from the first ink layer <NUM> to the second ink layer <NUM> via direct electrical contact between the first and second ink layers <NUM>, <NUM> of the resistance heater <NUM>.

Referring to <FIG>, the composite panel <NUM> is shown in a second configuration. In the second configuration, the first layer <NUM> and the integrated heater system <NUM>, including the resistance heater <NUM>, heater control module <NUM>, and capacitive sensor <NUM>, have a substantially non-planar shape. More specifically, the first layer <NUM> and integrated heater system <NUM> are curved. Optionally, a base layer <NUM> coupled to the first layer <NUM> may also be curved as shown. Although the composite panel <NUM> depicted in <FIG> has a simple non-planar shape (e.g., curved about a single axis), , However, the composite panel <NUM> can have any of various complex non-planar shapes.

Referring to <FIG>, the composite panel <NUM> includes a second layer <NUM> coupled to the integrated heater system <NUM> such that the integrated heater system <NUM> is positioned directly between the first and second layers <NUM>, <NUM>. In this manner, the integrated heater system <NUM> is sandwiched between the first and second layers <NUM>, <NUM> to form the composite panel <NUM>. As shown, the composite panel <NUM> is in the second configuration. In the second configuration, the first and second layers <NUM>, <NUM> and the integrated heater system <NUM> have a substantially non-planar shape, but could have a planar shape in a first configuration.

The second layer <NUM> or second ply is made from an electrically non-conductive material. Moreover, the second layer <NUM> can be an external layer of the composite panel <NUM>, such as for forming a façade of a structure. Alternatively, one or more additional layers can be coupled to the second layer <NUM> such that the second layer <NUM> is positioned between the additional layers and the integrated heater system <NUM> to act as an internal layer within the composite panel <NUM>. The second layer <NUM> may also sandwich the electrical terminals <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and communication lines <NUM>, <NUM> between the second layer <NUM> and the first layer <NUM>. The second layer <NUM> may be directly coupled to the first layer <NUM> at two or more ends to substantially envelope the integrated heater system <NUM> between the first and second layers.

Referring now to <FIG>, a die system <NUM> includes opposing dies 300A, 300B. The dies 300A, 300B define opposing and complimentary surfaces 310A, 310B, respectively. The surfaces 310A, 310B are shaped to define a desired non-planar shape of the composite panel <NUM>. Although not shown, the die system <NUM> includes actuators to move the opposing dies 300A, 300B toward and away from each other to respectively shape and release a flexible composite panel <NUM> between the dies. As shown in <FIG>, with a composite panel <NUM> positioned between the dies 300A, 300B, the dies are actuated toward each other as indicated by directional arrows. As the dies 300A, 300B move closer together, the surfaces 310A, 310B contact and deform the composite panel <NUM> according to the shape of the surfaces until the composite panel is deformed into the desired non-planar shape as shown in <FIG>.

The layers (e.g., first layer <NUM>, second layer <NUM>, and integrated heater system <NUM>) of the composite panel <NUM> can be bonded tougher using a resin-based bonding agent, or one or more of the layers is made from a resin-based material. Furthermore, the dies 300A, 300B may be heated and configured to compress the composite panel <NUM>. Heat transfer from the dies 300A, 300B to the resin-based bonding agent and/or materials, including the compressive force applied to the uncured composite panel <NUM> by the dies, acts to cure the resin and permanently form the composite panel <NUM> in the desired non-planar shape. Due to the ability of the inks of the ink layers <NUM>, <NUM>, and the capacitive sensor <NUM> and heater control module <NUM> to preferably deform and easily transfer phases between solid and liquid, the heat transfer to, compression of, and deformation of the inks during the formation of the composite panel <NUM> does not result in damage to or electrical disconnectivity in the ink layers. For this reason, and in view of this disclosure, the formation of the integrated heater system <NUM> using printed inks allows the use of integrated heater systems in stacked or composite panels as described herein. Although described above as applying both heat and compression to the composite panel <NUM>, the dies 300A, 300B may be configured to apply only one of heat and compression to cure resin in and form the composite panel in the desired non-planar shape.

