U.S. patent application number 17/225285 was filed with the patent office on 2021-07-22 for hand and foot heaters.
The applicant listed for this patent is DUPONT ELECTRONICS, INC.. Invention is credited to MARK ALLAN LAMONTIA, MEHRDAD MEHDIZADEH, MICHAEL R. MOSELEY.
Application Number | 20210219640 17/225285 |
Document ID | / |
Family ID | 1000005504802 |
Filed Date | 2021-07-22 |
United States Patent
Application |
20210219640 |
Kind Code |
A1 |
LAMONTIA; MARK ALLAN ; et
al. |
July 22, 2021 |
HAND AND FOOT HEATERS
Abstract
This invention provides gloves and socks containing printed
heaters. The glove or sock with a heater comprises a glove or sock,
a substrate with the outline of the glove or sock, and a heater
printed on the substrate wherein the substrate is laminated to the
glove or sock. The heater comprises two printed conductive bus bars
with extensions traversing the substrate and an array of printed
resistive areas arranged so that each area is between and overlaps
and is contiguous to two conductors, one of which is one of the bus
bars or its extensions and the second is the other bus bar or its
extensions.
Inventors: |
LAMONTIA; MARK ALLAN;
(LANDENBERG, PA) ; MEHDIZADEH; MEHRDAD; (AVONDALE,
PA) ; MOSELEY; MICHAEL R.; (New Castle, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DUPONT ELECTRONICS, INC. |
Wilmington |
DE |
US |
|
|
Family ID: |
1000005504802 |
Appl. No.: |
17/225285 |
Filed: |
April 8, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16057154 |
Aug 7, 2018 |
11006685 |
|
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17225285 |
|
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62618309 |
Jan 17, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A41B 11/00 20130101;
A41D 13/0051 20130101; B32B 27/40 20130101; A41D 1/002 20130101;
H05B 2203/017 20130101; H05B 3/342 20130101; A41D 2400/10 20130101;
A41D 19/01535 20130101; B32B 1/00 20130101; B32B 2255/10 20130101;
A41D 31/102 20190201; B32B 2255/26 20130101; B32B 2437/02
20130101 |
International
Class: |
A41D 19/015 20060101
A41D019/015; A41B 11/00 20060101 A41B011/00; A41D 1/00 20060101
A41D001/00; A41D 13/005 20060101 A41D013/005; B32B 1/00 20060101
B32B001/00; B32B 27/40 20060101 B32B027/40; H05B 3/34 20060101
H05B003/34 |
Claims
1-12. (canceled)
13. A method for preparing a glove with a heater, the method
comprising: a) providing a glove comprising a cuff surrounding the
wrist, a palm and the back of the hand connected to the cuff, and
separate sheaths for each finger and thumb, wherein the sheaths
extend from the palm and the back of the hand; b) stretching the
glove up to 130% in all directions on a stretcher to provide a
stretched cuff, stretched palm and back of the hand and stretched
sheaths, and maintaining the glove in the stretched state, wherein
the amount of stretching along the lengths of the sheaths is at
least as great or greater than that in other directions; c)
providing a substrate with the outline of the stretched glove and
with a cuff area corresponding to the cuff of the stretched glove,
a back of the hand area corresponding to the back of the hand of
the stretched glove, and sheath areas corresponding to the sheaths
of the stretched glove; d) printing a heater onto the substrate,
comprising: 1) printing two conductive bus bars on the area
corresponding to the cuff of the glove; 2) printing conductive
extensions from each bus bar, the conductive extensions traversing
the area corresponding to the back of the hand of the glove such
that a conductive extension of one bus bar traverses one side of
each area corresponding to a sheath of the glove, and a conductive
extension of the other bus bar traverses the opposite side of each
area corresponding to a sheath of the glove; and 3) printing an
array of resistive material areas arranged so that each printed
resistive material area is between and overlaps and is contiguous
to two conductors, one of which is one of the bus bars or its
extensions and the second is the other bus bar or its extensions
and with spaces of exposed substrate between adjacent resistive
material areas, wherein the sheet resistance R.sub.s of the
resistive material is between 10 and 50,000 .OMEGA./square; e)
laminating the substrate to the back of the stretched glove such
that the cuff of the stretched glove is laminated to the
corresponding area of the substrate, the back of the hand of the
stretched glove is laminated to the corresponding area of the
substrate, and the sheaths of the stretched glove are laminated to
the corresponding areas of the substrate; and f) removing the glove
from the stretcher.
