1. Field of the Invention
An automated local thermal management system useful for adjusting and controlling the temperature of clothing.
2. Description of the Prior Art
Heated clothing has been used for many years to provide warmth to motorcycle riders and other outdoor enthusiasts. These systems are comprised of a garment that contains heating elements, a power source and a control mechanism to turn on/off the heaters. People engaged in other outdoor activities such as hunters, snowmobile riders, high-low drivers, construction workers, and golf enthusiasts can also benefit from these heated clothing systems. Simple on/off switches were originally used to control the heating elements. Rheostats started to replace switches as they provided a variable amount of heat, not simply on/off. Over time, digital controls that use pulse width modulation replaced rheostats as the preferred method of variable control.
A thermal management system is disclosed in U.S. Pat. No. 8,084,722 by Haas et al. that includes at least one heated clothing article including a plurality of wiring connectors for electrical connection. A first control device includes a processor. The first control device includes at least one output driver producing an output current and electrically connected to the processor and to a power source and to the heated clothing article for providing the output current to the heated clothing articles through the wiring connectors. However, there remains a need for a thermal management system that further reduces the required interaction between the user and the automated local thermal management system to achieve a requested warmth. Completely eliminating the need to manually control is desirable since the vehicle operator is faced with changes in ambient temperature along with wind chill due to vehicle speed while being challenged with the demands of operating the vehicle or other demands to his or her attention.
The invention provides for such an automated local thermal management system including at least one user input and a velocity input and at least one temperature input each in communication with the processor. The processor contains software instructions for monitoring and processing readings from the user input and the velocity input and the temperature input for varying the output current of the output driver in response to changes in the user input and the temperature input and the velocity input readings by the processor.
The subject invention provides an automated local thermal management system that automatically compensates for changes in ambient temperature and wind chill due to vehicle speed using a simplified control that provides for a much higher level of comfort, convenience and safety. Instead of having to adjust various knobs or controls for each heated clothing article separately, the user only needs to adjust temperature through a single automated local thermal management system. This provides the user with the luxury of not being required to interact with the automated local thermal management system as often as required in systems with separate controls or those that do not compensate for changes in ambient temperature and air velocity speed. These subject invention can also be used indoors to conserve energy by improving comfort in a wider than normal range of indoor temperatures.
Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a heated clothing wireless temperature control apparatus constructed in accordance with the subject invention is shown in the Figures.
Thermodynamics is the science of how thermal energy (heat) moves, transforms, and affects all matter. The first law of thermodynamics is a scientific law that states when mechanical work is transformed into heat, or when heat is transformed into work, the amount of work and heat are always equivalent. Energy cannot be created or destroyed, only altered. The second law of thermodynamics states when a temperature difference exists between two objects, thermal energy transfers from the warmer areas (higher energy) to the cooler areas (lower energy) until thermal equilibrium is reached. A transfer of heat results in either electron transfer or increased atomic or molecular vibration.
Energy, in a process called heat transfer or heat flow, is constantly flowing into and out of all objects, including living objects. Heat flow moves energy from a higher temperature to a lower temperature. The bigger the difference in temperature between two objects, the faster heat flows between them. When temperatures are the same there is no change in energy due to heat flow.
It is important to know how much supplemental heat is needed to theoretically keep a human body warm under specific conditions (e.g. typical motorcycle riding). Heat has the units of energy, which is a quantity. Heat flow has the units of power, which is the rate that energy is being transferred. In the real world you can't stop the heat flow. Energy is flowing into and out of your body, and everything else, all the time.
Since one of the goals in designing heated clothing is to delay or eliminate the onset of hypothermia, it is necessary to also have a reasonable understanding of hypothermia. Hypothermia is a medical emergency that occurs when your body loses heat faster than it can produce heat, causing a dangerously low body temperature. Normal body temperature is around 98.6 F (37 C). Hypothermia occurs as the body temperature passes below 95 F (35 C). Hypothermia is most often caused by exposure to cold weather or immersion in a cold body of water. Primary treatments for hypothermia are methods to warm the body back to a normal temperature.
