Heater connector with temperature sensor

Abstract

A heating device for a vehicle seat heater that includes a carrier configured with one or more heating wires; a connector having one or more power wires and one or more temperature sensors, and configured to electrically connect the one or more heating wires to a controller or power source, the one or more temperature sensors are configured to respond to heat generated by the one or more power wires within the connector and provide one or more signals to the controller or power source to d estimate or determine a temperature generated by the one or more heating wires on the carrier.

Description

HEATER CONNECTOR WITH TEMPERATURE SENSORCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to US 63 / 665,307 filed on June 28, 2024 and to US 63 / 722,266 filed on November 19, 2024, the entireties of which are all hereby incorporated by reference herein for all purposes.FIELD

[0002] These teachings relate to a connector, a heater, a vehicle seat heater, and, more particularly, to a heater connector and / or a vehicle seat heater connector for a vehicle seat with one or more temperature sensors.BACKGROUND

[0003] Some vehicle seats include one or more amenities for improving occupant comfort. For example, some vehicle seats include one or more heating devices to provide heating functions to an occupant of the vehicle seat.

[0004] Some vehicle seat heaters include a flexible heating mat or carrier that supports one or more heating elements and one or more temperature sensors. During the assembly of such a vehicle seat heater, the placement or location of a temperature sensor on the carrier relative to the heating element may vary, which may impact the accuracy of temperature readings of the heating element by the temperature sensor. Also, due to the flexible nature of the heating mat or carrier, ensuring a secure connection of a temperature sensor on the heating mat or carrier may be burdensome and / or costly. Due to repeated weight loading and unloading on a vehicle seat during use, the attachment of the temperature sensor on the heating mat carrier may become lose or fail, which may have an impact on temperature sensing altogether. Accordingly, improvements may be desired.SUMMARY

[0005] These teachings provide a connector, a heater, a vehicle seat heater, and, more particularly, a heater connector and / or a vehicle seat heater connector with one or more temperature sensors.

[0006] A heating device according to these teachings for a vehicle seat heater includes a carrier configured with one or more heating wires; a connector having one or more power wires and one or more temperature sensors, and configured to electrically connect the one or more heating wires to a controller or power source, the one or more temperature sensors are configured to respond to heat generated by the one or more power wires within the connector and provide one or more signals to the controller or power source to d estimate or determine a temperature generated by the one or more heating wires on the carrier.

[0007] A connector according to these teachings for connecting one or more heating wires on a carrier to a controller or power source, the connector includes a base; one or more power wires situated on the base; and one or more temperature sensor wires situated on the base; the connector is configured to electrically connect the one or more heating wires on the carrier to the controller or power source via the one or more power wires, the one or more temperature sensor wires are configured to respond to heat generated by the one or more power wires within the connector and provide one or more signals to the controller or power source to estimate or determine a temperature generated by the one or more heating wires on the carrier.

[0008] The connector according to these teachings includes one or more temperature sensors. These temperature sensors are configured to generate or provide signals, data, or information relating to a reference temperature for understanding the temperature of the one or more heating elements on the carrier. The reference temperature may be based on a temperature within the connector, on the carrier, or both. A controller, power source, computer, processor, or the like such as machine learning, deep learning, a look up table, algorithm, etc., may be configured to calculate or determine or estimate a temperature of the one or more heating elements on the carrier using the reference temperature from within the connector. Accordingly, by including one or more temperature sensors in the connector, it may be possible to eliminate one or more temperature sensors from or on the carrier that contains the one or more heating elements. However in some embodiments disclosed herein, one or more temperature sensors or thermistors may be located on the carrier but may be securely attached thereto to prevent separation of the thermistor or temperature sensor from the carrier.

[0009] The heater may be configured to provide heating functions or effects to an occupant of a vehicle or vehicle seat. In some configurations, the heater may be incorporated into other vehicular surfaces, such as a steering wheel, console, door panel, headliner, dashboard, etc. Insome configurations, the heater may be incorporated into non-vehicular applications, such as a heating pad or mattress, medical pad, blanket, cushion, or other medical heating device, a home or office chair or couch, a jacket or other clothing, a wheelchair, etc. Accordingly, the vehicle seat heater may also be referred to simply as a heater. Similarly, the connector described herein is not especially limited to vehicular and / or vehicular seat applications. Instead, these teachings can be incorporated into other systems or devices that are not vehicular-related, such as those previously described.

[0010] The heater and / or one or more of the elements of the heater may include features described in: US 7,560,670; US 7,223,948; US 6,838,647; US 6,710,303; US 6,150,642; US 20200406797; and US 2010 / 0289303; all of which are expressly incorporated herein by reference for all purposes.

[0011] According to these teachings, a connector is disclosed for connecting a heater to a controller and / or a power source, the heater includes a carrier that supports one or more heating elements. The connector comprises a housing comprising a base; one or more temperature sensors supported on the base and configured to monitor or provide information relating to a temperature of the one or more heating elements and / or power wires in the connector; and one or more power wires supported on the base and configured to provide power from the controller and / or the power source to the one or more heating elements and to the one or more temperature sensors. An associated method of making or assembling a connector and heater is disclosed in these teachings. A heater comprising a connector according to these teachings is disclosed. A vehicle seat comprising a heater and connector according to these teachings is also disclosed.