14. A method for preparing a glove with a heater, the method
comprising: a) providing a glove comprising a cuff surrounding the
wrist, a palm and the back of the hand connected to the cuff, and
separate sheaths for each finger and thumb, wherein the sheaths
extend from the palm and the back of the hand; b) stretching the
glove up to 130% in all directions on a stretcher to provide a
stretched cuff, stretched palm and back of the hand and stretched
sheaths and maintain the glove in the stretched state, wherein the
amount of stretching along the lengths of the sheaths is at least
as great or greater than that in other directions; c) providing a
substrate with the outline of the stretched glove and with a cuff
area corresponding to the cuff of the stretched glove, a palm area
corresponding to the palm of the stretched glove, and sheath areas
corresponding to the sheaths of the stretched glove; d) printing a
heater onto the substrate, comprising: 1) printing two conductive
bus bars on the area corresponding to the cuff of the glove; 2)
printing conductive extensions from each bus bar, the conductive
extensions traversing the area 25 corresponding to palm of the
glove such that a conductive extension of one bus bar traverses one
side of each area corresponding to a sheath of the glove and a
conductive extension of the other bus bar traverses the opposite
side of each area corresponding to a sheath of the glove; and 3)
printing an array of resistive material areas arranged so that each
printed resistive material area is between and overlaps and is
contiguous to two conductors, one of which is one of the bus bars
or its extensions and the second is the other bus bar or its
extensions, and with spaces of exposed substrate between adjacent
resistive material areas, wherein the sheet resistance R.sub.s of
the resistive material is between 10 and 50,000 .OMEGA./square; e)
laminating the substrate to the palm of the stretched glove such
that the cuff of the stretched glove is laminated to the
corresponding area of the substrate, the palm of the stretched
glove is laminated to the corresponding area of the substrate, and
the sheaths of the stretched glove are laminated to the
corresponding areas of the substrate; and f) removing the glove
from the stretcher.
15-16. (canceled)
17. A sock with a heater, comprising: a) a sock comprising a
portion surrounding the ankle and part of the calf of the leg and a
top of the foot and a bottom of the foot connected to the portion
surrounding the ankle and part of the calf, wherein the top of the
foot and the bottom of the foot extend to the portions covering the
toes; b) a substrate with an area corresponding to the portion of
the sock surrounding the ankle and part of the calf of the leg and
with an area corresponding to the top of the foot of the sock
including the portion covering the toes; and c) a heater printed
onto the substrate, the heater comprising: i) two printed
conductive bus bars on the area corresponding to the portion of the
sock surrounding the ankle and part of the calf of the leg, wherein
each bus bar has printed conductive extensions that traverse the
area corresponding to the top of the foot of the glove such that a
conductive extension of one bus bar traverses one side of each area
corresponding to a toe of the sock and a conductive extension of
the other bus bar traverses the opposite side of each area
corresponding to a toe of the sock; and ii) an array of printed
resistive material areas arranged so that each printed resistive
material area is between and overlaps and is contiguous to two
conductors, one of which is one of the bus bars or its extensions
and the second is the other bus bar or its extensions and with
spaces of exposed substrate between adjacent resistive material
areas, wherein the sheet resistance R.sub.s of the resistive
material is between 10 and 50,000 .OMEGA./square, wherein the
substrate with the printed heater is laminated to the outside or
the inside of the sock such that the portion surrounding the ankle
and part of the calf of the leg is laminated to the corresponding
area of the substrate and the top of the foot of the glove is
laminated to the corresponding area of the substrate.
Description
FIELD OF THE INVENTION
[0001] This invention is directed to printable hand and foot
heaters.
BACKGROUND OF THE INVENTION
[0002] There is increasing interest in providing a variety of
heatable wearable garments. Among those are gloves with heaters to
warm the wearer's hands and footwear with heaters to warm the
wearer's feet. Currently typical commercialized heated garments are
heated by resistance wires. These wires have the disadvantage that
the presence of the wires renders the garments uncomfortable.