To significantly prolong or completely eliminate the onset of hypothermia compared to the human body alone, a reasonable target would be the efficient conversion of 50 watts of electrical energy into heat in a human body using well placed, well designed heating elements. Since hypothermia is defined as a drop of 3.6° F., external heat flow can be used to delay or eliminate hypothermia.
Carbon nanotechnologies can have an inroad for heating elements. In Japan, Kuraray Living has developed a full-face heating fabric using CNTEC, a carbon nanotube coated electro conductive fiber. This fiber was co-developed with Hokkaido University and others. This product uses conventional technology for the polyester fibers and carbon nanotubes, a cutting-edge material, as a coating for the fibers. The nanotubes are applied using conventional dye-printing technology, with a carbon nanotube network forming on the surface of every filament in the multi-filament structure. The resulting fabric is thin, lightweight, flexible and soft, and has a high level of washing durability. To maximize the efficiency of the heating element, and reduce the “heat signature” in military applications, it is desirable to incorporate a thermal mirror.
The automated local thermal management system 20, generally shown, includes a plurality of heated clothing articles 22, generally indicated, each including a plurality of carbon filaments 24. While the heated clothing articles 22 in the preferred embodiment include heated jackets, gloves, pant liners, chaps, and socks, it should be appreciated that the automated local thermal management system 20 could be used to control various other items such as, but not limited to heated seats, heated mirrors or any other heated items that may come in contact by a user of the automated local thermal management system 20. Although carbon filaments 24 are utilized in the preferred embodiment, it should be appreciated that any conductive material that can be used as a heating generating medium such as metal, metal alloy, conductive polymer, carbon nanotubes or other alternative heating elements may be used instead. Open circuits or breaks in the carbon filaments 24 or in other alternative heat generating medium can cause undesirable “hot spots” due to remaining unbroken filaments conducting additional current due to the loss of the ability of the broken filament to carry its share of the current. Therefore, each carbon filament 24, carbon nanotube, or other heat generating filament may additionally be individually coated with an electrically insulating material in order to create a separate electrical conductor within the filament bundle for each individually insulated part and therefore provide safer failure modes, avoiding hot areas during wire breaks. The carbon filaments 24 are woven into the heated clothing articles 22 in a specific pattern based on a continuous curve (
Several data communication bus structures are used in today's vehicles to control a wide variety or electrical and electromechanical devices. Such bus structures include but are not limited to CAN bus (Controller Area Network) and LIN (Local Interconnect Network). LIN is often used as an in-vehicle communication and networking serial bus between intelligent sensors and actuators operating at 12 volts. Other auto body electronics include air conditioning systems, doors, seats, column, climate control, switch panel, intelligent wipers, and sunroof actuators. The LIN specification covers the transmission protocol and the transmission medium. Another common communications bus standard is CAN bus (or CANBUS). CAN provides a method for microcontrollers and devices to communicate with each other within a vehicle without a host computer. CAN bus is a message-based protocol, designed specifically for automotive applications but now also used in other areas such as aerospace, maritime, industrial automation and medical equipment. Many other common and proprietary bus systems would work with the microclimate control system. Other present or future data communication bus systems and methods may be used by the automated local thermal management system 20 to receive and transmit data.
As best shown in
At least one of the heated clothing articles 22 includes an interface cable 30 for attachment to personal electronic equipment 32 (e.g. smart phone, music player, etc.) to enable charging of the personal electronic equipment 32 while the personal electronic equipment 32 is safely stored in a pocket. The interface cable 30 (e.g. a USB interface) could also enable the personal electronic equipment 32 to communicate to the heated clothing article 22 and automated local thermal management system 20 via the USB interface, for example. The heated clothing article 22 also includes a lighted logo 34. The lighted logo 34 includes a plurality of integrated lighting elements (e.g. LEDs) woven into the fabric of the heated clothing article 22.
This automated local thermal management system 20 can be used by motorcycle riders as well as people engaged in other outdoor activities such as hunters, snowmobile riders, high-low drivers, construction workers, and golf enthusiasts. However, the automated local thermal management system 20 is not limited to these uses. The automated local thermal management system 20 may also be used to create a microclimate or personal climate in other applications such as a wheel chair with heated components, heated articles used with a convertible vehicle, or building or other enclosure that is kept cooler to conserve energy.