[0012] One or more connectors may be used to connect the heater to the controller or power source. The controller or power source may be or may be part of a vehicle, a computer, a vehicle computer, a battery, an engine, HVAC controller, vehicle ECU, etc. The one or more connectors may provide an interface through which electrical power and signals are communicated between the power source, the controller, the one or more heating elements, the one or more temperature sensors, and any other components of the vehicle seat heater.

[0013] The one more connectors may include a region that includes one or more temperature sensors and / or thermistors. The one or more temperature sensors may generate a signal or data representative of a reference temperature within the connector or on the carrier of the heater in response to the supply of electrical energy or power thereto via the one or more power wires. Forexample, the one or more temperature sensors or thermistors may determine, measure, or correlate a temperature generated by one or more heating wires or power wires that are located in the connector, on the carrier, or both. In some configurations, the one or more temperature sensors or thermistors may be located on the carrier. In some configurations, the one or more temperature sensors or thermistors may be located only on the carrier. In some configurations, the one or more temperature sensors or thermistors may be located only on or in the connector. In some configurations, one or more of the temperature sensors or thermistors may be located in the connector and one or more temperature sensors or thermistors may be located on the carrier. The reference temperature may be used to estimate or identify the amount of heating power that is generated by the one or more heating elements on the carrier or substrate or in the connector that is supplied with the same electrical power from the controller power source.

[0014] Advantageously, in configurations where the temperature sensor or thermistor is in the connector, the reference temperature can be obtained from temperature sensors that are securely attached or concealed within the connector housing. As compared to other prior devices that include a temperature sensor attached or secured to the carrier or substrate material, the temperature sensor according to these teachings is less prone to failure due to separation or movement of the temperature sensor on the carrier or substrate in those other known devices. Moreover, because the wires associated with the temperature sensor are securely attached to the wires associated with the power wire within the connector by way of the cover projections pushing and holding the wires against each other within the connector, a secure electrical connection is maintained therebetween. The connector may be made from a suitable material, such as a plastic, plastic resin, a 3D printed material, or a composite material. The connector may be plastic injection molded or 3D printed. The connector may be made from a single housing or structure, or may be made from two or more structures that are joined together via one or more fasteners. The connector may be secured or attached to the structure of the carrier via one or more of any of the fasteners disclosed herein.

[0015] The heater device and / or the connector may include one or more heating elements. The one or more heating elements may be one or more resistive wires or conductors that are arranged on, below, and / or are integrated into a thickness of the carrier or substrate material. The one or more heating elements may be configured to be supplied with power from acontroller and / or power source via the one or more power wires extending into and through the connector.

[0016] The heater device and / or the connector may include one or more temperature sensors. The one or more temperature sensors may be one or more thermistors, one or more negative coefficient resistors (NTC), one or more positive temperature coefficient resistors (PTC), one or more heating elements, one or more reference heating elements, or a combination thereof. The one or more temperature sensors may be a glass negative coefficient resistors (NTC), or glass- encapsulated NTC. The one or more temperature sensors may be a thermistor that is sealed in an airtight glass bubble. The one or more temperature sensors function to measure a temperature of the heater, the heating element, or both. The one or more temperature sensors may provide one or more signals or measurements to a controller, and the controller may regulate the temperature of the heater, the amount of power supplied to the heating element, or both based on the one or more signals or measurements.

[0017] The one or more temperature sensors or temperature sensor wires may be located within or secured within the connector. More specifically, the one or more temperature sensors or wires connecting the temperature sensor may be secured to the housing of the connector, to the base of the connector, the cover of the connector, or a combination thereof. The one or more carriers or substrates on which the one or more heating elements are located is preferably free of a temperature sensor or NTC. However, in some configurations, the carrier or substrate may include a temperature sensor or NTC. This may allow one or more of the temperature sensors to function as a backup, reference, or check sensor, for ensuring accurate temperature sensing. The one or more temperature sensors or NTCs may be configured to be supplied with power from a controller and / or power source via the one or more power wires extending into and through the connector.

[0018] The connector may include one or more terminals, pins, connectors, crimps, and / or leads. The one or more terminals, pins, connectors, crimps, and / or leads may be electrically connected to a controller or power source. The one or more heating elements or wires may be directly connected to the terminals, pins, connectors, crimps, and / or leads, or may be connected thereto with a suitable electrical connector. The one or more temperature sensors or thermistors or temperature sensor wires may be directly connected to the one or more terminals, pins, connectors, crimps, and / or leads, or may be connected thereto with a suitable electrical connector

[0019] The heater device may include one or more substrates or carriers. A carrier may be configured as a base, sheet, panel, and / or substrate onto which or in which one or more elements of the vehicle seat heater are attached or supported on. The carrier may be flexible and / or configured to conform to various supporting and / or adjacent geometries of the vehicle, vehicle seat, and / or other adjacent structure. However, in some configurations, the carrier may be made from a substantially rigid material. The carrier may be made of a suitable material, which may be, or may be comprised of, one or more fabric, fleece, felt, polyester, a polyester point bond material, a woven material, a non-woven material, a polymer, plastic, metal, thermoset, an elastomer, high density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), synthetic fibers, polyethylene terephthalate, cotton, or any combination thereof.