[0003] An alternative is to use heaters with printed components
which would provide greater comfort to the wearer. In one such
version, a component of the heated garment is one or more areas of
resistive material, e.g., carbon, which serve as the resistive
heating element. between two bus bars. An additional problem with
heaters in hand wear and footwear is the strain to which they are
subjected during their use and and during donning and doffing.
There is a need for such heaters for hand wear and footwear.
SUMMARY OF THE INVENTION
[0004] This invention provides a glove with a heater, comprising:
[0005] a) a glove comprising a cuff surrounding the wrist, a palm
and the back of the hand connected to the cuff and separate sheaths
for each finger and thumb, wherein the sheaths extend from the palm
and the back of the hand; [0006] b) a substrate with the outline of
the glove and with an area corresponding to the cuff of the glove,
an area corresponding to the back of the hand of the glove and
areas corresponding to the sheaths of the glove; and [0007] c) a
heater printed onto the substrate, the heater comprising: [0008] i)
two printed conductive bus bars on the area corresponding to the
cuff of the glove, wherein each bus bar has printed conductive
extensions that traverse the area corresponding to the back of the
hand of the glove such that a conductive extension of one bus bar
traverses one side of each area corresponding to a sheath of the
glove and a conductive extension of the other bus bar traverses the
opposite side of each area corresponding to a sheath of the glove;
and [0009] ii) an array of printed resistive material areas
arranged so that each printed resistive material area is between
and overlaps and is contiguous to two conductors, one of which is
one of the bus bars or its extensions and the second is the other
bus bar or its extensions, and with spaces of exposed substrate
between adjacent resistive material areas, wherein the sheet
resistance R.sub.s of the resistive material is between 10 and
50,000 .OMEGA./square, wherein the substrate with the printed
heater is laminated to the outside or the inside of the glove such
that the cuff of the glove is laminated to the corresponding area
of the substrate, the back of the hand of the glove is laminated to
the corresponding area of the substrate and the sheaths are
laminated to the corresponding areas of the substrate.
[0010] In addition, this invention provides a glove with a heater,
comprising: [0011] a) a glove comprising a cuff surrounding the
wrist, a palm and the back of the hand connected to the cuff and
separate sheaths for each finger and thumb, wherein the sheaths
extend from the palm and the back of the hand; [0012] b) a
substrate with the outline of the glove and with an area
corresponding to the cuff of the glove, an area corresponding to
the palm of the glove and areas corresponding to the sheaths of the
glove; and [0013] c) a heater printed onto the substrate, the
heater comprising: [0014] i) two printed conductive bus bars on the
area corresponding to the cuff of the glove, wherein each bus bar
has printed conductive extensions that traverse the area
corresponding to the palm of the glove such that a conductive
extension of one bus bar traverses one side of each area
corresponding to a sheath of the glove and a conductive extension
of the other bus bar traverses the opposite side of each area
corresponding to a sheath of the glove; and [0015] ii) an array of
printed resistive material areas arranged so that each printed
resistive material area is between and overlaps and is contiguous
to two conductors, one of which is one of the bus bars or its
extensions and the second is the other bus bar or its extensions
and with spaces of exposed substrate between adjacent resistive
material areas, wherein the sheet resistance R.sub.s of the
resistive material is between 10 and palm of 50,000 .OMEGA./square,
wherein the substrate with the printed heater is laminated to the
outside or the inside of the glove such that the cuff of the glove
is laminated to the corresponding area of the substrate, the palm
of the glove is laminated to the corresponding area of the
substrate and the sheaths are laminated to the corresponding areas
of the substrate.