A first control device 36, generally indicated, includes an enclosure having an upper portion 38 and a lower portion 40 and an anterior portion 42 and a posterior portion 44 and a pair of walls 46 defining an inside chamber and defining a plurality of openings 48 extending into the inside chamber. The first control device 36 may be placed within one of the heated clothing articles 22. A first printed circuit board 50 is disposed in the inside chamber of the enclosure. A first microcontroller 52 (
A wiring socket 56 is attached to the first printed circuit board 50 and protrudes through one of the openings 48 disposed on the wall 46 of the enclosure. The pin out of the wiring socket 56 of the first control device 36 of preferred embodiment is as follows: Pins 1 and 2—power source, Pin 3—PWM Out1, Pin 4—PWM Out2, Pin 5—ID (Open=Jacket, GND=Pants), Pin 6—power source ground. The wiring socket 56 is electrically connected to the output drivers 28, the wiring connectors 26 of the heated clothing articles 22, and to the positive and negative terminal of a vehicle power source. The automated local thermal management system 20 of the preferred embodiment is powered from the vehicle, a portable/rechargeable battery pack, or a combination of vehicle power and battery pack via the wiring connector 26. However, it should be appreciated that power may alternatively be provided inductively. This inductive power could be provided through coils built into the vehicle and corresponding with coils integrated into the heated clothing articles 22, or could even be integrated into walls 46, floor, or ceiling of a building in which the automated local thermal management system 20 is being used. Because the first control device 36 is capable of detecting the type of power source, it can select a different running profile for each type of power source being used. For example, in the event that the first control device 36 and heated clothing articles 22 are using power from a battery pack, the first control device 36 will decrease the amount of power going to the heated clothing articles 22 in order to extend the life of the battery pack. The transition from wired or inductive power to operating exclusively with the battery pack is achieved seamlessly, the automated local thermal management system 20 automatically adjusts output current of the output drivers 28 depending on the power source available. However, the proposed control method does not allow the operator to plug the heated clothing into a power source without using a first control device 36.
In the preferred embodiment, the first control device 36 is connected to the heated clothing article 22 and is powered via internal wiring from either the vehicle or the battery pack. A battery charging circuit can be added to the first control device 36 to make a hybrid power source system. In this embodiment the heated clothing articles 22 are powered from a vehicle or a battery source. The vehicle power can be routed by the first control device 36 to both power the heated clothing articles 22 and recharge the battery pack simultaneously. Power is automatically prioritized based on if the first control device 36 detects it has battery power or vehicle power available. A reverse battery protection circuit 58 is attached to the first printed circuit board 50 and is electrically connected to the wiring socket 56 for protecting the first control device 36 from reversal of the positive terminal and negative terminal of the vehicle power source by disabling operation of the first control device 36. A voltage regulator 60 is attached to the first printed circuit board 50 and is electrically connected to the vehicle power source for regulating voltage supplied to the first control device 36. A voltage monitor 62 is attached to the first printed circuit board 50 and is electrically connected to the first microcontroller 52 and to the wiring socket 56 for monitoring the voltage of the vehicle power source. A first RF transceiver 64 (e.g. 433 Mhz) is attached to the first printed circuit board 50 and is electrically connected to the first microcontroller 52 for wireless communication. A first antenna 66 is attached to the first printed circuit board 50 and is electrically connected to the first RF transceiver 64 for transmitting a first radio frequency signal from the first RF transceiver 64 and for receiving radio frequency signals.
At least one status indicating device such as a Light Emitting Diode (LED) is attached to the first printed circuit board 50 and protrudes through one of the openings 48 disposed on the anterior portion 42 of the enclosure. In the preferred embodiment, one of these status indicating devices is a status LED 68. The status LED 68 is electrically connected to the first microcontroller 52 for visual feedback to a user of the status (e.g. power on/off) of the first control device 36. At least one reverse polarity LED 70 is attached to the first printed circuit board 50 and protrudes through one of the openings 48 disposed on the anterior portion 42 of the enclosure for providing visual status feedback to the user in response to the user reversing the attachment of the positive terminal and the negative terminal of the vehicle power source to the wiring socket 56. A plurality of heater output LEDs 72 are attached to the first printed circuit board 50 and each protrudes through one of the apertures disposed of the anterior portion 42 of the enclosure. Each of the heater output LEDs 72 are electrically connected to the first microcontroller 52 for visual feedback to the user of the output of the output drivers 28. Although the status indicating devices are all LEDs in the preferred embodiment, other devices such as, but not limited to light bulbs may be used instead.