[0020] The carrier may be provided in a myriad of shapes and sizes, which may depend on one or more factors such as the vehicle seat design, regions that are intended to be and not intended to be temperature controlled or heated by the heater. The carrier may include one or more heating elements.

[0021] Reference is made herein to one or more fasteners herein. The one or more fasteners may be used to secure the one or more heating elements to the substrate or carrier, may be use to secure the one or more power wires to the connector, may be used to secure the one or more temperature sensors or temperature sensor wires to the connector, may be used to secure the pieces of the connector together (i.e., the cover and the base), may be used to secure the base or connector to the substrate, may be used to secure the heater to the vehicle seat, such as to the frame or suspension in the vehicle seat or to the cushion of the vehicle seat, or any combination thereof. The one or more fasteners may be or may include one or more screws, adhesives, tapes, double sided tapes, patches, pressure sensitive adhesives, welds, RF welds, vibration welds, heat stakes, clips, hook on loop fasteners, sewing, stitching, glues, epoxies, rivets, screw bosses and screws extending therethrough, living hinges (i.e., as illustrated and described in Figs. 7 and 8), or any combination thereof.BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Fig. 1 is a side view of a vehicle with a vehicle seat and a heater.

[0023] Fig. 2 is a schematic top view of a heater and connector.

[0024] Fig. 3 is a perspective view of a base of the connector.

[0025] Fig. 4 is a perspective view of a base of the connector and a temperature sensor.

[0026] Fig. 5 is a perspective view of a base of the connector, a temperature sensor, and a power wire.

[0027] Fig. 6 is a perspective section view of a connector taken along line 6-6 in Fig. 2

[0028] Fig. 7 is a perspective view of a connector, with the cover in a closed position.

[0029] Fig. 8 is a perspective view of the connector of Fig. 7, with the cover in an open position.

[0030] Fig. 9 is a schematic top view of a heater and connector.

[0031] Fig. 10 is a schematic top view of a heater and connector.DETAILED DESCRIPTION

[0032] Fig. 1 illustrates a vehicle 10. The vehicle 10 comprises one or more vehicle seats 12. A vehicle seat 12 comprises a seating portion 14 and a backrest portion 16. The vehicle seat 12, the seating portion 14, and / or the backrest portion 16 may include one or more heating devices 18, which may also be interchangeably referred to as one or more vehicle seat heaters or heating devices 18.

[0033] Fig. 2 illustrates a vehicle seat heating device 18. The vehicle seat heating device 18 may be configured to provide a heating function or effect to an occupant of a vehicle or vehicle seat. In some configurations, the vehicle seat heating device 18 may be incorporated into other vehicular surfaces, such as a steering wheel, console, door panel, headliner, dashboard, etc. In some configurations, the vehicle seat heating device 18 may be incorporated into non-vehicular applications, such as a heating pad or mattress, a medical heating pad or blanket, a home or office chair or couch, a jacket or other clothing, a wheel chair, medical pad or blanket, etc. Accordingly, this is why the vehicle seat heating device 18 may also be referred to as a heating device 18 when part of non-vehicular applications and / or non-vehicle seat applications.

[0034] The heating device 18 may include one or more carriers 20. A carrier 20 may be or may be configured as a base, sheet, panel, support, and / or substrate onto which, at which, and / or in which, one or more elements of the heating device 18 are attached or supported on. The carrier 20 may be flexible and / or configured to conform to various supporting and / or adjacent geometries of the vehicle, vehicle seat, and / or other adjacent structure. However, in some configurations, the carrier 20 may be made from a substantially rigid material that is not flexibleand / or conformable. The carrier 20 may be made of a suitable material, which may be, or may comprise, one or more fabric, fleece, felt, polyesters, foam, polyester point bond materials, a woven material, a non-woven material, a plastic or resin material, a spunbond material, or any combination thereof. The carrier 20 may be provided in a myriad of shapes and sizes, which may depend on one or more factors such as the surrounding structure in which the heater is used, regions that are intended to be and not intended to be temperature controlled or heated by the heating device 18, etc.

[0035] The heating device 18 may include one or more heating elements 22. The one or more heating elements 22 may be one or more wires, resistive wires, conductors, or heat generating elements that are arranged at, on, below, and / or are integrated into a thickness of the carrier 20 material. The shape of the one or more heating elements 22 may be provided in a myriad of configurations, which may also depend on one or more factors like the vehicle seat design and / or regions intended to be heated and not heated. For example, the one or more heating elements 22 may be one or more resistive wires that wind, meander, zigzag, etc. on the carrier 20. The one or more heating elements 22 may be secured to the carrier via any suitable fastener, such as any of the fasteners disclosed herein (e.g., adhesive, sewing, pressure sensitive adhesive, tape, etc.). The one or more heating elements 22 may be configured to be supplied with power via a connector 28 and from a controller and / or power source 24. The controller or power source 24 may be directly or indirectly connected to the one or more heating elements 22 via a connector 28 and / or power wires 34, and then generate heat in response to the supply of power. The heat generated by the heating device and / or the one or more heating elements 22 may warm or increase a surface temperature of the vehicle seat and thus provide warmth to an occupant.