[0016] In another embodiment, this invention provides a glove with
a heater, comprising: [0017] a) a glove comprising a cuff
surrounding the wrist, a palm and the back of the hand connected to
the cuff and separate sheaths for each finger and thumb, wherein
the sheaths extend from the palm and the back of the hand; [0018]
b) a substrate comprising an area corresponding to the cuff of the
glove and an area corresponding to the palm of the glove; and
[0019] c) a heater printed onto the substrate, the heater
comprising: [0020] i) two printed conductive bus bars on the area
corresponding to the cuff of the glove, wherein each bus bar has a
printed conductive extension that traverses the area corresponding
to the palm of the glove such that a conductive extension of one
bus bar traverses one side of the area corresponding to the palm of
the glove and a conductive extension of the other bus bar traverses
the opposite side of the area corresponding to the palm of the
glove; and [0021] iii) one or more printed resistive material areas
arranged so that each printed resistive material area is between
and overlaps and is contiguous to the two printed conductive
extensions one from each bus bar on the area corresponding to the
palm of the glove, wherein the sheet resistance R.sub.s of the
resistive material is between 10 and 50,000 .OMEGA./square, wherein
the substrate with the printed heater is laminated to the outside
or the inside of the glove such that the cuff of the glove is
laminated to the corresponding area of the substrate and the palm
of the glove is laminated to the corresponding area of the
substrate.
[0022] In still another embodiment, this invention provides a glove
with a heater, comprising: [0023] a) a glove comprising a cuff
surrounding the wrist, a palm and the back of the hand connected to
the cuff and separate sheaths for each finger and thumb, wherein
the sheaths extend from the palm and the back of the hand; [0024]
b) a substrate comprising an area corresponding to the cuff of the
glove and an area corresponding to the back of the hand of the
glove; and [0025] c) a heater printed onto the substrate, the
heater comprising: [0026] i) two printed conductive bus bars on the
area corresponding to the cuff of the glove, wherein each bus bar
has a printed conductive extension that traverses the area
corresponding to the back of the hand of the glove such that a
conductive extension of one bus bar traverses one side of the area
corresponding to the back of the hand of the glove and a conductive
extension of the other bus bar traverses the opposite side of the
area corresponding to the back of the hand of the glove; and [0027]
ii) one or more printed resistive material areas arranged so that
each printed resistive material area is between and overlaps and is
contiguous to the two printed conductive extensions one from each
bus bar on the area corresponding to the back of the hand of the
glove, wherein the sheet resistance R.sub.s of the resistive
material is between 10 and 50,000 .OMEGA./square, wherein the
substrate with the printed heater is laminated to the outside or
the inside of the glove such that the cuff of the glove is
laminated to the corresponding area of the substrate and the back
of the hand of the glove is laminated to the corresponding area of
the substrate.
[0028] The invention also provides a method for preparing a glove
with a heater, the method comprising: [0029] a) providing a glove
comprising a cuff surrounding the wrist, a palm and the back of the
hand connected to the cuff and separate sheaths for each finger and
thumb, wherein the sheaths extend from the palm and the back of the
hand; [0030] b) stretching the glove up to 130% in all directions
on a stretcher to provide a stretched cuff, stretched palm and back
of the hand and stretched sheaths and maintain the glove in the
stretched state, wherein the amount of stretching along the lengths
of the sheaths is at least as great or greater than that in other
directions; [0031] c) providing a substrate with the outline of the
stretched glove and with a cuff area corresponding to the cuff of
the stretched glove, a back of the hand area corresponding to the
back of the hand of the stretched glove and sheath areas
corresponding to the sheaths of the stretched glove; [0032] d)
printing a heater onto the substrate, comprising: [0033] 1)
printing two conductive bus bars on the area corresponding to the
cuff of the glove; [0034] 2) printing conductive extensions from
each bus bar, the conductive extensions traversing the area
corresponding to the back of the hand of the glove such that a
conductive extension of one bus bar traverses one side of each area
corresponding to a sheath of the glove and a conductive extension
of the other bus bar traverses the opposite side of each area
corresponding to a sheath of the glove; and [0035] 3) printing an
array of resistive material areas arranged so that each printed
resistive material area is between and overlaps and is contiguous
to two conductors, one of which is one of the bus bars or its
extensions and the second is the other bus bar or its extensions
and with spaces of exposed substrate between adjacent resistive
material areas, wherein the sheet resistance R.sub.s of the
resistive material is between 10 and 50,000 .OMEGA./square; [0036]
e) laminating the substrate to the back of the stretched glove such
that the cuff of the stretched glove is laminated to the
corresponding area of the substrate, the back of the hand of the
stretched glove is laminated to the corresponding area of the
substrate and the sheaths of the stretched glove are laminated to
the corresponding areas of the substrate; and [0037] f) removing
the glove from the stretcher.
