PRIORITY

[0001] This application claims priority to US 63/117,499 filed on November 24, 2020, the entirety of which is hereby incorporated by reference herein for all purposes.

FIELD

[0002] These teachings relate to a heating system, a heating blanket and/or to a method of making a heating blanket. The heating blanket may have one or more integrated temperature sensors.

BACKGROUND

[0003] Heating blankets may be used in medical and/or non-medical applications to raise and/or maintain the body temperature of a patient or user. Exemplary heating blankets are disclosed in US 2019/0365113A1, in one or more of the family applications of US 2019/0365113A1, and US 2006/052852A1, all of which are incorporated by reference herein for all purposes. It would be desirable to improve the current state of the art by having an improved heating system, a heating blanket and/or to a method of making a heating blanket that includes one or more integrated temperature sensors.

SUMMARY [0004] These teachings provide a heating system and a heating blanket. These teachings provide a method of making a heating blanket. The heating blanket according to these teachings includes one or more integrated temperature sensors.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 illustrates a heating system, that includes a heating blanket.

[0006] FIG. 2 is a partially exploded view of a heating blanket.

[0007] FIG. 3 A is a front view of a heating segment of a heating layer of the heating blanket. [0008] FIG. 3B is a side view of Fig. 3 A.

[0009] FIG. 4A is a side view of Fig. 3 A.

[0010] FIG. 4B is a side view of Fig. 3 A in a folded configuration.

[0011] FIG. 5 is a side view of two heating segments each in the folded configuration of FIG. 4B that are joined together.

[0012] FIG. 6 is a front view of multiple heating segments of the heating layer of the heating blanket.

[0013] FIG. 7A is a side view of two heating segments of FIG. 3 A.

[0014] FIG. 7B is a side view of the two heating segments of FIG. 7A joined together.

[0015] FIG. 8 is a front view of multiple heating segments of the heating layer of the heating blanket.

[0016] FIG. 9 is a top perspective view of plural heating segments of the heating layer of the heating blanket.

[0017] FIG. 10 is a top perspective view of the plural heating segments of FIG. 9 joined together. [0018] FIG. 11 is a front view of the heating layer of the heating blanket. [0019] FIG. 12 is a front view of the heating layer of the heating blanket. [0020] FIG. 13 is a perspective view of the heating layer of the heating blanket. [0021] FIG. 14 an exploded view of the heating blanket. [0022] FIG. 15 is a front view of the heating blanket. [0023] FIG. 16 an exploded view of the heating blanket.

DETAILED DESCRIPTION

[0024] FIG. 1 illustrates a heating system 10. The heating system 10 may comprise a controller 12, one or more cables (for example, a first cable 14 and a second cable 16), and a heating blanket 18.

[0025] The heating system 10 and/or the heating blanket 18 according to these teachings may be or may include any of the elements, features, description, and/or construction disclosed herein. In other words, the construction, layers, and/or elements of the blanket 18 are found throughout this disclosure and may be combined, separated, omitted, duplicated, etc. to construct one or more embodiments of the system 10 and/or blanket 18. A non-limiting meaning or example of this is that the slits 74 shown and described in FIGS. 12 and 13 may be incorporated into the heating layer 28 illustrated and described in FIG. 10 or FIG. 3 A.

[0026] These teachings can be applied to the teachings disclosed in one or more of the following applications: US 63,117,499 filed on November 24, 2020; US 63/117,508 filed on November 24, 2020; US 63/233,991 filed on August 17, 2021; and US 63/117,501 filed on November 24, 2020. The aforementioned applications are all incorporated by reference herein for all purposes. Any PCT application filed by Applicant or at the direction of Applicant that claim priority to any of the aforementioned US priority applications are also incorporated by reference herein for all purposes. [0027] The controller 12 may be programmed, configured, or enabled to monitor and/or control the heating system 10, the heating blanket 18, one or more layers or elements of the heating blanket 18, or a combination thereof. The controller 12 may be programmed, configured, or enabled to supply the heating blanket 18 and/or one or more layers or elements of the heating blanket 18 with electrical power so that the heating blanket 18 and/or one or more layers or element of the heating blanket 18 can generate heat. The controller 12 may include a power source for supplying the electrical power to the heating blanket 18 or to one or more layers or elements of the heating blanket 18. The power source may include one or more batteries, solar panels, generators, or other power generating and/or storage means. Additionally, or alternatively, the controller 12 may be connected to a power source (i.e., a wall outlet, a generator, a battery, etc.) that supplies the electrical power to the controller 12 and then to the heating blanket 18 or to one or more layers or elements of the heating blanket 18.

[0028] The one or more cables 14, 16 may be configured or enabled to transfer or conduct electrical power from and/or between the controller 12 and/or a power source to the heating blanket 18 and/or one or more elements or layers of the heating blanket 18. The first cable 14 and/or the second cable 16 may be configured or enabled to transfer or conduct communication signals from and/or between the controller 12 and the heating blanket 18 or one or more layers or elements of the heating blanket 18 so that the controller 12, one or more other controllers, users, or systems can monitor and/or control operation of the heating blanket 18. In other words, based on one or more signals or commands communicated between the controller 12 and the heating blanket 18 (or one or more layers or elements of the blanket 18), the controller 12, a user, or other system may function to increase, decrease, or maintain an electrical power supply to the heating blanket 18 (or to one or more layers or elements of the heating blanket 18), may turn ON or turn OFF an electrical power supply to the heating blanket 18, may alert a user of a fault condition (e.g., too much heat, too little heat, etc.), or a combination thereof.

[0029] The first cable 14 and the second cable 16 may be integrated into a single cable for connecting the blanket 18 and the controller 12. The first and second cables 14, 16 may be divided or separated into additional sub-cables for connecting the blanket 18 and the controller 12. One or both of the cables 14, 16 may have one or more connectors or plugs 20 for connecting the cables together and/or for connecting to one or more ports, plugs, or connectors 22 on the controller 12 and/or to one or more ports, plugs, or connectors 24 on the heating blanket 18, heating layer 28, or other layers of the blanket 18.

[0030] FIG. 2 illustrates the heating blanket 18. The heating blanket 18 may comprise one or more layers or sheets. The one or more layers or sheets may comprise: one or more top or first cover layers 26, one or more heating layers 28, one or more insulating layers 30, one or more bottom or second cover layer 32, or a combination thereof. Another exemplary heating blanket 18 is illustrated and described below at FIG. 16. Remarks made with regard to the blanket 18 in FIG. 2 may apply to the blanket 18 in FIG. 16 and vice versa.

[0031] The top or first cover layer 26 may be arranged on top of the heating layer 28, which may be arranged on top of the insulating layer 30, which may be arranged on top of the bottom or second cover layer 32. However, it is understood that any of these layers may be arranged in any order. For example, the heating layer 28 may be arranged below the insulating layer 30. Additionally, or alternatively, one or more of these layers may be combined into a single layer. For example, the heating layer 28 and the insulating layer 30 may be combined into a single layer (by attaching the layers together or forming them from an integral layer, for example). Additionally, or alternately, one or more of the blanket layers may be duplicated. For example, another one or more insulating layers 30 may be provided below or above the heating layer 28 and/or one or more additional heating layers 28 may be provided above or below one or more insulating layers 30. In some configurations, one or more of the layers may be joined together via one or more fasteners or may even be formed from an integral layer. The one or more fasteners may be one or more pins, buttons, clasps, welds, stiches, hook and loop fasteners, adhesives, pastes, screws, zippers, tape, double sided tape, magnets, snaps, heat stakes, etc.

[0032] In some configurations, the first and second cover layers 26, 32 may be formed from a single cover layer. For exampe, if constructed as a single cover layer, it can be folded over itself to cover, sandwich, and/or envelope the one or more other middle layers of the blanket 18 (e.g., one or more insulating layers 30, heating layers 28, etc.) therewithin or therebetween.