[0036] The controller and / or power source 24 may comprise a battery, a vehicle battery, an AC power source, a DC power source, a computer, a processor, the vehicle, the vehicle ECU, the vehicle HVAC system or controller, a wall outlet, the like, or any combination thereof.

[0037] The one or more power wires 34 in the connector 28 may be the same as the one or more heating wires 22 on the carrier 20. This means, the one or more heating wire 22 may extend on the heating mat or carrier 20 and continuously extend into the connector 28 and ultimately terminate at the heating wire pins 35 (See e.g., Fig. 5). In other configurations, the one or more power wires 34 may be separate wires from the one or more heating wires 22 andconnected thereto inside the connector 28 or outside of the connector (e.g., on the mat or carrier 20).

[0038] The heating device 18 may include one or more temperature sensors. Referring to the subsequent figures generally, the one or more temperature sensors 26 may be configured to determine, sense, change, monitor, measure, and / or correlate a temperature or heat generated by the one or more heating elements 22 and / or power wires 34. The one or more temperature sensors 26 may be or may include one or more thermistors 52. The one or more temperature sensors 26 or thermistors 52 may be one or more NTC thermistors (Negative Temperature Coefficient sensor). An NTC thermistor may be a non-linear resistor, which may alter its resistance characteristics with temperature. More specifically, a resistance of an NTC thermistor may decrease as the temperature or heat generated by the heating elements 22 and / or power wires 34 increases. The one or more temperature sensors 26 may provide data or one or more signals to a computer or processor for determining, correlating, measuring, and / or estimating a temperature of the heat generated by the one or more heating elements 22 or power wires 34. The one or more temperature sensors 26 may be any other suitable sensor that is configured to suitably perform one or more of the temperature sensing functions described and / or gleaned herein. The one or more temperature sensors 26 may be one or more PTC thermistors.

[0039] The one or more temperature sensors 26 may be located within the connector 28. The one or more temperature sensors 26 may be positioned or arranged adjacent to the one or more power wires 34 in the connector 28. The one or more temperature sensors 26 may measure, monitor, correlate, and / or be used to determine the amount of heat generated by the heating elements 22 on the carrier 20 by monitoring or responding to the heat generated by the power wires 34. In other words, one or more signals may be provided by the one or more temperature sensors 26 to the controller or power source representing the temperature and / or heat generated by the one or more power wires 34 in the controller. The power source or controller may correlate those signals (via algorithm, look-up table, machine learning, deep learning, computer, processor, etc.) to the temperature being generated by the one or more heating wires 22 on the carrier 20.

[0040] In some previously developed thermal or heating systems, to determine a temperature of the heating wires on the carrier, one or more temperature sensors are provided on or in a carrier of the heater, in a region at, near, or adjacent to one or more heating elements. However,during mass assembly and / or manufacturing of such vehicle seat heaters, the location of the temperature sensor relative to the heating element may vary, which may have an impact on the accuracy temperature readings of the heating element. Moreover, due to the flexible nature of the carrier, ensuring a suitable connection of the temperature sensor on the carrier and / or power supply wires may be burdensome and / or costly. Furthermore, due to the repeated use and weight loading and unloading on the vehicle seat, the attachment of the temperature sensor on the carrier and / or connection to the one or more power wires may fail, which may have an impact on temperature sensing altogether. Therefore, the vehicle seat heater 18 according to these teachings may provide a solution to some of the deficiencies in the field by incorporating the one or more temperature sensors into the connector and fixing the sensors in a position relative to the heating wires that can be reproduced during mass assembly. Accordingly, the repeatability and reliability of the temperature sensor readings are made more consistent and reliable.

[0041] For example, the vehicle seat heating device 18 according to these teachings may be free of any temperature sensors attached to or supported on the carrier or mat where the one or more heating elements 22 are located. Instead, the one or more temperature sensors are arranged and secured to or within the connector 28. The connector 28 may be placed or provided in a non-active area of the vehicle seat that does not see much movement or weight loading and unloading during use. The connector 28 may include a rigid base or support structure that may help ensure a stable and suitable connection of or between the one or more temperature sensors and power wires that may prevent separation or disconnection thereof that may occur due to repeated use, loading, and unloading of the vehicle seat and / or a weak or faulty connection therebetween during the assembly and / or manufacturing process of the heater and / or connector. The connector 28 may be attached to the carrier or mat 20. The carrier 28 may be free of being attached to the carrier or mat 20 and may instead be located a distance away from the carrier or mat 20. This may allow the connector 28 to be located or placed in a safe and / or secure location away from active weight loading and unloading in the vehicle seat (e.g., an occupant entering and exiting the vehicle).

[0042] In some configurations, one or more temperature sensors may be provided on the carrier and in addition to being provided in or on the connector 28. Such a configuration may provide additional temperature sensors, which may be advantageous to have one or more backupor redundant sensors in case one or more sensors fail over time and / or to be used as a check or verification sensor to ensure the sensors and / or heater are functioning properly.