[0038] In addition, the invention provides a method for preparing a
glove with a heater, the method comprising: [0039] a) providing a
glove comprising a cuff surrounding the wrist, a palm and the back
of the hand connected to the cuff and separate sheaths for each
finger and thumb, wherein the sheaths extend from the palm and the
back of the hand; [0040] b) stretching the glove up to 130% in all
directions on a stretcher to provide a stretched cuff, stretched
palm and back of the hand and stretched sheaths and maintain the
glove in the stretched state, wherein the amount of stretching
along the lengths of the sheaths is at least as great or greater
than that in other directions; [0041] c) providing a substrate with
the outline of the stretched glove and with a cuff area
corresponding to the cuff of the stretched glove, a palm area
corresponding to the palm of the stretched glove and sheath areas
corresponding to the sheaths of the stretched glove; [0042] d)
printing a heater onto the substrate, comprising: [0043] 1)
printing two conductive bus bars on the area corresponding to the
cuff of the glove; [0044] 2) printing conductive extensions from
each bus bar, the conductive extensions traversing the area
corresponding to palm of the glove such that a conductive extension
of one bus bar traverses one side of each area corresponding to a
sheath of the glove and a conductive extension of the other bus bar
traverses the opposite side of each area corresponding to a sheath
of the glove; and [0045] 3) printing an array of resistive material
areas arranged so that each printed resistive material area is
between and overlaps and is contiguous to two conductors, one of
which is one of the bus bars or its extensions and the second is
the other bus bar or its extensions and with spaces of exposed
substrate between adjacent resistive material areas, wherein the
sheet resistance R.sub.s of the resistive material is between 10
and 50,000 .OMEGA./square; [0046] e) laminating the substrate to
the palm of the stretched glove such that the cuff of the stretched
glove is laminated to the corresponding area of the substrate, the
palm of the stretched glove is laminated to the corresponding area
of the substrate and the sheaths of the stretched glove are
laminated to the corresponding areas of the substrate; and [0047]
f) removing the glove from the stretcher.
BRIEF DESCRIPTION OF THE FIGURE
[0048] The FIGURE shows an embodiment of a printed heater on a
substrate with the outline of a glove.
DETAILED DESCRIPTION OF THE INVENTION
[0049] The invention relates to printed heaters for use in gloves
and footwear. The same concepts are used in forming these
heaters.
[0050] The glove with the heater comprises a glove, a substrate,
and a heater printed onto the substrate.
[0051] The glove comprises the typical parts of a glove--a cuff
surrounding the wrist, a palm and the back of the hand connected to
the cuff and separate sheaths for each finger and thumb.
[0052] The substrate is a flat piece of material with the outline
of the glove. The substrate has an area corresponding to the cuff
of the glove, an area corresponding to the back of the hand of the
glove or the palm of the glove and areas corresponding to the
sheaths of the glove. The material must be compatible with printing
of the heater components. In one embodiment the substrate material
is thermoplastic polyurethane.
[0053] A heater is printed onto the substrate. The heater comprises
two printed conductive bus bars on the area corresponding to the
cuff of the glove. Each bus bar has printed conductive extensions
that traverse the area corresponding to the back of the glove or
the palm of the glove such that a conductive extension of one bus
bar traverses one side of each area corresponding to a sheath of
the glove and a conductive extension of the other bus bar traverses
the opposite side of each area corresponding to a sheath of the
glove. The bus bars and the extensions may be printed at the same
time.
[0054] In some embodiments the bus bars and extensions are in the
form of straight lines or a combination of straight lines on the
areas corresponding to the cuff and the back of the hand of the
glove or the palm of the glove and slightly curved lines following
the outlines of the areas corresponding to the sheaths of the
glove. In another embodiment, at least some of the bus bars and
extensions are in the form of serpentines, i.e., wavelike,
undulating. In one such embodiment essentially all the bus bars and
extensions are in the form of serpentines. The serpentines are
designed to have the largest amplitude of undulation consistent
with the available space. The serpentines accommodate the large
strains that occur in the finger, sheath areas, during the use of
the glove and in the cuff and back of the hand or palm areas. The
serpentines also allow for stretching during the donning and
doffing of the gloves.