The first memory of the first microcontroller 52 contains computer instructions for processing information received by the first RF transceiver 64 and by the Bluetooth transceiver 54 to control the status LED 68 and the heater output LEDs 72 and to generate a pulse width modulated (PWM) output to command the output drivers 28 in order to alter the temperature of the heated clothing articles 22. A plurality of zones are defined by the first memory of the first microcontroller 52 and each contains at least one of the heated clothing articles 22 (e.g. torso, hands, legs, and feet) for temperature adjustment of the heated clothing articles 22 by the first microcontroller 52. At least one output driver 28 is needed for each zone. More than one first control device 36 can be used. This could allow the integration of one first control device 36 into a jacket that can control the torso and hands and an additional first control device 36 in the pants to control the legs and feet. In the case of overalls, one first control device 36 could control all zones.
A second control device 74, generally indicated, includes a housing having a top 76 and a bottom 78 and a front 80 and a back 82 and a pair of sides 84 which define an interior cavity and a plurality of apertures extending into the interior cavity. The housing is designed to be exposed to atmospheric elements and the preferred embodiment conforms to Ingress Protection (IP67). The housing includes a pair of protrusions 86 each disposed adjacent to one of the sides 84 and extending outwardly from the back 82 of the housing (FIGS. 4,5, and 6). The protrusions 86 each define a longitudinal slot 88 extending from the top 76 of the housing to the bottom 78 of the housing. A flexible strap 90 (
A second printed circuit board 92 is disposed in the interior portion of the housing. A second microcontroller 94 (
directly. The buttons 96 are used to control power on/off, temperature in all of the zones (e.g. torso, hands, legs, and feet), and zone balance and pairing. A micro USB port 98 is attached to the second printed circuit board 92 and extends through one of the apertures disposed on the bottom 78 of the housing. The micro USB port 98 is electrically connected to the second microcontroller 94 for connection to a computer to reprogram, to configure settings, and for connection to an external power supply. A rechargeable mobile battery 100 is disposed in the interior portion of the housing and is electrically connected to the micro USB port 98 and to the second microcontroller 94 for providing electrical power to the second control device 74. The mobile battery 100 is recharged by the external power supply through the micro USB port 98.
A plurality of comfort setting LEDs 102 are attached to the second printed circuit board 92 and each protrudes through one of the apertures disposed on the top 76 of the housing. The comfort setting LEDs 102 are electrically connected to the second microcontroller 94 for visual feedback to the user in response to the user depressing the buttons 96 (i.e. the appropriate comfort setting LED 102 will light depending on the level setting of by the user). The five settings displayed by the LED's represent five “expectations of the operator” or “comfort settings” and are controlled by pressing the button 96. Each button 96 press can be programmed to actuate full step or parts of a step (½/, ¼, etc.). To indicate that the rechargeable mobile battery 100 state of charge is low, the comfort setting LED 102 in use at the time will blink to provide visual feedback to the user. Similarly, the lighting of the comfort setting LED 102 in use at the time provides visual status feedback to the user of activation of the second control device 74.