[0043] The vehicle seat heating device 18 may include one or more connectors 28. A connector 28 may function to connect and / or to provide an interface or communication device through which power and / or communication signals can be communicated to or between the vehicle seat heating device 18, the one or more heating elements 22, the one or more temperature sensors 26, the vehicle 10, vehicle ECU, vehicle HVAC system, and / or the controller or power source 24. The connector 28 may be one or more plugs, ports, receptacles, ports, or a combination thereof.

[0044] With additional reference to Figs. 3-9, the connector 28 comprises a housing 30 comprising a base 32; one or more temperature sensors 26 configured to monitor or provide information relating to a temperature of the one or more heating elements 22 or power wires 34 or generated by the one or more heating elements 22 or power wires 34; and one or more power wires 34 configured to provide power from the controller and / or the power source 24 to the one or more heating elements 22 and / or to the one or more temperature sensors 26. In other configurations, the one or more temperature sensors 26 may be individually or directly powered and / or in communication with the power source or controller 24. The connector 28 can be attached to the carrier 20 that supports the one or more heating elements 22 via one or more suitable fastening devices 48. The one more fastening devices 48 may also function to attach or secure a lid or cover 44 of the housing to the base 32. The fastening device 48 may be, or may include any of the fastening devices disclosed herein.

[0045] Referring now to Figs. 3-6, the base 32 of the connector 28 comprises one or more channels 36. For example, the connector 28 may comprise two channels 36 that are generally or substantially arranged parallel to one another. A channel 36 may be a pre-defined path, recess, conduit, section, or region of the base 32 or connector 28 into or on which one or more wires of the one or more temperature sensors 26 is / are received and supported, one or more wires of the one or more power wires 34 is / are received and supported, or both. For example, a channel 36 may be defined by a pair of opposing walls extending upwardly from the base 32 (and / or downwardly from the cover or lid of the connector) and that are spaced apart, sized, and configured to accommodate and retain a thickness of the one or more wires. Preferably, the size of the channel 36 is such that the temperature sensors 26 and the power wires 34 are at leastslightly clamped or retained therein so that the wires are restricted or prevented from easily moving around within the channel and / or falling out of the channel. In some configurations, a channel may support only one wire. In other configurations, a channel may support more than one wire that are either stacked on top of one another or arranged adjacent to one another (i.e., a side by side and / or diagonal wire arrangement).

[0046] The opposing walls of a channel may include an outer wall 38 and an inner wall 40. The outer wall 38 may be a peripheral or perimeter wall that surrounds or defines an enlarged inner region or boundary 50. The inner region or boundary 50 of the connector may also be referred to as a temperature sensing region 50. The temperature sensor 26 and / or thermistor 52 may be arranged in this temperature sensing region 50. The temperature sensing region 50 may be located at a front or forward end of the connector that is arranged closest to the carrier or mat. The one or more power wires 34 may also be arranged or located in this temperature sensing region 50. During use, the one or more power wires 34 may transmit power or current from the controller or power source to the one or more heating elements 22 located on the carrier. In doing so, the one or more power wires 34 may generate heat within the connector, which may be sensed or detected by the temperature sensor 26 and / or thermistor 52 in the temperature sensing region 50 of the connector. Accordingly, the temperature generated by the one or more heating elements on the carrier may be estimated, determined, measured, correlated by sensing the temperature generated by the one or more power wires in the connector.

[0047] Sensing or detecting a temperature of the heating element within the connector may allow for an improved method or way of estimating or determining the temperature generated by the one or more power wires or heating wires on the carrier without having to place an actual temperature sensor or thermistor on the carrier itself. Advantageously, by not having to place a temperature sensor or thermistor on the carrier itself, there is less risk that the position of the temperature sensor or thermistor on the carrier is not in the correct position relative to the heating elements (e.g., less manufacturing or assembly variation) and / or reduced risk that the temperature sensor or thermistor separates from the carrier over time and during use. The temperature sensed or determined by the one or more temperature sensors and / or thermistors in the connector may be conveyed or supplied by one or more signals to the controller or power source through the temperature sensor wires extending from the connector to the controller or power source.

[0048] In some configurations, one or more other or additional temperature sensors may be located on the carrier, and configured to detect, measure, or determine the temperature generated by the heating elements on the carrier. This measurement or determination may be compared to the reference temperature sensed or determined within the connector to determine if both measured or determined temperatures are within a predetermined range which may help determine or confirm that the temperature sensors and heating elements are properly working. In the event that the reference temperature drastically differs from the temperature measured by the one or more sensors on the carrier, a fault or signal may be issued which may notify the user or the manufacturer that one of the temperature sensors and / or the heating elements are not properly functioning.

[0049] The outer wall 38 of the base 32 may comprise one or more openings 42 through which the one or more power wires 34 may extend from to connect to the heating element 22 on the carrier 20. The openings 42 may be arranged on opposite sides of the inner region or boundary 50 as illustrated. In other configurations, the one or more openings 42 may be arranged on the same side of the inner region or boundary 50 or adjacent to one another. In some configurations, the one or more openings 42 may be arranged at a front or leading end of the connector, to reduce or minimize the number or twists, turns, or bends before connecting to the one or more heating wires on the carrier or mat.