[0055] The heater also comprises resistive material areas that
serve as the heating elements. An array of the printed resistive
material areas is arranged so that each printed resistive material
area is between and overlaps and is contiguous to two conductors,
one of which is one of the bus bars or its extensions and the
second is the other bus bar or its extensions. There are high
strain areas at the major knuckles at the base of the fingers where
the area corresponding to the back of the glove attaches to the
areas corresponding to the sheaths. There is also a high strain
area between the area corresponding to the thumb sheath and the
area corresponding to the adjacent finger sheath. In an embodiment,
these high strain areas are devoid of printed resistive material
areas. There is also a relatively high strain area at the minor
knuckles in the midfingers. In one embodiment these areas are also
devoid of printed resistive material areas.
[0056] Each resistive material area has a cross-section orthogonal
to the distance, i.e., the length of the area, between the two
contiguous conductive bus bars or extensions. These dimensions
maybe different for resistive material areas on different areas of
the glove. In order for a resistive material area to provide
uniform heating the cross-section should be uniform along the
length of the resistive material area. In one embodiment the
resistive material areas are in the form of rectangles. In another
embodiment some of the resistive material area s are in the form of
serpentines.
[0057] There is exposed substrate in spaces between adjacent
resistive material areas. If the substrate is breathable then the
heater has the additional advantage of being breathable so that air
and moisture, i.e., water vapor, can pass through the exposed
regions of the permeable substrate in the spaces between adjacent
resistive material areas. This can provide additional comfort to
the wearer. If the substrate is not breathable portions of the
exposed substrate between adjacent resistive material areas are
removed to render the heater breathable and provide extra
stretchability. These areas may be removed in any case to provide
extra stretchability.
[0058] In one embodiment, the resistive material has sheet a
resistance R.sub.s of between 10 and 50,000 .OMEGA./square. In
another embodiment, the resistive material has sheet a resistance
R.sub.s of between 200 and 5000 .OMEGA./square.
[0059] In some embodiments, the printed conductive bus bars and
extensions are silver bus bars and extensions and the printed
resistive material is carbon. In other embodiments, the printed bus
bars and extensions are copper bus bars and extensions and the
printed resistive material is carbon. In still other embodiments,
the printed conductive bus bars and extensions are silver-silver
chloride, gold or aluminum.
[0060] The electrically conductive areas and bus bars referred to
herein are formed from polymer thick film pastes containing an
electrical conductor. When the printed conductive bus bars and
extensions are silver, they are formed using polymer thick film
silver pastes. The resistive material is also printed using a
polymer thick film paste. When the printed resistive material is
printed carbon, it is formed using a polymer thick film carbon
paste. When using polymer thick film pastes, the polymer is an
integral part of the final composition, i.e., the bus bars, the
extensions or the resistive areas.
[0061] The FIGURE shows an embodiment of a printed heater on a
substrate 1 with the outline 2 of a glove. The heater comprises two
printed conductive bus bars 3 and 4 on the area corresponding to
the cuff of the glove. Bus bar 3 has printed conductive extensions
5 and bus bar 4 has printed conductive extensions 6 that traverse
the area corresponding to the back of the glove of the glove.
Extensions 5 and 6 have further extensions. Extensions 5 have
further conductive extensions 7 that traverse one side of each area
corresponding to a sheath of the glove and extensions 6 have
further conductive extensions 8 that traverse the opposite side of
each area corresponding to a sheath of the glove. Both bus bars 3
and 4 are shown as a combination of straight lines and serpentines.
The extensions 5, 6, 7 and 8 are in the form of serpentines. The
dielectric areas 9 insulate the bus bar 3 from the extensions 6.
The heater also comprises resistive material areas 10 that serve as
the heating elements. An array of the printed resistive material
areas 10 is arranged so that each printed resistive material area
is between and overlaps and is contiguous to two conductors, one of
which is one of the bus bars 3 or its extensions 5 or 7 and the
second is the other bus bar 4 or its extensions 6 or 8.
