Heated Garments and Methods for Constructing Heated Garments

Abstract

Heated garments that are flexible, stretchable, and durable are described, along with methods for constructing such garments. The heated garments comprise a garment body, a heating wire forming a heater array stitched to a heating section of fabric, and a main current line for providing electrical current to the heating wire. A transition element is formed over the connection of the heating wire and the main current line to induce formation of a fabric flex line such that the heating wire is subjected predominately to torsion forces instead of flexion forces upon flexion at the fabric flex line. The heated garment includes a flexible thermally conductive and electrically resistive material covering the heating wire. The heater array may be integral to the garment body or may be removable.

1 . A heated garment comprising:
 a garment body;   a heating wire forming a heater array attached to a fabric that is part of the garment body or is configured for arrangement within the garment body; and   a main current line configured to provide electrical current to the heating wire via a transition element which induces formation of a fabric flex line, wherein the heating wire extends from the transition element over and past the fabric flex line such that the heating wire is subjected predominately to torsion forces instead of flexion forces upon flexion at the fabric flex line.   
     
     
         2 . The heated garment of  claim 1 , wherein the transition element comprises a housing to protect a connection between the heating wire and the main current line, the housing comprising a pair of outward extensions, wherein a line passing through the ends of the extensions defines the fabric flex line. 
     
     
         3 . The heated garment of  claim 1 , wherein the heating wire is stitched into the fabric. 
     
     
         4 . The heated garment of  claim 1 , wherein the heating wire comprises multiple wires braided and/or twisted together. 
     
     
         5 . The heated garment of  claim 1 , further comprising a flexible thermally conductive material that is electrically resistive covering the heating wire. 
     
     
         6 . The heated garment of  claim 5 , wherein the thermally conductive material comprises a thermally conductive silicone and/or a thermally conductive polyurethane. 
     
     
         7 . The heated garment of  claim 1 , further comprising a thermal insulating layer configured such that the heater array is between the thermal insulating layer and a wearer of the garment. 
     
     
         8 . The heated garment of  claim 1 , wherein the garment comprises underwear and the heating array is arranged at the front side of the underwear. 
     
     
         9 . The heated garment of  claim 1 , wherein the heater array is integral to the garment body. 
     
     
         10 . The heated garment of  claim 1 , wherein the heater array is removable from the garment body. 
     
     
         11 . A heated garment comprising:
 a garment body;   a heating wire forming a heater array stitched to a fabric that is part of the garment body or is configured for arrangement within the garment body;   a main current line configured to provide electrical current to the heating wire;   a transition element comprising a housing to protect a connection between the heating wire and the main current line, the housing comprising a pair of outward extensions that induces formation of a fabric flex line at the ends of the outward extensions; and   a flexible thermally conductive material comprising a thermally conductive material covering the heating wire;   wherein the heating wire extends from the transition element over and past the fabric flex line such that the heating wire is subjected predominately to torsion forces instead of flexion forces upon flexion at the fabric flex line.   
     
     
         12 . A method of constructing a garment for providing heat to a body part of a wearer of the garment, the method comprising the steps:
 stitching a heating wire to a first side of fabric to form a heating section that is arranged within or integral to the garment, the heating wire having a connection point for connection to a main current line for providing electrical current to the heating wire; and   applying a transition element over the connection point to induce formation of a fabric flex line;   wherein the heating wire is attached to the fabric from the connection point to the fabric flex line such that the heating wire is subjected predominately to torsion forces instead of flexion forces upon flexion of the fabric flex line.   
     
     
         13 . The method of  claim 12 , wherein the heating wire comprises multiple wires twisted and/or braided together. 
     
     
         14 . The method of  claim 12 , further comprising the step of applying a thermally conductive material that is electrically insulative over the heating wire. 
     
     
         15 . The method of  claim 14 , wherein the thermally conductive material comprises any one or combination of a thermally conductive silicone and a thermally conductive polyurethane. 
     
     
         16 . The method of  claim 14 , wherein the thermally conductive material is applied as a curable liquid that impregnates the heating section of fabric. 
     
     
         17 . The method of  claim 12 , further comprising applying a thermal insulating layer, wherein the heating wire is positioned between the thermal insulating layer and a wearer of the garment. 
     
     
         18 . The method of  claim 12 , further comprising:
 concurrently forming a thermally conductive layer over a first side of the heating wire and a thermal insulating layer over a second side of the heating wire by applying a liquid composition comprising thermally insulative particles and thermally conductive particles to the first side of the heating wire, wherein the thermally insulative particles are smaller than the thermally conductive additive particles;   wherein a first portion of the composition stays on top of the fabric to form the thermally conductive layer and a second portion of the composition impregnates the fabric on the second side of the heating wire to form the thermal insulating layer, and   wherein there is a higher concentration of the thermally conductive additive particles in the first portion compared to the second portion of the composition.   
     
     
         19 . The method of  claim 12 , further comprising temporarily stiffening the fabric prior to stitching the heating wire. 
     
     
         20 . The method of  claim 12 , wherein the garment comprises underwear and the heating section is positioned at the front side of the underwear.