Surface heating system and method for producing it and a heatable object
A surface heating system consists of a support and a heating layer that contains an electrically conductive plastic. The heating layer is formed by a flexible film. A heatable object made as such a surface heating system. A method for producing a surface heating system, where a heating layer containing an electrically conductive plastic bonded to a support, and where the heating layer is formed by initially applying an electrically conductive, especially a foam plastic material onto the support and then hardening the plastic material on the support. Alternatively, the method produces a surface heating system with a heating layer of an electrically conductive plastic is bonded to a support. The heating layer is produced from an electrically conductive, especially a foam plastic material, and then arranged on the support. Another alternative of the method consists of bonding a heating layer with an electrically conductive plastic to a support. A fabric is produced as the support. Contact terminals from power supply wires are woven into the fabric when it is made or afterwards, and then a heating layer is applied to the support and the contact terminals.
1. A surface heating system comprising:
an air permeable support including a flexible fabric mesh layer having a plurality of fibers strands;
a flexible conductive heating layer, including an electrically conductive plastic affixed to the flexible layer of fibers of the air permeable support,
wherein the electrically conductive plastic contains:
about 20–35% of a rubber;
about 20–35% tetrahydrofuran;
about 5–25% graphite; and
about 20–35% of a polyurethane; and
a power supply wire including a contact terminal in electrical connection with the flexible conductive heating layer, wherein the contact terminal is positioned between the air permeable support and flexible conductive heating layer.
2. A surface heating system as set forth in claim 1 , wherein the air permeable support is formed from a woven or nonwoven fabric.
3. A surface heating system as set forth in claim 2 , wherein the air permeable support is made of a nonwoven fiber material.
4. A surface heating system as set forth in claim 1 , wherein the flexible conductive heating layer includes polyurethane, one-component polyurethane, cross linked one-component polyurethane, or PU foam.
5. A surface heating system as set forth in claim 1 , wherein the flexible conductive heating layer includes a UV-resistant, hydrolysable, and vapor-permeable plastic material.
6. A surface heating system as set forth in claim 1 , wherein the electrically conductive plastic includes graphite.
7. A surface heating system as set forth in claim 1 , further comprising a plurality of power supply wires each including contact terminals in electrical connection with the flexible conductive heating layer.
8. A surface heating system as set forth in claim 7 , wherein the contact terminals are positioned between the air permeable support and flexible conductive heating layer.
9. A surface heating system as set forth in claim 7 , wherein the contact terminals are positioned in the flexible conductive heating layer.
10. A surface heating system as set forth in claim 7 , wherein the contact terminals are affixed to the flexible conductive heating layer by stitching or gluing.
11. A surface heating system as set forth in claim 7 , further comprising a power control unit operably connected to the plurality of power supply wires.
12. A surface heating system as set forth in claim 7 , wherein the air permeable support is formed by a woven fabric and the contact terminals are positioned within the woven fabric.
13. A surface heating system as set forth in claim 1 , wherein the flexible conductive heating layer is formed directly on the air permeable support by spraying, rolling, or spreading.
14. A surface heating system as set forth in claim 1 , wherein the air permeable support is molded.
15. A surface heating system as set forth in claim 14 , wherein the air permeable support is molded to form portion of a mattress, a seat cushion, or a seat back.
16. A surface heating system as set forth in claim 1 , wherein the electrically conductive plastic contains:
about 30–70% graphite; and
about 30–70% aqueous polyurethane binder.
17. A surface heating system as set forth in claim 16 , wherein the electrically conductive plastic contains rubber.
18. A surface heating system as set forth in claim 1 , wherein the flexible conductive heating layer includes carbon fibers.
19. A surface heating system as set forth in claim 18 , wherein the flexible conductive heating layer consists of carbon fibers.
20. A beatable object, comprising a surface heating system as defined in claim 1 .
21. A heatable object as set forth in claim 20 , wherein the heatable object is a car seat.
22. A beatable object as set forth in claim 21 , wherein the heating layer is anatomically matched to a contacting portion of a user.
23. A beatable object as set forth in claim 20 , wherein the heatable object further comprises a cover covering the surface heating system.
24. A heatable object as set forth in claim 23 , wherein the cover is a material selected from the group consisting of a fabric, leather, synthetic material, and combinations thereof.
25. A surface heating system as set forth in claim 1 , wherein the air permeable support is formed from a nonwoven fabric and the electrically conductive plastic is a foam.
26. A surface heating system as set forth in claim 25 , wherein contact terminals are located between the support and the heating layer.
27. A surface heating system comprising:
an air permeable support including a flexible fabric mesh layer having a plurality of fiber strands;
a flexible conductive heating layer, including an electrically conductive plastic affixed to and at least partially surrounding each of the plurality of fiber strands, wherein the electrically conductive plastic contains:
about 20–35% of a rubber;
about 20–35% tetrahydrofuran;
about 5–25% graphite; and
about 20–35% of a polyurethane; and
a power supply including wire including a contact terminal, the contact terminal forming a plurality of electrical connections with the flexible conductive heating layer.
28. A surface heating material as set forth in claim 27 wherein the plurality of fiber strands are incorporated within the flexible conductive heating layer.
29. A surface heating material as set forth in claim 27 wherein the contact terminals are positioned within the plurality of fiber strands.
30. A surface heating material as set forth in claim 29 wherein the contact terminals are woven in the plurality of fiber strands.
31. A surface heating material as set forth in claim 27 further comprising a cover covering the flexible conductive heating layer.
32. A surface heating material as set forth in claim 27 , wherein the air permeable support is molded to form a portion of a mattress, a seat cushion, or a seat back.