[0062] The substrate with the printed heater is laminated to the
outside or the inside of the glove. The substrate can be laminated
to the palm or to the back of the hand of the glove. Because of the
expected additional use of the palm of the glove as compared to the
back of the glove and the additional wear and strain on the printed
heater components, it is believed a more robust heater will be
provided if the heater is laminated to the back of the hand of the
glove, i.e., such that the cuff of the glove is laminated to the
corresponding area of the substrate, the back of the hand of the
glove is laminated to the corresponding area of the substrate, and
the sheaths are laminated to the corresponding areas of the
substrate.
[0063] In embodiments in which the substrate is laminated to the
outside of the glove, this glove may be used as the inside glove or
liner of a two-glove pair with a second glove as the outside glove
of the pair. The second glove covers and protects the heater on the
outside of the inner glove. In other embodiments involving a
two-glove pair, the substrate may be laminated to the inside of the
outer glove.
[0064] The invention also provides a method for making a glove as
described above. The glove may be stretched up to 130% in all
directions with the amount of stretching along the lengths of the
sheaths being at least as great or greater than that in other
directions. When the glove is stretched, the outline of the
substrate is the outline of the stretched glove.
[0065] The same concepts are used in forming heaters for socks as
in forming heaters for gloves.
[0066] A sock with a heater comprises a sock, a substrate, and a
heater printed onto the substrate.
[0067] The sock comprises the typical parts of a sock, a portion
surrounding the ankle and part of the calf of the leg and a top of
the foot and a bottom of the foot connected to the portion
surrounding the ankle and part of the calf. The top of the foot and
the bottom of the foot extend to the portions covering the
toes.
[0068] The substrate is a flat piece of material with the outline
of the sock. The substrate has an area corresponding to the portion
of the sock surrounding the ankle and part of the calf of the leg,
an area corresponding to the top of the foot of the sock. The
material must be compatible with printing of the heater components.
In one embodiment the substrate material is thermoplastic
polyurethane.
[0069] A heater is printed onto the substrate. The heater comprises
two printed conductive bus bars on top of the area corresponding to
the portion of the sock surrounding the ankle and part of the calf
of the leg. Each bus bar has printed conductive extensions that
traverse the area corresponding to the top of the foot such that a
conductive extension of one bus bar traverses one side of each area
corresponding to a toe of the foot and a conductive extension of
the other bus bar traverses the opposite side of each area
corresponding to a toe of the foot. The bus bars and the extensions
may be printed at the same time.
[0070] In some embodiments the bus bars and extensions are in the
form of straight lines or a combination of straight lines on the
areas corresponding to the ankle and the back of the foot of the
sock and slightly curved lines following the outlines of the toes.
In another embodiment, at least some of the bus bars and extensions
are in the form of serpentines, i.e., wavelike, undulating. In one
such embodiment essentially all the bus bars and extensions are in
the form of serpentines. The serpentines are designed to have the
largest amplitude of undulation consistent with the available
space. The serpentines accommodate the large strains that occur in
the area of the ankle and the areas of the toes. The serpentines
also allow for stretching during the putting on and doffing of the
socks.
[0071] The heater also comprises resistive material areas that
serve as the heating elements. An array of the printed resistive
material areas is arranged so that each printed resistive material
area is between and overlaps and is contiguous to two conductors,
one of which is one of the bus bars or its extensions and the
second is the other bus bar or its extensions.
[0072] Each resistive material area has a cross-section orthogonal
to the distance, i.e., the length of the area, between the two
contiguous conductive bus bars or extensions. In order for the area
to provide uniform heating this cross-section should be uniform
along the length of the resistive material area.
[0073] There is exposed substrate in spaces between adjacent
resistive material areas. If the substrate is breathable than the
heater has the additional advantage of being breathable in the
sense that air and moisture, i.e., water vapor, can pass through
the exposed regions of the permeable substrate in the spaces
between adjacent resistive material areas. This can provide
additional comfort to the wearer. If the substrate is not
breathable portions of the exposed substrate between adjacent
resistive material areas are removed to render the heater
breathable and provide extra stretchability. These areas may be
removed in any case to provide extra stretchability.