[0033] In some configurators, the first and second cover layers 26, 32 may be formed from a single cover layer or joined together to function or act like a duvet or pillowcase with one or two or three open ends. If there are two open ends, they may oppose one another, or adjoin one another. The one or more middle layers of the blanket 18 (e.g., one or more insulating layers 30, heating layers 28, etc.) may be inserted or slid into the duvet or pillowcase structure through one or more of the open ends. The one or more open ends may then be closed via one or more of any of the fasteners disclosed herein. Alternatively, one or both of the open ends may remain open. This may enable or provide for the middle layers of the blanket to be removed from within the cover for service, maintenance, and/or replacement of one or more of the layers, washing or sterilizing of the cover, or both. Alternatively, the one or more fasteners used to close the one or more open ends may be opened and closed (e.g., via snaps, buttons, hook and loop fasteners, zippers, etc.) to access and/or remove/install the middle layers. One or more of any of the middle layers of the blanket 18 may eliminated or omitted or duplicated. [0034] In some configurations, the top or cover layer 26 may be the same as the bottom cover layer 32 (i.e., same or similar material, structure, composition, size, etc.). In other configurations, the two cover layers 26, 32 may be different (i.e., different material, structure, composition, size, etc.) This means, one of the cover layers 26, 32 may be made from a different material, may include additional or different insulating or heat deflecting/reflecting properties, etc. In some configurations, the top layer 26 should always face up or away from the patient, and the bottom layer 32 should always face down or towards a patient or bed, or vice versa.

[0035] One or both of the cover layers 26, 32 may be made from suitable material that allows heat generated by the heating layer 28 to pass through or be conducted from the heating layer 28 to warm a patient or object near or in contact with one or more layers of the blanket 18 or proximate or adjacent to one or more layers of the blanket 18. The cover layer 26, 32 material may be made of a suitable material that resists liquid (i.e., blood, disinfectants, water, cleaners, chemicals, etc.) absorption and/or penetration. This may advantageously protect the inside layers and elements of the heating blanket 18 from damage from liquid penetration. For example, one or both of the cover layers 26, 32 may be made of one or more materials that include: a nonwoven fabric, sheet, or material; a spunbond or spunlaid fabric, sheet, or material; a polypropylene fabric, sheet, or material; an LDPE film or coating applied onto one or both layers; or a combination thereof. Other materials that meet medical use specification requirements may be utilized, including any of the materials disclosed herein for any of the other blanket layers. In some configurations, one or both of the cover layers 26, 32 may be made of a suitable material that can be washed, wiped clean, autoclaved, and/or disinfected so that the blanket 18, one or both of the cover layers 26, 32 can be reused. [0036] The blanket 18 may include one or more insulating layers 30. The insulating layer 30 may be made from a suitable material that functions to retain heat generated by the heating layer 28, and/or direct or re-directed heat generated by one or more of the heating layers 28 to radiate in a particular direction, for example, in a direction of a user or patient as opposed to away from the user or patient, or vice versa. The insulating layer 30 may function to direct or distribute heat generated by the heating layer 28 at least partially across an entire surface of the heating blanket 18 to reduce, minimize, or eliminate any isolated hot and/or cold spots. The insulating layer 30 may function to direct or distribute heat generated by the heating layer 28 to certain areas or regions of the blanket 18, and prevent the heat generated by the heating layer 28 to be directed or distributed to other layers of the blanket 18. The insulating layer 30 may function to direct or distribute the heat generated by the heating layer 28 so that certain layers of the heating blanket 18 are warmer than others. This may be advantageous to provide the blanket 18 with the ability to have isolated warmer sections and/or cooler sections.

[0037] For example, the insulating layer 30 may be made of one or more materials that include a fleece material. Other materials that meet medical use specification requirements may be utilized, including any of the materials disclosed herein for any of the other blanket layers. The insulating layer 30 may be attached to any of the layers of the heating blanket. The insulating layer 30 may be free from direct attachment to any of the layers of the heating blanket. For example, the one or more insulating layer 30 may be attached to one or more heating layers 28, one or more other insulating layers 30, one or both of the cover layers 26, 32, or a combination thereof via one or more of any of the fasteners disclosed herein (i.e., pins, buttons, clasps, welds, stiches, hook and loop fasteners, adhesives, pastes, screws, zippers, tape, etc.) [0038] The heating blanket 18 may include one or more heating layers 28. The heating layer 28 and/or elements of the heating layer 28 may be configured or enabled to generate heat in response to a supply of electrical energy. The heating layer 28 may generate heat by converting electrical energy supplied by the controller 12 and/or one or more power supplies or power sources into heat energy. The one or more power supplies or sources may be one or more batteries, wall outlets, AC power, DC power, solar panels, generators, or a combination thereof. The blanket 18 and/or the heating layer 28 may include one or more connectors or plugs 24 for communicating with the controller 12 and/or power supply (FIG. 1) via the one or more cables 14, 16. The heating layer 28 may comprise one or more heating segments 34, 34’.

[0039] FIGS. 3A and 3B illustrate a heating layer 28. The heating layer 28 may comprise one or more heating segments 34. One heating segment 34 is illustrated in FIG. 3 A. A heating segment 34 may be a layer of the heating layer 28 and/or of the blanket 18 that includes one or more sub layers. The one or more sub layers of the heating layer 28 may include one or more carrier or base layers 36 and/or one or more foil layers 38. In some configurations, the carrier or base layer 36 may be located below the foil layer 38 or above the foil layer 38. In some configurations, the foil layer 38 may be located above and below the carrier layer 36 such that the carrier layer 36 is sandwiched between the foil layers 38. In some configurations, the base layer 36 and the foil layer 38 may be a single, integrated layer. In other configurations, the foil layer 38 may be separate from the base layer 36 but subsequently arranged, supported, attached, secured, or connected to the base layer 36.

[0040] The base layer 36 may function to stabilize or provide a support structure or carrier for the foil layer 38 or other elements or layers of the heating layer 28. The base layer 36 may be made of a suitable material, such as polyurethane, polypropylene, polymethylene, polyethylene terephthalate (PET), Polyimide (PI), the like, or a combination thereof. The base layer 36 may be electrically conductive or electrically non-conductive. The base layer 36 may be an insulator. The base layer 36 maybe more rigid or stiff than the foil layer 38, or vice versa. The base layer 36 may be a

[0041] The foil layer 38 may comprise a suitable electrically conductive material, such as metal, copper, aluminum, nickel, copper clad aluminum, the like, or a combination thereof. The foil layer 38 may comprise one or more conductor paths or conductor traces 40. By selecting a suitable material for the foil layer 38 and/or a suitable size or shape of the conductor paths or traces 40 (i.e., width, thickness, height, length, shape, material, etc.), the foil layer 38 and/or the one or more conductor paths or traces 40 may be, or may comprise, or may function as one or more electrical heating elements 42, one or more sensing elements 46, or both. In other configurations, one or more heating elements 42 and/or sensing elements 46 may be attached or connected to the one or more conductor paths or traces 40 via a suitable fastener, electrical connector, and/or adhesive, such as for example conductive adhesive, soldering, welding, etc. The one or more conductor paths or traces 40 may function to conduct or carry electrical energy and/or electrical communication signals between the heating blanket, heating segments, the controller, power source, or a combination thereof. In certain other configurations, it is envisioned that electrical power and/or electrical communication signals may be additionally or instead wirelessly communicated or transmitted between the elements of the heating system and/or heating blanket. [0042] The one or more conductors or traces 40 or heating elements 42 may generate heat in response to electrical power or signals that are supplied to the heating segment. The one or more conductors or traces 40 or heating elements 42 may be one or more resistors, heating resistors, wire heaters or resistors, or a combination thereof. The one or more conductors or traces 40 or heating elements 42 may be one or more wire conductors attached, place, or integrated into the base layer, foil layer, or both. The one or more conductors or traces 40 or heating elements 42 may any other suitable heater that is configured to suitably perform one or more of the heating functions. The heating layer 28 may comprise any of the heating elements disclosed herein. The one or more heating elements 42 may be one or more PTC heaters.

[0043] The one or more sensing elements 46 may be configured to determine, sense, change, and/or monitor a temperature or heat generated by the heating layer and/or the one or more heating elements 42 or conductors or traces 40. The one or more sensing elements 46 may be one or more thermistors. The one or more sensing elements 46 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. The resistance of NTC thermistor will decrease as the temperature generated by the heating elements 42 and/or sensed by the sensing elements 46. The one or more sensing elements 46 may be any other suitable sensor that is configured to suitably perform one or more of the sensing functions.