A light sensor 104 is attached to the second printed circuit board 92 and is aligned with one of the apertures disposed on the top 76 of the housing. It is electrically connected to the second microcontroller 94 for detecting ambient light and signaling the second microcontroller 94 to adjust the brightness of the comfort setting LEDs 102 (e.g. dimming during night use). A temperature input is also attached to the second printed circuit board 92 and electrically connected to the second microcontroller 94 for generating an electrical output proportional to an ambient temperature. In the preferred embodiment, this temperature input is a thermistor 106, however it should be appreciated that other alternative temperature inputs could be used. A second RF transceiver 108 is attached to the second printed circuit board 92 and is electrically connected to the second microcontroller 94 for wireless communication with the first control device 36. A second antenna 110 is attached to the second printed circuit board 92 and is electrically connected to the second RF transceiver 108 for transmitting a second radio frequency signal from the second RF transceiver 108 and for receiving the first radio frequency signal from the first antenna 66. By using a wireless control system the operator can place the control system in line-of-sight (e.g. second control device 74 on wrist of the operator or user), again reducing the time the vehicle operator spends making comfort adjustments. The wireless control also allows for the heated clothing article 22 to be worn outside of a second layer that can be used to protect or create the microclimate. This allows the operator to effectively add and subtract clothing layers with the push of a button. A velocity input is attached to the second printed circuit board 92 and is electrically connected to the second microcontroller 94 for transmitting a signal indicating a velocity of the housing to the second microcontroller 94. In the preferred embodiment, the velocity input takes the form of an accelerometer 112. Alternatively, a GPS receiver or microphone detecting environmental noise (e.g. wind noise) or any other means of sensing motion could be used instead of or in addition to the accelerometer 112 to determine velocity. This velocity sensing could also take the form of a CAN dongle 114 that may be attached to a diagnostic port of the vehicle and in communication with the vehicle to receive information such as vehicle speed directly from the vehicle to be used in adjusting the temperature of the clothing. Many users of smartphones enable velocity sensing, so this could also be provided by communications with the smartphone. This velocity sensing could also take the form of obtaining data from the vehicle's communications bus. One embodiment uses a CAN dongle 114 that may be attached to a diagnostic port of the vehicle and in communication with the vehicle to receive information such as vehicle speed directly from the vehicle to be used in adjusting the temperature of the clothing. The CAN dongle 114 can read CAN messages such as, but not limited to vehicle speed and send real time data, either by wire or wirelessly to the second control device 74. Other data can be provided includes user control and settings for the microclimate control system. In these instances vehicle operators can repurpose or multi-purpose the existing vehicle controls or develop dedicated controls to communicate messages to the automated local thermal management system 20 through the vehicle bus system. The CAN dongle 114 will also act as a pass through so that other CAN systems may be attached. Using the existing vehicle communications bus or providing a dedicated bus to communicate with the local thermal management system 20 components such as heated clothing articles 22, seats and backrests is desirable to ensure the highest levels of automation for user comfort, convenience and safety. A slower more cost effective bus structure such as LIN bus may also be used. Similarly, if a smartphone, tablet or Bluetooth enabled personal electronic equipment 32 is in communication with the first control device 36 through the Bluetooth transceiver 54 or through a the interface cable 30, velocity sensing could be done by utilizing the GPS receiver and/or accelerometers 112 built into many smartphones or tablets. In an embodiment in which the automated local thermal management system 20 is used in a building or other enclosure that is kept cooler to conserve energy, this communication with a smartphone or tablet could also provide the ability for the automated local thermal management system 20 to detect if the user has walked into or out of a building. This would allow the automated local thermal management system 20 to adjust the temperature of the heated clothing articles 22 accordingly.
The second memory of the second microcontroller 94 contains software instructions for monitoring the buttons 96, the accelerometer 112, the thermistor 106, and the light sensor 104 and processing and transmitting a PWM request to the first control device 36. Additionally, sensors may also be included for Rehman input (e.g. pulse rate, skin temperature, etc.) or in the heated clothing articles 22 to provide additional information to the first control device 36. The second control device 74 sends information back 82 to the first control device 36 so the communication is bi-directional. Two way communication is needed for a “sleep mode” function to save the run time of the mobile battery 100 of the second control device 74. The second memory is reprogrammable using a personal computer 116 connected to the micro USB port 98. Using the micro USB port 98 and a proprietary encryption algorithm, firmware updates can be provided by a dealer sales network and directly from a website using the micro USB port 98 to both the second control device 74 as well as the first control device 36 via the second control device 74 (or via the first control device 36 if connected through the Bluetooth transceiver 54 of the first control device 36). This will allow both the first control device 36 and second control device 74 to be upgraded in the field.