[0050] The inner wall 40 may extend partially or entirely along or adjacent to the outer peripheral or perimeter wall 38. In the illustrated example, the inner wall 40 comprises a plurality of upwardly extending discrete posts or projections 41 that define the channel 36 between the inner wall 38 and the outer wall 40. However, in other configurations, the inner wall may be formed of a substantially contiguous structure adjacent to the outer wall. In an assembled position, the wire of the temperature sensor 26 may be located below the wire of the power wire 34. In some configurations, the orientation or arrangement may be reversed so that the power wire 34 is below the wire of the temperature sensor 26. In other embodiments, like the one illustrated in Figs. 7 and 8, the temperature sensor and power wires may be arranged adjacent to one another in a side-by-side and / or diagonal arrangement.

[0051] The one or more power wires 34 may be connected or terminated at one or more power wire connectors, terminals, crimp, plugs, or pins 35. The one or more temperature sensor wires 26 may be directly connected or terminated at one or more temperature sensor wireconnectors, terminals, crimp plugs or pins 27. The one or more connectors, terminals, crimp, plugs or pins 35, 27 may be arranged within the connector and configured to connect with one or more mating connectors, terminals, plugs, crimps, or pins on at the power supply and / or controller side.

[0052] The one or more power wire connectors, terminals, crimp, plugs, or pins 35, 27 may be located within a plug or port region of the connector. Referring back to Fig. 2, the plug or port region 31 may be a region of the connector that a controller plug or receptacle is configured to engage to electrically connect to the connector and heating device. The plug or port region 31 may be located at one end of the connector and the inner region of boundary 50 that includes the thermistor 52 is located at an opposite end of the connector that is closer to the carrier.

[0053] In the event the one or more heating wires 22 on the carrier extend into the connector and are integrally formed as one or more power wires 36, the one or more heating wires 22 may be directly connected or terminated at one or more heating wire wire connectors, terminals, crimp plugs or pins 35.

[0054] One or more strain reliefs may be arranged within the connector or outside of the connector. A strain relief may be configured to reduce or prevent physical stress from being transmitted from an external environment or external stress such as pulling, bending, twisting, or vibrations, to the internal connections and components of the connector and / or wires 24, 26. A strain relief may be or may include a sleeve, bushing, spring, cable gland, cable tie, back shell, heat shrink tubing, coil, or a combination thereof.

[0055] Referring now to Fig. 6, the housing 30 of the connector 28 comprises a cover 44. The cover 44 co-acts with the base 32 to cover or enclose the one or more power wires 34 and the one or more temperature sensors 26. The cover 44 and the base 32 may form a hermetic seal or connection. A hermetic seal may be formed by providing a seal or other element to keep moisture, air, environment out of the connector. In other configurations, the connection may be a non-hermetic connection. The cover 44 comprises one or more projections or fingers 46 that are generally aligned with and configured to extend into the one or more channels 36. The one or more channels 36 may also be referred to as a yoke. The one or more projections or fingers 44 are configured to force or press or retain the two wires 34, 26 together into the channel or yoke to create and maintain an electrical connection therebetween. Accordingly, power supplied from the controller and / or power source 24 to the one or more heating elements 22 on the carrier20 via the one or more power wires 34 is also provided to the one or more temperature sensors 26 within the connector 28.

[0056] The temperature sensor 26 functions to provide a reference temperature of heat generated by the power wires in the connector (i.e., within the temperature sensing region 50 of the connector) that can be used to determine a temperature generated by the one or more heating elements 22 on the carrier 20. The wires of the temperature sensor 26 extend through the connector 28 and are electrically connected to the controller and / or power source 24 for monitoring the amount of power supplied to the one or more heating elements 22 and / or the temperature being generated by the one or more heating elements 22. Accordingly, in this illustrated example, the thermistor 52 is located inside of the connector 28 and the reference heater is also located in side of the connector 28.

[0057] Advantageously, by security holding the temperature sensor 26 within the connector 28 or housing 30 in the channels 36 as opposed to being located on the flexible carrier 20, risk of the temperature sensor 26 providing inaccurate readings and / or being removed or separated from the carrier 20 or power wire is reduced or minimized. Moreover, in the event a temperature sensor needs to be serviced or replaced, a temperature sensor located within a connector may provide for easier serviceability vs one that is arranged or connected to the carrier. By supporting a temperature sensor within structure located in the connector, a material savings may be appreciated because less fasteners (i.e., tape, glue, etc.) is required to be applied to the carrier to secure a temperature sensor thereto. By placing the one or more temperature sensors at the connector instead of the carrier, the connector may be pre-assembled off site, and therefore a manufacturing and / or cycle time of the carrier and heater assembly can be reduced. Numerous other benefits may be realized by a person having ordinary skill in the art.

[0058] The one or more power wires 34 and temperature sensor wires 26 may be connected to one or more crimps, plugs, pins, or connectors that may be connected to another plug, connector, or power source or controller 24.

[0059] Figs. 7, 8, and 9 illustrate a connector 28 comprising a housing 30 comprising a base 32; one or more temperature sensors 26 having one or more thermistors 50 supported on the base 32 and configured to measure, detect, and / or to provide information relating to a temperature of a heating element 22 supported on base 32 and / or the carrier 20 (Fig. 9); and one or more power wires 34 supported on the base 32 and configured to provide power from the controller and / orthe power source 24 to the one or more heating elements 22 and to the one or more temperature sensors 26.

