Covered conductor and heater formed therewith

Abstract

There is disclosed a conductor having a conductive element and a covering surrounding at least a portion of the conductive element Preferably, the covering has an inner portion and an outer portion formed of different materials such that the melting point of the inner portion is higher than the melting point of the outer portion. The conductor is particularly useful for forming heaters, which may be integrated into a seat of an automotive vehicle.

1 . A method of manufacturing a heater comprising: 
 applying a covering around a conductor by extruding, brushing, dabbing, painting, pouring, pressing the covering onto the conductor or submerging the conductor in a bath;    patterning the covered conductor on at least one surface of a substrate; and activating the covering to attach the covered conductor to the substrate to form a heater.    
   
   
       2 . The method of  claim 1  wherein the activating step comprises applying heat to the covered conductor.  
   
   
       3  The method of  claim 2  wherein the activating step comprises energizing the conductor to emit sufficient heat to activate the covering.  
   
   
       4 . The method of  claim 1  wherein the applying step further comprises extruding the covering around the conductor,  
   
   
       5 . The method of  claim 4  wherein the patterning step further comprises patterning the covered conductor on a fabric substrate selected from the group consisting of fleece, gauze and felt.  
   
   
       6 . The method of  claim 3  wherein the applying step further comprises applying a covering with a melting temperature gradient.  
   
   
       7 . The method of  claim 3  wherein the applying step further comprises applying a covering with an inner portion and an outer portion, wherein the portion have differing melting temperatures.  
   
   
       8 . The method of  claim 7  wherein the portions differ in melting temperature by at least 40° C.  
   
   
       9 . The method of  claim 1  further comprising attaching the covering attached substrate to a seat cushion, a trim cover or combinations thereof.  
   
   
       10 . A method of manufacturing a heater consisting essentially of: patterning a conductor with a covering on at least one surface of a substrate; activating the covering to attach the conductor to the substrate to form a heater; incorporating the heater into a vehicle seat.  
   
   
       11 . The method of  claim 10  further consisting essentially of applying the covering around the conductor by extruding, brushing dabbing, painting, pouring, pressing the covering onto the conductor or submerging the conductor in a bath;  
   
   
       12 . The method of claim  1 I 1  further consisting essentially of extruding the covering around the conductor.  
   
   
       13 . The method of  claim 1   0  wherein the activating step comprises applying heat to the covered conductor.  
   
   
       14 . The method of  claim 13  wherein the activating step comprises energizing the conductor to emit sufficient heat to activate the covering.  
   
   
       15 . A method of manufacturing a heater comprising: 
 patterning a conductor with a covering on a substrate followed substantially immediately by    attaching the covered conductor to the substrate to form a heater by activating the covering.    
   
   
       16 . The method of  claim 15  wherein the attaching step comprises heat activating the covering to attach the conductor to the substrate,  
   
   
       17 . The method of  claim 16  wherein the attaching step comprises energizing the conductor to emit sufficient heat to melt the covering,  
   
   
       18 . The method of  claim 17  further comprising incorporating the heater into a vehicle seat.  
   
   
       19 . The method of  claim 15  further comprising applying to the conductor with a covering having an inner portion and an outer portion, wherein the portion have differing melting temperatures.  
   
   
       20 . The method of  claim 15  further comprising extruding a covering around the conductor.