[0044] In some configurations, the foil layer 38 may be placed on the base layer 36 and/or connected thereto via one or more fasteners, or simply overlayed on the base layer 36. The foil layer 38 may then be subjected to an operation where certain portions of the foil layer 38 are removed from the base layer 38, while other portions of the foil layer 38 remain on the base layer 36. The operation may be a milling, grinding, etching, or other material removal operation. The portions of the foil layer 38 remining on the base layer 36 after the operation may be the electrically conductive traces or conductor paths 40, one or more electrical heating elements 42, one or more sensing elements 46, or a combination thereof. Accordingly, the one or more electrically conductive traces or conductor paths 40, one or more electrical heating elements 42, one or more sensing elements 46, or a combination thereof may be integrally formed on the foil layer 38 and/or base layer 36. In the event that the foil layer 38 and the base layer 36 are formed as a single, integral layer, then the one or more electrically conductive traces or conductor paths 40, one or more electrical heating elements 42, one or more sensing elements or temperature sensors 46, or a combination thereof may be integrally formed on the base layer 36 after the material removal operation. Additionally, or alternatively, one or more heating elements 42, conductive traces or conductor paths 40, and/or sensing elements 46 may be subsequently attached or connected to the traces or conductor paths 40 or the remining portions of the foil layer 38 after the material removal operation.

[0045] In some configurations, the foil layer 38 may be subjected to the aforementioned material cutting or removal operation to form the electrically conductive traces or conductor paths 40 and/or one or more electrical heating elements 42 before being installed or placed onto the base layer 36. [0046] In some configurations, another foil layer 38’ may be subjected to another material removal operations to form the electrically conductive traces or conductor paths 40 sending elements 46. The another foil layer 38’ that includes the electrically conductive traces or conductor paths 40 sensing elements 46 may then be placed over and/or under the foil layer 38 which contains the electrically conductive traces or conductor paths 40 and/or one or more electrical heating elements 42. A laminate may then be placed over, under, and/or around the two layers to connect the two layers together. One or more of the electrically conductive traces or conductor paths 40 may be accessible through the laminate in order to attach one or more heaters and/or sensing elements thereto. In such a configuration, the one or more heating elements and/or sensing elements may be arranged above the laminating layer, while the one or more electrically conductive traces or conductor paths 40 are located below the laminate. [0047] An outer laminating layer may be provided over, under, and/or around the base layer 36 and the foil layer 38 to connect, join, and/or maintain the position of the two layers 36, 38 together. The laminating layer may function to protect one or both of the layers 36, 38 from damage if liquid and/or solid contaminates enter the blanket 18 and/or penetrate one or more of the cover layers 26, 32 and/or insulating layers 30. The laminating layer may function to distribute heat generated by the heating layer 28 and/or the foil layer 38.

[0048] In some configurations, the foil layer 38 and/or the remaining portions of the foil layer 38 may be covered with a suitable material, cladding, and/or surface treatment to allow attachment or connecting of one or more heating elements 42, one or more electrical conductors 44, one or more sensing elements 46, or a combination thereof to the foil layer 38. This may be advantageous when the foil layer 38 is made of a material that is or includes aluminum. Because aluminum or other similar materials may oxidize on their surface that may inhibit or prevent solder or other attaching mechanism from bonding to it, a need may exist for a cladding (e.g., copper or like materials) and/or a surface treatment to be applied to the foil layer 38 before electrical components like heating elements 42, sensing elements 46, conductors 44, and/or the like can be attached thereto. An example of a surface treatment that may be applied to the aluminum and/or foil layer 38 is MINA, developed by AVERATEK.

[0049] The heating segment 34 may be a generally planar and/or elongated member or flexible sheet that comprises one or more heating sections 48 and one or more sensing sections 50.

[0050] The one or more heating sections 48 may comprise one or more heating elements that are configured to generate heat in response to a supply of electrical energy. [0051] The one or more sensing sections 50 may comprise one or more sensing elements that are configured to monitor or determine an amount of heat generated by the one or more heating sections 48 or heating elements.

[0052] The sections 48, 50 may be separate sections that are connected together in a subsequent forming operation, or the two sections 48, 50 may be integrally formed without having to attach or connect the two sections together.

[0053] The one or more heating sections 48 may be made of one or more carrier or base layers 36 and one or more foil layers 38. One or more dividers 52 may be provided or defined between two adjacent sections 48, 50. The sections 48, 50 and the divider 52 may be located in a common plane. The divider 52 may be electrically conductive or electrically non-conductive. While the divider 52 is illustrated as extending along an axis that is generally parallel to a longitudinal axis of the heating segment 34, it is understood that the divider 52 may extend along an axis that is perpendicular to a longitudinal axis of the heating segment 34 or located at any other angle besides parallel to the longitudinal axis of the heating segment 34. In other words, the divider 52 may extend at a diagonal or different angle relative to a longitudinal axis L of the heating segment 34. Furthermore, the size (i.e., width and/or length) of the two sections 48, 50 may be substantially the same or substantially different. In other words, a size (width and/or length) of one of the sections 48, 50 may be larger or greater than the other section 48, 50 or a size of the two sections may be generally the same.

[0054] The heating segment 34, the foil layer 38, or both, may include one heating zone 54 or a plurality of heating zones 54. For exampe, FIG. 3A illustrates four (4) heating zones 54, which are further identified as A-D and separated or defined between the dashed lines 55. The number of heating zones 54 can vary depending on the manufacturing process of making the heating segment 34 or heating layer. In other words, a short heating segment 34 may be made of, or comprise only one heating zone 54. Or, a longer heating segment 34 may be made of, or comprise virtually any number of heating zone 54 (e.g., two or more zone 54, five or more zone 54, ten or more zone 54, fifty or more zone 54, etc.). Advantageously, this means that a heating blanket 18 can be constructed having virtually any size (e.g., length or width) by varying the size (i.e., length or width) of the heating segment 34, which thus varies the number of heating segments 34.

[0055] While the plurality of heating zones 54 are illustrated as each having generally the same size (e.g., height and width), it is understood that each of the heating zones 54 may have a different size from one another (e.g., a different height and/or width relative to other heating zones 54). Each heating zone 54A, B, C, D may include one or more conductor paths or traces 40, one or more heating elements 42, one or more sensing elements 46, or a combination thereof.

[0056] In some configurations, one or more of the heating zones 54 have exactly one heating element 42 and exactly one sensing element 46. The heating element 42 may be the conductive trace 40 that extends or meanders within the heating zone 54. The extending or meandering heating element 42 or conductor 40 may meander or extend into the adjacent heating zones 54 or may be exclusively located in a single zone. The exactly one heating element 42 may be located in the heating section 48 and the exactly one sensing element 46 may be located in the sensing section 50. In some configurations, one sensing element 46 may be provided for each heating element 42 or for each pair of heating elements 42.

[0057] In some configurations, one or more of the sensing sections 50 may include one or more conductor paths or traces 40, one or more heating elements 42, one or more sensing elements 46, or a combination thereof. In some configurations, one or more of the sensing sections 50 may include one or more conductor paths or traces 40 and one or more sensing elements 46 but may be free of one or more heating elements 42.

[0058] An overlay or laminate may be placed over the foil layer 36, the base layer 36, or both. The overlay may function to protect the foil layer 38, the conductor paths or traces 40, any elements attached to the foil layer 38 and/or traces 40, or a combination thereof. For example, the overlay or laminate may protect the foil layer 38 and/or heating segment 34 from electrical shorting or other damage, for example if a liquid or other contaminants penetrates the cover layer(s) and/or enters the blanket. For example, the overlay may comprise a polyethylene terephthalate (PET) that is attached to the foil layer 36, base layer 36, or both via an adhesive such as a pressure sensitive adhesive (PSA).