[0074] In one embodiment, the resistive material has sheet a
resistance R.sub.s of between 10 and 50,000 .OMEGA./square. In
another embodiment, the resistive material has sheet a resistance
R.sub.s of between 200 and 5000 .OMEGA./square.
[0075] In some embodiments, the printed conductive bus bars and
extensions are silver bus bars and extensions and the printed
resistive material is carbon. In other embodiments, the printed bus
bars and extensions are copper bus bars and extensions and the
printed resistive material is carbon. In still other embodiments,
the printed conductive bus bars and extensions are silver-silver
chloride, gold or aluminum.
[0076] The electrically conductive areas and bus bars referred to
herein are formed from polymer thick film pastes containing an
electrical conductor. When the printed conductive bus bars and
extensions are silver, they are formed using polymer thick film
silver pastes. The resistive material is also printed using a
polymer thick film paste. When the printed resistive material is
printed carbon, it is formed using a polymer thick film carbon
paste. When using polymer thick film pastes, the polymer is an
integral part of the final composition, i.e., the bus bars, the
extensions or the resistive areas.
EXAMPLE
[0077] A printed heater on a substrate that can be used as a glove
liner for a heated glove was prepared essentially with the
configuration shown in the FIGURE.
[0078] A sheet of lamentable thermoplastic substrate (TPU) (Bemis
ST604 obtained from Bemis Corp., Shirley, Mass.) was used for the
substrate upon which the heater was printed. The components of the
heater were sequentially screen printed onto the substrate along
with the outline of a 115% stretched cotton glove, i.e., a glove
stretched 15% above its normal size.
[0079] The pastes used for the screen printing were DuPont.TM.
Intexar.TM. PE 874 Conductive Silver paste, DuPont.TM. ME 775
Crossover Dielectric paste, and DuPont.TM. Intexar.TM. PE 671
Stretchable Carbon Conductor (all obtained from DuPont Co.,
Wilmington, Del.). Optionally, DuPont.TM. Intexar.TM. PE773
Stretchable Encapsulant paste (DuPont Co., Wilmington, Del.) may
also be used before and after printing the dielectric paste. The
conductive inks were patterned onto the flexible substrate using
typical screen printing practices. After each printing, the printed
film was exposed to 130.degree. C. for 8 minutes. The silver
printing and the carbon printing were each repeated in order to
achieve the desired properties.
[0080] As shown in the FIGURE the glove liner was fabricated with
119 identical printed resistive carbon rectangular areas, each of
which serves as a heater. These individual heaters were wired in
parallel. The individual heaters were 3.59 mm wide. Between the
connecting conductive traces, they were 11.68 mm long. This ratio
of length to width gives an individual heater a resistance equal to
3.25 times the sheet resistance of the carbon. Since each of the
119 tiles had identical dimensions, the overall resistance of the
heater was 3.25.times.R.sub.carbon/119, where R.sub.carbon is the
sheet resistance of the carbon. The overall resistance of the
conductors was empirically determined to be 65.times.R.sub.silver,
where R.sub.silver is the sheet resistance of the silver
conductors. Under the testing conditions of stretch & heat, the
materials used in the fabrication of Example 1 had the following
sheet resistances: [0081] R.sub.carbon=4900 .OMEGA./square [0082]
R.sub.silver=0.062 .OMEGA./square and the heated glove liner showed
a total resistance of approximately 140 .OMEGA..
[0083] The glove liner was encapsulated using a flexible TPU sheet
cover which was bonded to the glove liner using nip roll
lamination.
[0084] 24 volts DC was applied to the glove liner's terminals while
it was worn on a hand with no insulating shell. After 20 seconds,
the individual heaters closest to the user's skin were observed to
be at 37.degree. C. Individual heaters that were not in good
contact with the user (due to wrinkles in the glove liner) were
observed to be up to 52.degree. C. since the user's body rapidly
conducts heat away from the individual heaters in good contact.
[0085] 24V DC was applied to the glove liner when it was not worn
on a hand. The individual heaters were observed to be at a more
uniform 45-53.degree. C.
* * * * *