The composite panel <NUM> can be formed into a non-planar shape using techniques other than those associated with the die system <NUM>. For example, an uncured flexible composite panel <NUM> can be shaped into a desired non-planar shape using casts, jigs, or molds and allowed to cure in ambient temperature conditions. Alternatively, as will be described below, the first layer <NUM> of the composite panel <NUM> can be pre-formed into a non-planar shape and the components of the integrated heater system <NUM> can be printed onto a non-planar surface of the first surface.

Referring to <FIG>, at least some components of the integrated heater system <NUM> can be printed onto the first layer <NUM> of the composite panel <NUM> using at least one ink printing head. A printer (not shown) can include two ink printing heads 150A, 150B for printing the first and second inks, respectively, of the first and second ink layers <NUM>, <NUM>. As shown in <FIG>, the first ink printing head 150A includes a first ink source <NUM> containing a first ink and a nozzle for dispensing a first ink <NUM> from the first ink source. As shown by directional arrows, the first ink printing head 150A moves translationally relative to (e.g., parallel to) a surface of the first layer <NUM> onto which the first ink layer <NUM> is to be printed. As the first ink printing head 150A moves along the surface of the first layer <NUM>, the first ink printing head dispenses the first ink <NUM> onto the surface of the first layer to form the first ink layer <NUM>. The first ink printing head 150A can dispense a uniform thickness of the first ink <NUM> onto the first layer <NUM> to form the first ink layer <NUM>. The first ink <NUM> is an electrically conductive ink as described above.

As shown in <FIG>, after printing the first ink layer <NUM>, the second ink printing head 150B, which includes a second ink source <NUM> containing a second ink and a nozzle for dispensing a second ink <NUM> from the second ink source, moves translationally along a surface of the first ink layer <NUM> onto which the second ink layer <NUM> is to be printed. As the second ink printing head 150B moves along the surface of the first ink layer <NUM>, the second ink printing head dispenses the second ink <NUM> onto the surface of the first ink layer to form the second ink layer <NUM>. The second ink printing head 150B can dispense a uniform thickness of the second ink <NUM> onto the first ink layer <NUM> to form the second ink layer <NUM>. The second ink <NUM> is a switching-type PTC ink as described above.

Referring back to <FIG>, the first ink printing head 150A, or other ink printing head, can also be used to print the capacitive sensor <NUM> and/or heater control module <NUM> onto the first layer <NUM>. For example, as the first ink printing head 150A, or other ink printing head, moves relative to the surface of the first layer <NUM>, the first ink printing head 150A, or other ink printing head, dispenses the first ink <NUM>, or another ink, onto the surface of the first layer to form the capacitive sensor <NUM> and/or the heater control module <NUM>. Alternatively, one or both of the capacitive sensor <NUM> or heater control module <NUM> can be printed onto the first layer <NUM> during a different printing process, or preformed and mounted onto the first layer <NUM> prior to or after the resistance heater <NUM> is printed onto the first layer <NUM>.

Although ink printing heads 150A, 150B can be used to print components of the integrated heater system <NUM> using an inkjet printing process, it is recognized that other printing techniques can be used to print the first and second ink layers. For example, components of the integrated heater system <NUM> can be printed using one or more conventional printing processes, such as screen printing, rotary screen printing, and gravure printing processes. Also, components of the integrated heater system <NUM> may be printed using conventional atomized jetted deposition techniques, which may include airbrushing the ink layers using an airbrush coupled to a gantry.

Referring to <FIG>, a method <NUM> of making and using a composite panel with an integrated heater system is shown. Generally, the method <NUM> may provide at least one utilization of a crush core manufacturing technique. Notwithstanding, other crush core manufacturing techniques, or any of various other manufacturing techniques, could be used to make a composite panel as described herein without departing from the essence of the presently claimed subject-matter. The method <NUM> includes providing a first non-conductive layer, which can be flexible, at <NUM>. Additionally, the method <NUM> includes printing a conductive layer onto the first non-conductive layer using a conductive ink at <NUM>. Then, the method <NUM> includes printing a heater layer onto the first non-conductive layer using a PTC ink, or other ink, at <NUM>. The method <NUM> also includes printing a capacitive sensor or similar sensor onto the first non-conductive layer using conductive ink at 407A and applying (e.g., mounting or printing) a heater control module onto the first non-conductive later at 407B. Additionally, the method <NUM> includes applying or coupling a second non-conductive layer, which may be flexible, onto the heater layer, capacitive sensor, and heater control module, to form a composite panel at <NUM>.

