Heater for automotive vehicle and method of forming same

1. A heated seat comprising:

a) a seat including a trim layer over a cushion that includes a trench, and

b) a heater disposed between the trim layer and the cushion, the heater including:

i) a polymeric film flexible carrier including a lateral side edge that has a cutout geometry that defines an indentation that projects inwardly from the lateral side edge, and the cutout aligns with the trench;

ii) a first conductive medium screen printed upon the carrier wherein the first conductive medium includes:

1) a negative section having a plurality of first extensions;

2) a positive section having a plurality of second extensions; and

3) a base portion on the plurality of first extensions and the plurality of second extensions; and

iii) a second screen printed conductive medium that includes a plurality of strips, each of the strips in overlapping relation with one of the plurality of first extensions and one of the plurality of second extensions, the plurality of strips also extending parallel to the first and second extensions, the second conductive medium exhibiting a positive thermal coefficient;

iv) a protective polymeric dielectric coating with a thickness of between 100 microns and 3 millimeters disposed over the first conductive medium and the second conductive medium;

v) an insulation layer; and

vi) an electric connection attached to the base portion for wiring the heater to a power source;

wherein the heater includes one or more through-hole openings in generally parallel alignment with a portion of the cutout for aiding the bending of the heater so that the heater conforms to contours of the seat cushion and resides in the trench, and the cutout geometry is such that stress upon the first conductive medium is relieved when the heater is curved about the seat cushion and is extended at least partially into the trench.

2. An article as in claim 1 , wherein the flexible carrier has an hour-glass shape.

3. An article as in claim 2 , wherein the one or more through-hole openings is centralized and adjacent to the cutout.

4. An article as in claim 1 , wherein the electric connection includes a first electrical connection and a second electrical connection.

5. An article as in claim 4 , wherein the only electrical connections of the heater are the first electrical connection and the second electrical connection.

6. An article as in claim 1 , wherein the plurality of strips are uniformly spaced apart from each other.

7. An article as in claim 1 , wherein each strip of the plurality of strips has the same shape.

8. An article as in claim 1 , wherein each strip has a continuous density throughout.

9. An article as in claim 1 , wherein the flexible carrier is formed of a material having a dielectric constant greater than 1.

10. An article as in claim 1 , wherein the flexible carrier is formed of a material having an elongation at failure greater than 15 percent.

11. An article as in claim 1 , wherein the flexible carrier is formed of a material having an elongation at failure greater than 50 percent.

12. An article as in claim 1 , wherein the polymeric film flexible carrier is polyester.

13. An article as in claim 1 , wherein the insulation layer is fleece.

14. An article as in claim 1 , wherein the first conductive medium or the second conductive medium is geometric.

15. An article as in claim 1 , wherein the first conductive medium or the second conductive medium is contoured.

16. An article as in claim 1 , wherein the insulation layer is laminated over the first conductive medium, the second conductive medium, and the protective polymeric dielectric coating.

17. A heated seat comprising:

a) a seat including a trim layer over a cushion that includes a trench, and

b) a heater disposed between the trim layer and the cushion and being attached to the cushion with a tie string, the heater including:

i) a polymeric film flexible carrier including a lateral side edge that has a cutout geometry that defines an indentation that projects inwardly from the edge, and aligns with the trench;

ii) a first conductive medium screen printed upon the carrier wherein the first conductive medium includes:

1) a negative section having a plurality of first extensions;

2) a positive section having a plurality of second extensions; and

3) a base portion on the plurality of first extensions and the plurality of second extensions; and

iii) a second screen printed conductive medium that includes a plurality of strips, each of the strips in overlapping relation with one of the plurality of first extensions and one of the plurality of second extensions, the plurality of strips also extending parallel to the first and second extensions, the second conductive medium exhibiting a positive thermal coefficient;

iv) an insulation layer; and

v) an electric connection attached to the base portion for wiring the heater to a voltage source;

wherein the heater includes one or more elongated through-hole openings generally aligned with the cutout, including at least one generally centralized opening, for aiding the bending of the heater so that the heater conforms to contours of the seat cushion, and the cutout geometry is such that stress upon the first conductive medium is relieved when the cutout of the heater is extended at least partially into the trench and attached with the tie string.

18. The heater as in claim 17 , wherein a voltage applied to the heater is variable.

19. The heater as in claim 17 , wherein the flexible carrier includes an hour-glass shape.

20. The heater as in claim 17 , wherein the at least one generally centralized through-hole opening is generally rectangular.

21. The heater as in claim 17 , wherein the electric connection includes a positive terminal riveted to the positive section base portion, a negative terminal riveted to the negative section base portion, and a wire attached to the positive terminal and the negative terminal connecting each to the voltage source.

22. The heater as in claim 17 , further including a protective polymeric dielectric coating with a thickness of between 100 microns and 3 millimeters disposed over the first and second conductive mediums.

23. A heated seat comprising:

a) a seat including a trim layer over a cushion that includes a trench, and

b) a heater disposed between the trim layer and the cushion and being attached to the cushion with a tie string, the heater including:

i) a polymeric film flexible carrier including a lateral side edge that has a cutout geometry that defines at least one hourglass shape and includes an indentation that projects inwardly from the edge, and the cutout aligns with the trench;

ii) a first conductive medium screen printed upon the carrier wherein the first conductive medium includes:

1) a negative section having a plurality of first extensions;

2) a positive section having a plurality of second extensions; and

3) a base portion on the plurality of first extensions and the plurality of second extensions; and

iii) a second screen printed conductive medium that includes a plurality of strips, each of the strips in overlapping relation with one of the plurality of first extensions and one of the plurality of second extensions, the plurality of strips also extending parallel to the first and second extensions, the second conductive medium exhibiting a positive thermal coefficient;

iv) an electric connection attached to the base portion for wiring the heater to a voltage source;

wherein the heater includes one or more elongated through-hole openings adjacent to a portion of the cutout, including at least one generally centralized elongated opening, and an opening between the indentation and the generally centralized elongated opening that includes a portion that runs generally parallel with the generally centralized elongated opening and the edge defining the indentation, the geometry of the heater being selected so that stress is relieved when the cutout of the heater is extended at least partially into the trench and attached with the tie string.

24. The heater of claim 23 , further including a protective polymeric dielectric coating with a thickness of between 100 microns and 3 millimeters disposed over the first and second conductive mediums.

25. The heater of claim 23 , further including an insulating layer.