[0059] The heating segment 34, the base layer 36, the foil layer 38, or a combination thereof may include one or a plurality of connecting regions 56. A connecting region 56 may be a portion of a heating segment 34, the base layer 36, the foil layer 38, the heating zone 54, or a combination thereof used for connecting or joining together multiple different heating segments 34, base layers 36, foil layers 38, heating zones 54, or a combination thereof. A connecting region 56 may permit electrical energy and/or electrical communication signals to be transferred, communicated, and/or conducted between or through adjacent and/or connected heating segments 34 and the controller 12, power source, etc. (Fig. 1). A connecting region 56 may be provided on any of the edges or perimeter of the heating segment 34, the base layer 36, the foil layer 38, heating zone 54, or a combination thereof. A connecting region 56 may also be located at the divider 52, as discussed below with reference to FIGS. 4A-6, or even at the divider 55. A connecting region 56 may comprise one or more conductors or traces that enables transmission or conduction of heat, electrical power, communication signals, or a combination thereof between different heating segments 34 and/or elements on the segments (traces, heating elements, sensing elements, etc.) [0060] With additional reference to FIGS. 4A and 4B, a heating segment 34 can be manipulated from a generally planar construction illustrated in Figs. 3 A, 3B, 4A into a folded or 3-dimensional construction illustrated in Fig. 4B. The heating section 48 and/or the sensing section 50 may be folded or moved about the divider 52 (See arrow in Fig. 4A) so that the sections 48, 50 become juxtaposed or adjacent each other as illustrated in Fig. 4B. In the folded configuration, the foil layer 38 of the sensing section 50 may face or may be adjacent or juxtaposed to the foil layer 38 of the heating section 48. However, in other folded configurations, the base layer 36 of the sensing section 50 may face or may be adjacent or juxtaposed to the base layer 36 of the heating section 48. In the folded configuration, the sensing section 50 and the heating section 48 are located in different, adjacent planes. The two planes may be generally parallel to each other, or the two planes may be slightly angled relative to each other, depending on the size of the divider 44 and/or the folding of the sections 48, 50 and how tight the fold is at the divider 52. The sensing section 50 comprises one or more sensing elements that are configured to monitor or determine an amount of heat generated by the one or more heating elements in the heating section 50 upon which it is now located adjacent to after folding.

[0061] Referring now to FIG. 5, the two heating segments 34, 34’ are connected, coupled, or joined together to form the heating layer 28 (or a portion of a heating layer 28 if additional heating segments 34 are subsequently connected to form a larger heating layer 28 and/or heating blanket 18). Each of the two heating segments 34, 34’ are folded into the configured illustrated in Fig. 4B. The two heater segments 34, 34’ can be connected, coupled, or joined together by abutting, joining together, or putting into contact the respective dividers 52, 52’. The coupled two heater segments 34, 34’ can be held together via suitable fasteners, such as welds, stitching, adhesives, tape, etc. Thus, the dividers 52, 52’ function as a connecting region 56 on each heating segment 34. When connected together via the dividers 52, 52’, electrical energy and/or signals may be communicated or conducted between the two heater segments 34, 34’ . This means that the dividers 52, 52’ and/or connecting regions 56 include at least one electrical conductor 44 or path 40. The dividers 52, 52’ may also include one or more heating elements 42 and/or sensing elements 46.

[0062] FIG. 6 illustrates a heating layer 28 or a portion of heating layer 28 that comprises four (4) heating segments 34, 34’, 34”, and 34’”. Heating segments 34 and 34’ are coupled together via the dividers 52, 52’ as shown in Fig. 5. Similarly, heating segments 34” and 34’” are coupled together via their respective dividers by folding the respective sections 48, 50 according to FIGS. 4 A and 4B and coupling them together according to FIG. 5. The heating segments 34 and 34” are then connected or coupled together via respective connecting regions 56 located or defined at the side edges thereof. Accordingly, electrical energy and/or signals may be communicated or conducted between all of the heater segments 34, 34’, 34”, and 34’” and the controller and/or power source (FIG. 1).

[0063] In FIG. 6, an optional support 58 may be provided to assist with connecting the heater segments 34, 34’, 34”, and 34’”. The support 58 may be an adhesive tape. The support 58 may be electrically conductive so that electrical energy and/or signals may be communicated or conducted between all of the heater segments 34, 34’, 34”, and 34’” and the controller or power source. The support 58 may be non-electrically conductive or may be an insulator. The support 58 may extend along a longitudinal axis L of the segments and/or heating layer 28. A similar support may also extend at the other regions of the connecting regions 56, for example, in the vertical regions between heater segments 34 and 34” and 34’ and 34’”. [0064] The heating blanket 18, the heating layer 28, and/or one or more of the heating segments 34 may include one or more connectors 24. A connector 24 may be used to connect or couple the heating blanket 18, the heating layer 28, and/or one or more of the heating segments 34 to the controller 12 or power source. The connector 24 may be enabled to communicate, transmit, and/or conduct electrical energy and/or signals between the controller 12 and the one or more heating segments 34. The connector 24 may be electrically connected to the one or more conductor paths or traces 40, the support 58, the one or more connecting regions 56, or a combination thereof. [0065] By connecting or joining together two or more heater segments 34, a heating layer 28 and/or blanket 18 of any size may be constructed. Advantageously, this means that a common machine and/or process may be used to construct commonly sized and shaped heater segments 34 that can then be manipulated, arranged, and/or joined together with other similar heater segments 34 to form a heating layer 28 and/or blanket 18 of any desired shape or size.

[0066] FIGS. 7 A and 7B illustrate another exemplary method of joining together two or more heating segments 34, 34’ . The heating segments 34, 34’ are brought together such that the sensing section 50 of heating segment 34 is juxtaposed or placed adjacent to or in contact with the heating section 48’ of heating segment 34’ and the sensing section 50’ of heating segment 34’ is juxtaposed or placed adjacent to or in contact with the heating section 48 of heating segment 34. In such a connection, the foil layer of the sensing section 50 may face or may be adjacent or juxtaposed to or in contact with the foil layer of the heating section 48’ . However, in some folded configurations, the base layer of the sensing section 50 may face or may be adjacent or juxtaposed to or in contact with the base layer of the heating section 48’.

[0067] The sensing section 50 or the one or more sensing elements of sensing section 50 of heating segment 34 is configured to monitor or determine an amount of heat generated by the one or more heating elements of the heating section 48’ of heating segment 34’. The sensing section 50’ or the one or more sensing elements of sensing section 50’ of heating segment 34’ is configured to monitor or determine an amount of heat generated by the one or more heating elements of the heating section 48 of heating segment 34.

[0068] FIG. 8 illustrates a heating layer 28 or a portion of heating layer 28 that comprises four (4) heating segments 34, 34’, 34”, and 34’”. Heating segments 34 and 34’ are coupled as shown in Fig. 7B. Similarly, heating segments 34” and 34’” are also coupled according to FIG. 7B. The heating segments 34 and 34” are then connected or coupled together via respective connecting regions 56 at the side edges thereof. Accordingly, electrical energy and/or signals may be communicated or conducted between all of the heater segments 34, 34’, 34”, and 34’”.

[0069] An optional support 58 may be provided to assist with connecting the heater segments 34, 34’, 34”, and 34’”. The support 58 may be an adhesive tape. The support 58 may be electrically conductive so that electrical energy and/or signals may be communicated or conducted between all of the heater segments 34, 34’, 34”, and 34’” and the controller or power source. The support 58 may be an insulator or non-electrically conductive. The support 58 may extend along a longitudinal axis L of the segments and/or heating layer 28. A similar support may also extend at the other regions of the connecting regions 56, for example, in the vertical regions between heater segments 34 and 34” and 34’ and 34’”.

[0070] The heating blanket 18, the heating layer 28, and/or one or more of the heating segments 34 may include a connector 24. The connector 24 may be used to connect or couple the heating blanket 18, the heating layer 28, and/or one or more of the heating segments 34 to the controller 12. The connector 24 may be enabled to communicate, transmit, and/or conduct electrical energy and/or signals between the controller 12 and the one or more heating segments 34. The connector 24 may be electrically connected to the one or more conductor paths or traces 40, the support 58, the one or more connecting regions 56, or a combination thereof. The connector 24 may be directly connected to one of the heating segments 34, and signals may be passed from the heating segment 34 that is directly connected to the connector 24 to the other heating segments 34’, 34”, and 34’” that are connected to the heating segment 34. Alternatively, the connector 24 may be directly electrically connected to more than one heating segment.