[0060] It is understood that any of the description relating to Figs. 7, 8, and 9 can be incorporated into the connector illustrated and described in the previous figures, and vice versa.

[0061] The base 32 of the connector 28 comprises a plurality of channels 36 into which the one or more wires of the temperature sensor 26 and power wires 34 are received and supported. The one or more wires of the temperature sensor 26 and / or power sires 34 may be attached directly (integrally part of or attached) to the terminals on the connector for connecting to the controller and / or power source. A channel 36 may be defined by a pair of opposing walls extending upwardly from the base 32 that are spaced apart and sized and configured to accommodate and retain a thickness of the temperature sensor and power wires. The opposing walls may include an outer wall 38 and an inner wall 40. In an assembled position, the wire of the temperature sensor 26 may be located adjacent to the power wire 34. However, in another assembled position, like the one illustrated and discussed above at Figs. 3-6, the wire of the temperature sensor 26 may be located below (or above) the power wire 34, like in the previous examples at Figs. 3-6.

[0062] The outer wall 38 or the base 32 may comprise one or more openings 42 through which the power wire 34 may extend from to connect to the heating element 22 on the carrier 20.

[0063] The housing 30 of the connector 28 comprise a cover 44. The cover 44 is attached or connected to the base 32 via a suitable fastener, such as a living hinge 54, or any of the other fasteners or fastening devices disclosed herein. The cover can be moved between an open and closed configuration by moving or pivoting the cover 44 about the living hinge 54. During assembly of the connector, the cover is folded over the living hinge and then secured to the base via one or more of the fasteners disclosed herein.

[0064] The one or more power wires 34 may be connected or terminated at one or more power wire connectors, terminals, crimp, plugs, or pins. The one or more temperature sensor wires 26 may be directly connected or terminated at one or more temperature sensor wire connectors, terminals, crimp plugs or pins. The one or more connectors, terminals, crimp, plugs or pins may be arranged within the connector plug and configured to connect with one or more mating connectors, terminals, plugs, crimps, or pins on at the power supply and / or controller side.

[0065] Referring to Fig. 9, the connector 28 may be attached to the carrier 20 via a suitable fastener disclosed herein. The heating wires 22 may extend from the connector 28 and may be attached to the carrier 20. The one or more heating wires 22 may meander all over the carrier and may extend under the connector 28 or the base of the connector under the thermistor 52 or temperature sensor 26. Accordingly, the thermistor 52 or temperature sensor 26 located within a region inside of the connector 28 may measure, determine, sense the temperature generated by the one or more heating wires 22 located on the carrier 20 and arranged under or below the connector 28. Accordingly, in this illustrated example, the thermistor 52 is located inside of the connector 28 and the reference heater is located on the carrier 20.

[0066] Advantageously, by security holding the temperature sensor 26 and thermistor 52 within the connector 28 or housing 30 as opposed to being located on the flexible carrier 20, risk of the temperature sensor 26 providing inaccurate readings and / or being removed or separated from the carrier 20 is reduced or minimized. Moreover, in the event a temperature sensor needs to be serviced or replaced, a temperature sensor located within a connector may provide for easier serviceability vs one that is arranged or connected to the carrier. By supporting a temperature sensor within structure located in the connector, a material savings may be appreciated because less fasteners (i.e., tape, glue, etc.) is required to be applied to the carrier to secure a temperature sensor thereto. By placing the one or more temperature sensors at the connector as opposed to the carrier, the connector may be pre-assembled off site, and therefore a manufacturing and / or cycle time of the carrier and heater assembly can be reduced. Numerous other benefits may be realized by a person having ordinary skill in the art.

[0067] Fig. 10 illustrates a connector 28 and carrier 20. The connector 28 or housing 30 may be attached or connected to the carrier 20 with a suitable fastener 48, such as any of the fasteners disclosed herein. The fastener 48 may be a glue tape. The connector 28 comprises terminals or leads that are at one end connected to a controller or power source. The other end of the terminal leads are connected to or are one or more heating wires 22 and one or more temperature sensing wires 26. One or more thermistors 52 may be connected to the one or more temperature sensors or wires 26. The thermistor 52 may be located outside of the housing 30 and attached to the carrier 20 with a suitable fastener, which may be any fastener disclosed herein. The fastener in the illustrated example may be a patch 56 or tape to sure the thermistor 52 to prevent the thermistor from moving or detaching from the carrier 20. The heating wire 22 may be shaped sothat the thermistor 52 is arranged between two legs of the heating wire 22. Accordingly, in this illustrated example, the thermistor 52 and the reference heater are located on the carrier 20.

[0068] The thermistor 52 may be arranged between two legs of the heating wire 22 that are closely positioned relative to one another. As can be seen, the heating wire 22 is spaced further apart from itself in other areas of the carrier or mat where there is no thermistor 52 or temperature sensor. By arranging the temperature sensor or thermistor in a region where the legs of the heating wire 22 are closer together, a more accurate temperature measurement can be obtained.

[0069] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. The above description is intended to be illustrative and not restrictive. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use.

[0070] Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to this description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

[0071] Plural elements or steps can be provided by a single integrated element or step. Alternatively, a single element or step might be divided into separate plural elements or steps.