The second memory also includes a Pulse Width Modulation (PWM) algorithm and a plurality of PWM lookup tables for processing adjustments to the output current of the output drivers 28 of the first control device 36 and the PWM request is communicated to said first control device 36 by the second RF transceiver 108. PWM algorithm computation is minimized with the use of lookup tables. The PWM algorithm of the second memory controls the output temperature of the heated clothing articles 22. The lookup tables are generated in advance on a personal computer 116, much like an ignition or injection table for an Engine Control Unit (ECU). The final settings for the pulse width modulation are derived from an algorithm that compensates for a variety of inputs in the preferred embodiment such as ambient temperature from the temperature input, vehicle speed from the velocity input, vehicle voltage level from the voltage monitor 62, buttons 96 of the second control device 74, and zone controls 118 to determine the output current of the output drivers 28 of the first control device 36. The final PWM output is also affected by the input voltage detected by the voltage monitor 62 and is reduced if there is an over-voltage condition detected. The PWM algorithm operates in at least three heating modes including but not limited to: burst mode which provides an initial heat sensation to the user, re-comfort mode which adjust the amount of heat or cooling when the user is too cold or too hot, and maintenance mode which meets the users current level of comfort. The PWM algorithm may also utilize other inputs, including but not limited to Rehman inputs (i.e. human body sensing such as skin temperature and pulse rate), and temperature of the carbon filaments 24. The PWM algorithm may optionally adjust the final settings for the pulse width modulation based on the power source type (rechargeable battery pack or vehicle power). Different zone profiles are used if the heated clothing article 22 is powered from a battery pack than the profiles that are used if it is plugged into the vehicle. In this manner battery power can be conserved and optimize the temperature of the hands or feet if the operator prefers. As the user continues to adjust heat settings, the second control device 74 will begin to learn their personal preferences and adapt to ensure that base settings will provide the maximum level of comfort. This includes but is not limited to adjust the PWM for time of day, personal heat preference, as well as before and after meals.
In the case where the outer layer of clothing is not the same as the heated clothing article 22, the first control device 36 and second control device 74 communicate wirelessly. An alternate approach is used for heated clothing articles 22 where the carbon filaments 24 and protective outer layer are incorporated into one garment. In this garment configuration a lower cost wired system can exist between the first control device 36 and the second control device 74. In the case of a wired system, power for the second control device 74 is received through wiring in the heated clothing articles 22 and communication between the first control device 36 and second control device 74 is achieved using a controller area network (CAN Bus) or other wired communications scheme. For example, the second control device 74 could be connected to a connector (e.g. USB) in the heated clothing article 22 (e.g. sleeve of a jacket) which then is connected to the first control device 36. Additionally, communication between the heated clothing articles 22 could be achieved using a CAN bus or other communications network.
The first control device 36 and second control device 74 can be configured using either a personal computer 116 (
A plurality of inputs including vehicle speed, vehicle voltage, ambient temperature, weather, light sensing (sun load), heating element temperature, heating element junction temperature, human skin temperature, human pulse, zone settings, and comfort settings available to the automated local thermal management system 20 through the variety of sensors, wireless controls, analog to digital inputs, smartphones and bus systems. Automation is achieved using these inputs to define the PWM output algorithm. To achieve a high level of automation (minimal user interaction), the PWM algorithm is optimized for safety, comfort and convenience. Determining safe operation modes is the first priority of the PWM algorithm. For example, in the example embodiment described above, if the input supply voltage is too high for the specific heating elements used in the system, then the PWM output is either limited or turned off entirely. Similarly if the ambient temperature is too high for safe full power operation then the PWM is limited or turned off entirely. When the PWM is in an active output state the above embodiment then alters the PWM output based on the vehicle speed, zone bias settings, comfort settings and light sensing. Further refinement of the PWM output comes from learning the user preferences. For example in the above embodiment changes to the comfort settings are stored and analyzed to adjust the center point further reducing the need for future interaction with the automated local thermal management system 20. In this way the above embodiment demonstrates automation is based on function, design and learning from customer preferences.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims. The use of the word “said” in the apparatus claims refers to an antecedent that is a positive recitation meant to be included in the coverage of the claims whereas the word “the” precedes a word not meant to be included in the coverage of the claims. In addition, the reference numerals in the claims are merely for convenience and are not to be read in any way as limiting.
This application claims the benefit of provisional application Ser. No. 61/830,416 filed Jun. 3, 2013.
Number | Date | Country | |
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61830416 | Jun 2013 | US |