[0071] FIG. 9 illustrates a heating layer 28. The heating layer 28 comprises plural heating segments 34, 34’, 34” and 34’”. Remarks regarding the heating layer 28 from any of the figures and/or paragraphs herein may apply to FIG. 9 and vice versa. The heating layer 28 may include only heating segments 34 and 34” and/or only heating segments 34’ and 34’”.

[0072] The heating segments 34, 34’ may be integrally formed or may be connected at a connecting region 56 or by a support 58. Similarly, the heating segments 34”, 34’” may be integrally formed or may be connected at a connecting region or by a support. In other configurations, the heating segments 34, 34’ and/or 34”, 34’” may be separated at the connecting region 56 by a cutting, slicing, or separating operation. The separated heating segments may be joined with other heating segments to make the heating layer 28. Alternatively, a heating layer 28 may be made with only one of the heating segments 34, 34’ and/or 34”, 34’”.

[0073] Each heating segment 34, 34’, 34”, 34’ ’ comprises one or more heating sections 48 having one or more conductor paths or traces 40 and/or one or more heating elements 42. Each heating segment 34, 34’, 34”, 34” comprises one or more sensing sections 50. Each sensing section 50 comprises one or more fingers 60, 60’, 60”, 60’” projecting or extending or cantilevering from a long edge of the respective heating segment. The fingers may also or instead project from one or more short edges of the heating segment and/or from both long edges of a heating segment. The sensing sections 50 and/or fingers 60 may be integrally formed or formed as separate components and connected together using one or more of any of the fasteners disclosed herein. Each finger comprises one or more conductor traces 40 and/or sensing elements 46, 46’, 46”, 46’”. The heating segments 34, 34’, 34” and 34’” may include one or more other features disclosed in any of the figures herein and/or description.

[0074] Referring back to Figs. 3A-7B, the sensing sections 50 in Figs. 3 A-7B may have a sheet like structure projecting from the edge of the heating section 48. In contrast, the sensing sections 50 in Figs. 8-11 may be fingers or teeth or other projections that extend from an edge of the heating section 48. In other words, a gap of void or absence of material may be defined between adjacent sensing sections 48. The gap between adjacent sensing sections 48 may be tuned to obtain accurate temperature readings from the corresponding heating section.

[0075] FIG. 10 illustrates the heating segments 34, 34’, 34”, 34” of FIG. 9 joined or connected together to form a heating layer 28. More specifically, a finger or sensing element is configured to contact or sense heat provided or generated by an adjacent heating section in a different heating segment. Stated another way, referring to both FIGS. 9 and 10, the one or more fingers 60 or sensing elements 46 overlap or are positioned or placed on or below the heating segment 34” or heating elements 42”; the one or more fingers 60’ or sensing elements 46’ overlap or are placed on or below the heating segment 34’” or heating elements 42’”; the one or more fingers 60’” or sensing elements 46’” overlap or are placed on or below the heating segment 34’ or heating elements 42’; the one or more fingers 60” or sensing elements 46” overlap or placed on or below the heating segment 34 or heating elements 42’.

[0076] FIG. 11 illustrates another heating layer 28 that includes heating segments 34, 34’, 34”, and 34” ’ . Remarks regarding the heating layer 28 from any of the figures and/or paragraphs herein may apply to FIG. 11, and vice versa. In some configurations, the heating layer 28 may include only one heating segment, or more than the four segments shown in this figure. Also, the heating segments may be arranged in any pattern or orientation. For example, while the heating segments of FIG. 11 are arranged to form a rectangular heating layer 28, the segments may be arranged to form other shapes, such as a square, L-shape, T-shape, J-shape, I-shape, etc. This applies to any of the other heating segments and/or layers herein.

[0077] The heating layer 28 may include any number of heating segments (i.e., the layer 28 can have as little as one segment or any plurality of segments). The heating layer 28 may include the elements or features illustrated and described in the previous figures. In FIG. 11, however, the sensing section 50 is a separate piece or layer than the one or more heating sections 48 and/or heating segments 34, 34’, 34”, and 34’”. In other words, one or more of the heating segments 34, 34’, 34”, and 34’” may be one or more layers that include the one or more conductor paths or traces 40 and/or one or more heating elements 42, and then a separate layer or sheet that includes the sensing section 50 (e.g., the one or more sensing elements 46 and connecting traces 40) may be applied onto (i.e., placed above and/or below) the one or more heating segments 34, 34’, 34”, and 34’”. The two layers may be connected or attached via one or more fasteners or adhesives, for example: tape, welding, pins, switches, hook and loop fasteners, adhesive pastes. Additionally, or alternatively, a laminate may be provided above, below, and/or around the sheets to join and maintain the layers together. The adhesives, fasteners, and/or laminate may function to restrict or prevent any relative movement between the two sheets.

[0078] The edges or connecting regions 56 (See FIG. 3 A) of each heating segment 34, 34’, 34”, and 34’” may be brought together and connected to each other via one or more supports or other mechanisms. The sensing section 50 may then be provided over and/or below each of the one or more heating sections 48. The sensing section 50 may be attached to the heating segments [0079] The sensing section 50 comprises one or more fingers 60 having sensing elements 46 for sensing heat generated by each of the one or more heating sections 48. The heating elements 42 and/or sending elements 46 can be electrically connected via one or more traces to an edge region of the heating layer 28, to the connector 24.

[0080] FIGS. 12 and 13 illustrate the heating layer 28. The heating layer 28 may include any of the features, elements, and/or description in any of the figures and paragraphs disclosed herein, and any of the teachings in FIGS. 12 and 13 may be applied to any of the other Figures and/or paragraphs herein.

[0081] The heating layer 28 may include one or more slits, slots, cuts, voids, tears, openings, apertures, absence of material 74, which will hereafter be referred to herein as one or more slits 74. The one or more slits 74 may be arranged anywhere on the profile of the heating layer 28 (e.g., along the edges, in a center region, at a top region, bottom region, left region, right region, etc.). One or all of the heating segment 34, 34’, 34”, 34” may include one or more slits 74. One or all of the heating segments may be free of any slits 74. The one or more slits may extend through one or more or all layers of the heating layer 28, for example, through the layer that includes the one or more conductor paths or traces 40 and/or one or more heating elements 42, the layer that includes the sensing section 50, and/or the laminating layer that surrounds the two aforementioned layers.

[0082] The one or more slits 74 may function to add flexibility to the heating layer 28 to allow the heating layer 28 and/or blanket 18 to confirm to the surround areas and/or a patient’s body as shown in FIG. 14. One or more of any of the other layers of the blanket 18 discussed herein (e.g., the one or more insulation layers and/or the one or more cover layers) may include similar slits 74 to further provide flexibility and ability for the blanket 18 to conform to the surroundings and/or a patient. One or more of any of the layers discussed herein may be free of any slits.

[0083] The one or more slits 74 may be provided in regions that are free of any conductors, heaters, sensors, etc. The one or more slits 74 may be continuous and meander and/or extend along an entire length of the heating layer 28, or the one or more slits may be discrete, individual slits 74 scattered along the length or profile of the heating layer 28. The one or more slits may have any shape (circular, square, rectangle, triangle, etc.). The one or more slits may be perforations. In some instances, the one or more slits may not extend through the entire thickness of the layer. Instead, a slit may be a thinned, recessed, or scalloped part of the material. In other words, such a slit may be thinner region of the material thickness of the particular layer.

[0084] In some configurations, one or more attachment features may be passed through the one or more slits 74. For example, one or more attachment features that connect the layers of the blanket (e.g., cover layer 30, 32, heating layer 28, insulating layers 30) may pass through the one or more slits 74 in the heating layer 28. This may provide for the layers to be connected together without having or bond, pierce, or attach directly to the heating layer 28. Instead, the attachment may pass through a void of slit 74 already defined in the heating layer 28 before being assembled to the blanket 18. The attachment feature may be any attachment feature disclosed herein (e.g., weld, stich, button, clasp, rivet, hook and loop fastener, heat stake, magnet, etc.).