[0072] The disclosure of "a" or "one" to describe an element or step is not intended to foreclose additional elements or steps. For example, disclosure of “a motor” does not limit the teachings to a single motor. Instead, for example, disclosure of “a motor” may include “one or more motors.”

[0073] While the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be used to distinguish one element, component, region, layer or section from another region, layer orsection. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings.

[0074] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0075] The invention illustratively disclosed herein may be practiced in the absence of any element which is not specifically disclosed herein.

[0076] Any of the elements, components, regions, layers, and / or sections disclosed herein are not necessarily limited to a single embodiment. Instead, any of the elements, components, regions, layers, and / or sections disclosed herein may be substituted, combined, and / or modified with any of the elements, components, regions, layers and / or sections disclosed herein to form one or more embodiments that may not be specifically illustrated or described herein.

[0077] The disclosures of all articles and references, including patent applications and publications, testing specifications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

Claims

CLAIMS1) A heating device for a vehicle seat heater comprising: a carrier configured with one or more heating wires; a connector comprising one or more power wires and one or more temperature sensors, and configured to electrically connect the one or more heating wires to a controller or power source, the one or more temperature sensors are configured to respond to heat generated by the one or more power wires within the connector and provide one or more signals to the controller or power source to d estimate or determine a temperature generated by the one or more heating wires on the carrier.2) The heating device according to claim 1, wherein the carrier is free of any temperature sensors.3) The heating device according to claim 1 or 2, wherein the temperature generated by the one or more heating wires on the carrier is determined using only the one or more temperature sensors in the connector, wherein the connector comprises a plug or port to which the controller or power source is connected.4) The heating device according to claim 3 or to any one of the previous claims, wherein the one or more heating wires and the one or more temperature sensors are terminated to a respective pin or crimp in the connector.5) The heating device according to any one of the previous claims, wherein the connector comprises a base and a cover, the base comprises a channel into which one or more wires of the one or more temperature sensors are received, the cover is connected to the base for enclosing the one or more wires within the connector.6) The heating device according to claim 5, wherein the one or more power wires that supply electrical power to the one or more heating wires are received into the channel.7) The heating device according to claim 6, wherein one or more temperature sensors are located on top of the one or more power wires in the channel.8) The heating device according to claim 6, wherein the one or more power wires are located onto of the one or more temperature sensors within the connector.9) The heating device according to claim 7 or 8, wherein the cover comprises a downwardly extending projection or finger that is configured to contact and push the one or more power wires and the one or more wires of the one or more temperature sensors together within the channel.10) The heating device according to any one of claims 5-9, wherein the channel is defined by an outer wall and an inner wall, wherein the inner wall is defined by one or a plurality of upwardly extending projections extending along a length of the outer wall.11) The heating device according to any one of the previous claims, wherein the outer wall defines an enlarged region or boundary into which into which the one or more temperature sensors are received or where a thermistor material of the one or more temperature sensors is located, wherein the enlarged region or boundary is located at an end of the connector that is closer to the carrier than a region of the connector that is connected to the controller or power source.12) The heating device according to any one of the previous claims, wherein the outer wall comprises one or more openings through which the one or more power wires extend from to connect to the one or more heating elements on the carrier.13) The heating device according to claim 12, wherein the outer wall comprises two openings that are arranged on opposite sides of the enlarged inner region or boundary for the one or more power wires to extend.14) The heating device according to claim 12 or 13, wherein the one or more power wires and the one or more heating wires are the same integral wire.15) The heating device according to any one of claims 5-14, wherein the cover is secured to the base with a living hinge, wherein during assembly of the connector the cover is folded over the living hinge to enclose the one or more power wires and the one or more temperature sensors within the connector.16) A connector for connecting one or more heating wires on a carrier to a controller or power source, the connector comprising: a base; one or more power wires situated on the base; and one or more temperature sensor wires situated on the base; wherein the connector is configured to electrically connect the one or more heating wires on the carrier to the controller or power source via the one or more power wires, the one or more temperature sensor wires are configured to respond to heat generated by the one or more power wires within the connector and provide one or more signals to the controller or power source to estimate or determine a temperature generated by the one or more heating wires on the carrier.17) The connector according to claim 16, wherein the base comprises a channel into which the one or more power wires and the one or more temperature sensor wires are received.18) The connector according to claim 17, wherein the one or more temperature sensors are located on top of the one or more power wires in the channel, and the connector comprises a cover with a downwardly extending projection or finger that is configured to contact and push the one or more power wires and the one or more wires of the one or more temperature sensors together within the channel.19) The connector according to claim 17 or 18, wherein the channel is defined by an outer wall and an inner wall, wherein the inner wall is defined by a plurality of upwardly extending projections extending along a length of the outer wall. 120) The connector according to claim 19, wherein the temperature generated by the one or more heating wires on the carrier is determined using only the one or more temperature sensors in the connector, wherein the connector comprises a plug or port to which the controller or power source is connected; and wherein the outer wall defines an enlarged region or boundary into which into which the one or more temperature sensors are received or where a thermistor material of the one or more temperature sensors is located, wherein the enlarged region or boundary is located at an end of the connector that is closer to the carrier than a region of the connector that is connected to the controller or power source.

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