The method <NUM> can further include shaping the composite panel into a non-planar shape at <NUM> and hardening the composite panel in the non-planar shape at <NUM>. Also, the method <NUM> includes electrically coupling an electrical power source to the conductive layer at <NUM>.

The method <NUM> includes adjusting a voltage applied to the conductive layer based on input from the capacitance sensor at <NUM>. The voltage can be an equilibrium voltage defined as a voltage sufficiently high that if constantly applied to the heater layer would allow the temperature of the heater layer to reach the equilibrium temperature. The method <NUM> additionally includes, at <NUM>, generating heat from the heater layer responsive to the voltage applied to the conductive layer.

In the above description, certain terms may be used such as "up," "down," "upper," "lower," "horizontal," "vertical," "left," "right," "over," "under" and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an "upper" surface can become a "lower" surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms "including," "comprising," "having," and variations thereof mean "including but not limited to" unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. Further, the term "plurality" can be defined as "at least two.

Additionally, instances in this specification where one element is "coupled" to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, "adjacent" does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.

As used herein, the phrase "at least one of", when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, "at least one of" means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, "at least one of item A, item B, and item C" may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, "at least one of item A, item B, and item C" may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.

The schematic flow chart diagrams included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.

Some of the functional units described in this specification have been labeled as modules, in order to more particularly emphasize their implementation independence. For example, a module may be implemented as a hardware circuit comprising custom VLSI circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components.

Modules may also be implemented in software for execution by various types of processors. An identified module of computer readable program code may, for instance, comprise one or more physical or logical blocks of computer instructions which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the module and achieve the stated purpose for the module.

Indeed, a module of computer readable program code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network. Where a module or portions of a module are implemented in software, the computer readable program code may be stored and/or propagated on in one or more computer readable medium(s).

The computer readable medium may be a tangible computer readable storage medium storing the computer readable program code. The computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, holographic, micromechanical, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing.

More specific examples of the computer readable medium may include but are not limited to a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a portable compact disc read-only memory (CD-ROM), a digital versatile disc (DVD), an optical storage device, a magnetic storage device, a holographic storage medium, a micromechanical storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, and/or store computer readable program code for use by and/or in connection with an instruction execution system, apparatus, or device.

The computer readable medium may also be a computer readable signal medium. Such a propagated signal may take any of a variety of forms, including, but not limited to, electrical, electro-magnetic, magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport computer readable program code for use by or in connection with an instruction execution system, apparatus, or device. Computer readable program code embodied on a computer readable signal medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, Radio Frequency (RF), or the like, or any suitable combination of the foregoing.

The computer readable medium may comprise a combination of one or more computer readable storage mediums and one or more computer readable signal mediums. For example, computer readable program code may be both propagated as an electro-magnetic signal through a fiber optic cable for execution by a processor and stored on RAM storage device for execution by the processor.

Claim 1:
A composite panel (<NUM>), comprising:
a first layer (<NUM>) made from an electrically non-conductive material;
a resistance heater (<NUM>) printed onto the first layer (<NUM>);
a capacitive sensor (<NUM>) applied onto the first layer (<NUM>), the capacitive sensor (<NUM>) being operably coupled with the resistance heater (<NUM>);
a heater control module (<NUM>) applied onto the first layer (<NUM>), configured to vary a voltage to the resistance heater (<NUM>) at least partially in response to the input sensed by the capacitive sensor (<NUM>); and
a second layer (<NUM>) adjacent the resistance heater (<NUM>), the capacitive sensor (<NUM>) and the heater control module (<NUM>), the resistance heater (<NUM>), the capacitive sensor (<NUM>) and the heater control module (<NUM>) being positioned between the first layer (<NUM>) and the second layer (<NUM>), and the second layer (<NUM>) being made from an electrically non-conductive material;
wherein the resistance heater (<NUM>) is configured to generate heat at least partially in response to input sensed by the capacitive sensor (<NUM>),
wherein the first layer (<NUM>), the resistance heater (<NUM>), the capacitive sensor (<NUM>), the heater control module (<NUM>) and the second layer (<NUM>) are flexible, and
wherein the first layer (<NUM>), resistance heater (<NUM>), capacitive sensor (<NUM>), and second layer (<NUM>) together form a sandwich panel, the sandwich panel having a non-planar shape.