[0085] FIG. 14 illustrates the heating blanket 18. The heating blanket 18 may comprise one or more layers. The one or more layers may include: a top or first cover layer 26, a heating layer 28, a plurality of insulating layers 30, a bottom or second cover layer 32 and one or more connectors or plugs 24. All remarks regarding the heating blanket 18 illustrated and described in any of the figures and/or paragraphs may apply to the blanket illustrated in FIG. 14 and vice versa.

[0086] One or both of the cover layers 26, 32, may have a size that is greater than or larger than one or more of the other middle layers of the blanket 18, like the heating layer 28 and/or the insulating layers 30.

[0087] It is understood that a blanket 18 and/or heating layer 28 may be constructed by combining the teachings in any of the Figures. This may further provide ability to construct a custom sized heating blanket and/or heating layer 28 without having to manufacture heating layers 28 or heating segments 34 of various sizes.

[0088] With additional reference to FIG. 15, an assembled blanket 18 is shown. The blanket 18 includes a first attachment region 62. The first attachment region 62 may be located within or inside a periphery or edges of 66 of the blanket 18 (e.g., within the perimeter or outside or outer most edge of the blanket 18 or the cover layers 30, 32). The first attachment region 62 may join attach or connect together one or more layers of the blanket 18. For example, the first attachment region 62 may connect or join together the cover layers 30, 32. However, it is within the scope of this disclosure that the first attachment region 62 may also connect together one or more of the other middle layers 28, 30 of the blanket 18.

[0089] The first attachment region 62 may surround the entire perimeter of the heating layer 28 or other middle layers like an insulation layer so that the heating layer 28 and/or other middle layers are contained within a pouch or envelope defined by the cover layers 30, 32 within a boundary of the first attachment region 62. Alternatively, the first attachment region 62 may not extend around an entire perimeter of the heating layer 28; instead, the first attachment region 62 may be arranged adjacent one or more edges of the heating layer 28, two or more edges, three or more edges, etc. For example, in FIG. 15, the first attachment region 62 is illustrated adjacent two opposing edges of the heating layer 28.

[0090] The first attachment region 62 may be formed with suitable attachment or connection elements, such as welding stitching, adhesives, clamps, pins, hook and loop fasteners, snaps, buttons, clasps, tape, and the like. The first attachment region 62 may be a continuous region. This means that there are no gaps, spaces, or absence of attachment material in the first attachment region 62. Alternatively, the first attachment region 62 may be intermittent - this means there may be spaces, gaps, or absence of attachment material in the first attachment region 62. For example, if the first attachment region 62 comprises welding (e.g., ultrasonic, RF, etc.), then there may be gaps, spaces, or absence of weld material adjacent to sections that include the weld material. Air may pass through the gaps, spaces, or absence of weld material such that there is no hermetic seal of the layers inside of the pouch. Alternatively, if the first attachment region 62 is continuous and comprises welding, then there are no gaps, spaces, or absence of welding in the attachment region 62. A hermetic seal may be achieved in such a configuration, such that there is little or no exchange of air between the inside pouch containing the one or more layers and the region on the other side of the attachment region 62.

[0091] The heating blanket 18 may include one or more flaps 64. The one or more flaps 64 may be regions of the blanket 18 between the first attachment region 62 and an outermost edge 66 of the blanket 18, the one or more layers, the one or more cover layers 30, 32, or a combination thereof. The one or more flaps 64 may be arranged along the long edges of the blanket 18, the short edges of the blanket 18, or both. One or more of the long edges and/or short edges may be free of a flap 64. [0092] The one or more flaps 64 may be free of any middle layers, except for one or both of the cover layers 30, 32. Alternatively, the one or more flaps 64 may also include one or more of the middle layers (i.e., heating layer 28, insulation layers 30, or both.) The one or more flaps 64 may be used to secure the blanket 18 to a bed, stretcher, floor, around a patient, or a combination thereof. For example, the one or more flaps 64 may be tucked under a patient or mattress or secured to a frame to prevent the blanket 18 from moving or falling off. The one or more flaps 64 may be used to hang the blanket when not in use.

[0093] The heating blanket 18 may include a second attachment region 68. The second attachment region 68 may join attach or connect together one or more layers of the blanket 18. For example, the second attachment region 68 may connect or join together the cover layers 30, 32. However, it is within the scope of this disclosure that the second attachment region 68 may also connect together one or more of the other layers 28,8, 30 of the blanket 18.

[0094] The second attachment region 68 may be located at or near the outermost edge or perimeter 66 of the layers and/or blanket 18. The second attachment region 68 may be arranged around an entire perimeter of the heating layer 28. The second attachment region 68 may not be arranged around an entire perimeter of the heating layer 28; instead, the second attachment region 68 may be arranged adjacent one or more edges of the blanket 18. The blanket 18 may be free of the second attachment region 68 and/or the first attachment region 62 in a region 70 where the connector 24 connects to the blanket 18 and/or heating layer 28. By being free of the second attachment region 68 in this location (and also possibly free of the first attachment 62), access to the one or more inner layers or the heating layer 28 may be provided so that one or more connectors 24 and/or plugs can be connected to the heating layer 28. [0095] The second attachment region 68 may be formed with suitable attachment or connection elements, such as welding stitching, adhesives, clamps, pins, hook and loop fasteners, snaps, buttons, clasps, tape, and the like. The second attachment region 68 may be a continuous region. This means that there are no gaps, spaces, or absence of attachment material in the second attachment region 68. A continuous second attachment region 68 may or may not provide a hermetic seal within the blanket. The second attachment region 68 may be intermittent - this means there may be spaces, gaps, or absence of attachment material in the second attachment region 68. For example, if the second attachment region 68 comprises welding (e.g., ultrasonic, RF, etc.), then there may be gaps, spaces, or absence of weld material. An intermittent second attachment region 68 may be free from providing a hermetic seal, meaning air can pass through the second intermittent attachment region 68. Alternatively, if the second attachment region 68 is continuous and comprises welding, then there are no gaps, spaces, or absence of welding in the attachment region 68 and air may be restricted or prevented from passing through the attachment region 68.

[0096] The heating blanket 18 may include a third attachment region 72. The third attachment region 72 may join attach or connect together one or more layers of the blanket 18. For example, the third attachment region 72 may connect or join together two or more of the inner layers of the blanket 18, like the one or more heating layers 28 and one or more insulating layers 30. For example, the third attachment region 72 may connect or join together one or more of the inner layers of the blanket 18, like the one or more heating layers 28 and one or more insulating layers 30 to one or more of the cover layers 30, 32. The third attachment region 72 may be a tape or adhesive that is between or sandwiched between two or more of the layers 26, 28, 30, 32 of the heating blanket 18. The third attachment region 72 may be a tape or adhesive that is provided around edges of two or more of the inside layers 28, 30 of the heating blanket 18, or both. The third attachment region 72 may be anywhere, including attaching the outer edges or perimeter of the layers. The third attachment region 72 may be anywhere, including on or between the faces or profiles of the layers, between the outer edges or perimeter. The third attachment region 72 may be formed with suitable attachment or fastening elements, such as welding stitching, adhesives, clamps, pins, hook and loop fasteners, snaps, buttons, clasps, tape, double sided tape, PSA, and the like.

[0097] FIG. 16 illustrates the heating blanket 18. The heating blanket 18 may comprise one or more layers. The one or more layers may be selected from: a top or first cover layer 26, a heating layer 28, a plurality of insulating layers 30, a bottom or second cover layer 32 and one or more connectors or plugs 24. All remarks regarding the heating blanket 18 illustrated and described in any of the figures and/or paragraphs may apply to the blanket illustrated in FIG. 12 and vice versa. [0098] It is understood that a blanket 18 and/or heating layer 28 may be constructed by combining the teachings in any of the Figures. This may further provide ability to construct a custom sized heating blanket and/or heating layer 28 without having to manufacture heating layers 28 or heating segments 34 of various sizes.

[0099] The following paragraphs provide additional disclosure regarding the heating system, the method of making the heating system and/or heating blanket, the heating blanket, and one or more layers or elements of the heating blankets. All disclosure relating to any element may be combined, omitted, duplicated, omitted, or modified by any teaching herein to form a heating system, blanket, and/or method of manufacturing of the same.

[0100] The heating system may include one or more heating blankets. A heating blanket may be enabled or configured to generate heat. A heating blanket may include one or more layers and/or elements that are enabled or configured to convert electrical energy into heat energy to generate heat. The electrical energy may be supplied from a power source, controller, or both. The electrical energy may come from an AC power source, a DC power source, or both.

[0101] A heating blanket may be placed over, under, or around a patient, user, animal, object, etc. to increase or maintain a temperature of the user, animal, object, etc. and/or increase air surrounding the user, animal, object, etc. For example, a heating blanket may be used to cover a user, animal, or object from a top side. A heating blanket may be used to wrap a user, patient, animal, or object so the top, bottom and sides of the user, animal, or object are covered. A heating blanket may be used to support a user, patient, animal, or object from a bottom side (e.g., the heating blanket may be a pad or mattress or a mattress cover). A heating blanket may be used cover or wrap only a portion of a user or patient, such as an arm, leg, torso, head, etc. A heating blanket may be used in medical and/or non-medical procedures.

[0102] A heating blanket (and/or one or more layers of the heating blanket) may have any shape. For example, the heating blanket and/or one or more of the layers thereof, may have a generally rectangular shape, a square shape, circular or round shape, oblong or oval shape, etc.

[0103] A heating blanket (and/or one or more layers of the heating blanket) may be radiolucent or at least generally transparent, to X-rays so a patient can be warmed during a medical procedure. [0104] A heating blanket may include one or more layers. The one or more layers may include a top or first cover layer, a heating layer, an insulating layer, and a bottom or second cover layer. One or more of these layers may be duplicated and/or eliminated. One or more of the layers may be divided into two or more layers. Two or more of these layers may be combined into a single layer. Any of the layers may be arranged in any order. Any of these layers may include one or more sub layers. For example, the heating layer may include a base or carrier layer and a foil or conductive layer.

[0105] A heating blanket and/or one or more layers of the heating blanket (e.g., heating layer) may include one or more plugs, ports, and/or connectors for connecting to one or more of the cables, controllers, power sources, or a combination thereof. The heating blanket and/or one or more layers of the blanket, may include one or more knobs, buttons, levers, switches, and/or keypads for turning the system ON and OFF, increase and/or decreasing a heat output from the heating blanket, increasing and/or decreasing a power supply to the heating blanket, monitoring the heating performance of the heating blanket, suppressing one or more alarms, or a combination thereof. [0106] A heating blanket may include one or more layers. A heating blanket may include on eo more heating layers. A heating layer may function to generate heat. A heating layer or one or more elements or components of the heating layer may function to convert electrical energy or power into heating energy or heat.

[0107] A heating layer or one or more of the other layers, may be flexible, stretchable, foldable, bendable, Tollable, and/or foldable. The heating layer, or one or more of the other layers may be adapted to stretch into a 3 -dimensional compound curve without wrinkling or folding while maintaining electrical conductivity, and subsequently return to the same generally planar shape. The heating layer may include one or more slits, slots, recesses, holes, or absence of material. The one or more slits, slots, recesses, holes, or absence of material may function to provide for the heating layer and/or blanket to bend, fold, and/or conform to a patent or object. The one or more slits, slots, recesses, holes, or absence of material may function to provide for one or more fasteners to puncture or extend through the heating layer to connect together two or more layers of the blanket. [0108] The heating layer may be made of one or more layers or sub layers. The one or more layers of the heating layer may be a base or carrier layer and a foil or conductive layer.

[0109] A heating layer may include one or more base or carrier layers. A base or carrier layer may function to support the foil or conductive layer that is placed on top and/or on the bottom of the carrier layer. A foil or conductive layer may surround a base or carrier layer. A base or carrier layer may function to provide strength and/or rigidity to the heating layer.

[0110] A base or carrier layer may be made of a suitable material, such as polyurethane, polypropylene, polymethylene, or the like. A base or carrier layer may be made of a conductive or non-conductive material. The base or carrier layer may be made of a woven or knitted material. The base or carrier layer, or any other layer of the heating blanket, may be made of a material that is flexible, stretchable, foldable, bendable, Tollable, or the like. This may advantageously enable the heating layer, or any other layer of the blanket to be easily folded, rolled, crumbled,

[0111] A heating layer may include one or more foil or conductive layers. The conductive layer may function to convert electrical energy or power into heating energy or heat. The conductive layer may comprise one or more electrically conductive materials. For example, the conducive layer may be made of or comprise a material such as metal, copper, aluminum, nickel, silver, or the like.

[0112] The conductive layer may be supported on one or more carrier or base layers. The conductive layer may be supported on one side of the base layer (e.g., a top side). The conductive layer may be supported on both sides of the base layer (e.g., a top and bottom side).

[0113] The conductive layer may be placed, attached, connected, secured, welded, and/or printed onto the base layer. The conductive layer may be a foil, sheet, layer. The conductive layer may undergo one or more operations to remove certain portions of the conductive layer from the base layer. The portions of the conductive layer remaining on the base layer may be formed into one or more bus bars, conductive traces or conductive paths, heating elements, temperature sensors, or a combination thereof. The operation may provide for the remaining portions to have different thickness, widths, shapes, and/or contours to form the respective traces or conductive paths, heating elements, temperature sensors, or a combination thereof. The operation may include a milling, dry milling, grinding, stamping, shaping, or other material removal process. The operation may be free of any acid etching or acid removal or chemical solvent or copper etching or acid corrosion process, which may thus be more environmentally friendly. Alternatively, or additionally, the operation may be a printing operation, where the one or more bus bars, conductive traces or conductive paths, heating elements, temperature sensors, or a combination thereof are printed or applied onto the base layer.

[0114] The conductive layer may undergo one or more operations or processes to remove and/or prevent the formation of aluminum oxide on the conductive layer. This may optionally occur before or after any material removal operations. Such process may include nickel-palladium or nickel-silver plating. A surface treatment such as MINA developed by AVERATEK can be applied to the aluminum. The surface treatment may provide for the conductive layer or the remaining portion of the conductive layer after the material removal option to accept solder so that one or more elements like traces, conductors, heating elements, temperature sensors, or a combination thereof can be attached.

[0115] A heating segment may have one or more connecting regions. A connecting region may be a region or section of the heating segment that functions, allows, or permits one or more heating segments to be connected to another one or more heating segments. For example, a heating segment may comprise one or more conductors, conductive traces, conductive paths, heating elements, temperature sensors, or a combination thereof. By connecting together one or more connecting regions, electric power and/or communication signals may be conducted and/or communicated between and/or through the connecting heating segments. This allows multiple heating segments to be connected together and then controlled and/or monitored via the controller. [0116] A connecting region may be located at one or more of the edges of the heating segment. A connecting region may be located at one or more outer edges or outer most perimeter. A connecting region may be located across a planar face of the heating segment. A connecting region may be formed by folding, bending, creasing, and/or manipulating a heating segment. Adjacent connecting regions may be connected together via one or more fasteners, adhesives, conductors, tapes, pastes, adhesives, or the like.

[0117] The heating layer, heating segment, and/or the conductive layer may include one or more heating elements. A heating element may function to generate heat in response to being supplied with electrical energy.

[0118] A heating element may have an operating voltage of between about 10 and 50 V or between about 12 and 24 V. A heating element heating element may have a power density of between about 10 and 500 W/m ² , between about 50 and 300 W/m ² , or between about 150 and 250 W/m A heating element may have a power output between about 10 and 500 W, between about 50 and 200 W, or between about 100 and 130 W. A heating element may have a resistance between about 1 and 10 Ohm or between about 2 - 6 Ohm.

[0119] A heating element may be an integral part of the conductive layer. That is, after the conductive layer undergoes a material removal process, the remaining sections of the conductive layer may include or be the one or more heating elements. Additionally, or alternatively, a heating element may be attached to the remining sections of the conductive layer and/or the carrier layer via an attaching operation, such as printing, welding, soldering, etc.

[0120] A heating layer, heating segment, heating zone, or a combination thereof may include one or more heating elements. If a heating layer, segment, zone, or a combination thereof includes plural heating elements, the plural heating elements may be arranged electrically in series, electrically parallel to each other, or a combination thereof.

[0121] A heating element may be a resistor. A heating element may be a positive temperature coefficient (PTC) heater. A PTC heater may be a self-regulating heater. The heating element may be made of or comprise a material such as metal, copper, aluminum, nickel, silver, or the like. [0122] The heating layer, heating segment, and/or the conductive layer may include one or more conductive traces or paths. A conductive trace or path may function to transfer or conduct electrical energy from the controller or power source to the one or more heating elements, sensing elements, or both. A conductive trace or path may function to transfer or conduct electrical communication signals between the controller or power source and the more heating elements, sensing elements, or both.

[0123] A conductive trace or path may be an integral part of the conductive layer. That is, after the conductive layer undergoes a material removal process, the remaining sections of the conductive layer may include or be the one or more conductive traces or paths. Additionally, or alternatively, a conductive trace or path may be attached to the remining sections of the conductive layer and/or the carrier layer via an attaching operation, such as printing, welding, soldering, etc. The conductive trace or path may be made of or comprise a material such as metal, copper, aluminum, nickel, silver, or the like. [0124] conductor or trace may function to electrically connect together one or more controllers, heating segments, heating zones, heating elements, sensing elements, or a combination thereof. An electrical conductor or trace may include exactly one heating element and/or sensing element. An electrical conductor or trace may include plural heating elements and/or sensing elements. A heating segment may thus include one or more conductors or traces per each heating zone.

[0125] The electrical conductors or traces may be arranged anywhere on the heating layer, heating zone, heating segment, or a combination thereof. For example, one or more of the conductors or traces may be arranged along a center longitudinal axis of the heating layer, heating zone, heating segment, or a combination thereof. For example, one or more of the conductors or traces may be arranged in a region located above or below a center longitudinal axis of the heating layer, heating zone, heating segment, or a combination thereof. For example, one or more of the conductors or traces may be arranged along a bottom, top, or side edge of the heating layer, heating zone, heating segment, or a combination thereof. For example, one or more of the conductors or traces may be arranged along a planar face of the heating layer, heating zone, heating segment, or a combination thereof.

[0126] The heating blanket, heating layer, heating zone, heating segment, or a combination thereof may include one or more sensing elements. A sensing element may function to monitor, detect, and/or control one or more of the heating elements. Each heating zone and/or heating segment may include at least one sensing element to monitor and/or control the heating elements in that heating zone. A sensing element may have a NTC semiconductor. A sensing element may be a flat measuring resistor made of a material such as the heating element.

[0127] A sensing element may service as a safety sensor. As a safety sensor, the sensing element may decrease power supplied to the heating element or decrease a heating output if the temperature sensed is at or above a pre-determined level. This may advantageously function to reduce or prevent chances of excessive patient warming or patient burning. The sensing element, safety sensor, or both may be in electrical communication (wired and/or wireless) with an alarm that may be part of the controller or heating blanket to alert (via an audible and/or visual signal) to alert a user and/or operation of a fault, over heat condition, underheat condition, or a combination thereof. [0128] The heating blanket may include one or more sensing elements per heating zone, per heating element, and/or per pair of heating elements.

[0129] The measuring and/or monitoring results of the sensing element may be only related to a part of heating layer, heating segment, heating zone, or a combination thereof. This may advantageously provide for the ability to monitor and understanding heating performance of each heating zone and/or heating element, which may be desirable to debug and locate hot spots (spots or areas with high or excessive heating temperatures) and/or cold spots (spots or areas with little or low heating temperature).

[0130] The sensing element may be electrically connected to the heating element, the controller, the power source, or a combination thereof. One or more sensing element may be electrically connected to the heating element, the controller, the power source, or a combination thereof via one or more conductors or traces. Advantageously, by connecting a sensor element to the controller via a dedicated conductor, the controller may easily monitor the heating performance in a particular heating zone.

[0131] The heating layer may include one or more cover layers. The one or more cover layers may function to protect and/or conceal the other layers of the heating blanket. The one or more cover layers may function to reduce or minimize changes of the heating layer contacting or burning a user or patient. The one or more cover layers may function to restrict or prevent liquids from penetrating the heating blanket and contacting one or more of the other layers, like the heating layer. The one or more cover layers may protect a user or patent from electric shock hazards, burning due to excessive or elevated temperatures generated by the heating layer, or both.

[0132] The one or more cover layers may include a top layer, a bottom layer, or both. In some instances, the top and bottom cover layers may be formed from a single layer that wraps around the other layers of the heating blanket (e.g., the heating layer and/or the insulting layer). In other instances, the top and bottom cover layers may be discrete pieces that are connected together to form an envelope or bag structure, into which the other layers of the heating layer are located. [0133] One or more of the layers may be connected together. For example, the front and back layers may be connected together; the heating layer may be connected to the insulating layer; the insulating layer may be connected to the top layer and/or the bottom layer; the heating layer may be connected to the top layer and/or bottom layer; or any other combination thereof. By connecting one or more of the layers together, it may advantageously reduce or prevent one or more of the layers from moving relative to each other. The one or more layers may be connected with an electrically conductive adhesive, weld, or fastener and/or a non-electrically conducive weld, adhesive, or fastener. For example, the one or more layers may be connected with a one or more rivets, stitching, grommets, hook and loop fasteners, staples, buttons, snaps, push pins, hot melt welding, welding, rf welding, adhesives, glues, and/or the like. Alternatively, one or more of the layers may be free of any connection to one or more other layers.

[0134] The top and bottom cover layers may be joined together to form a hermetically sealed heating blanket. This means that the region between the two cover layers is sealed such that air is unable to enter a region between the two cover layers and/or exit the region between the two cover layers. In other words, there is no or substantially no exchange or air between a region inside the cover layers and/or blanket and the surrounding environment.

[0135] Alternatively, the top and bottom cover layers may be joined together to form a non- hermetically sealed heating blanket. This means that air is able to enter a region between the two cover layers and/or exit the region between the two cover layers. In other words, there is an at least partial exchange or air between a region inside the cover layers and/or blanket and the surrounding environment. Air gaps, voids, or openings may be formed in one or both of the top and bottom cover layers. Voids or breaks in the welds or seals around a perimeter of the heating layer and/or cover layers may permit air to enter and/or exit the region inside the blanket. An opening may be defined in a part of the blanket to access the heating layer. This may allow the connector and/or PCB to be connected and/or disconnected from the heating layer. The connector may also be free of a hermetic seal. That is, an exchange of air may take place through the two parts of the housing of the connector and/or through a region where the PCB extends through the receptacle of the connector.

[0136] The cover layer may be made of a suitable material that to restricts or prevent liquids (disinfectants, blood, etc.) from penetrating and/or being absorbed. For example, the cover layer may be made from a textile material, such as an impregnated or non-impregnated fleece. The cover layer may be made of a spunbond meltblown (SMS) polypropylene with an LDPE film coating. The cover layer may be made from a material comprising polypropylene, LDPE (polyethylene), PVC, urethane, or a combination thereof. The cover layer may comprise a nylon or woven nylon. The cover layer may be made of a material comprising of polypropylene, low- density polymethylene (LDPE) polypropylene, fleece, non-woven fleece, polymeric foam or film, a thermally insulating material, a high-loft fibrous non-woven material, foam, compressible foam, or a combination thereof. The cover layer may include a coating that repels liquids. The cover layer may comprise any of the materials disclosed herein. The cover layer may have a weight on the order of about 30 or more GSM (grams per square meter) or less than 30 GSM. Preferably, the cover layer may have a weight of about 32 GSM. The cover layer may be made of a composition of a nonwoven material and a cover material. The composition may have a weight on the order of about 3 or more GSM or less than 30 GSM. The nonwoven material may have a weight on the order of about 20 or more GSM or less than 20 GSM. The cover material on the nonwoven material (i.e., an LDEP film) may have a weight on the order of about 12 or more GSM or less than 12 GSM. The cover layer may have a tinsel strength of about 7.0 KG/IN (MD) or more or less, 5.5 KG/IN (CD) or more or less, per ASTM D5034-95. The cover layer may have a tear strength of about 2 LB/IN (MD) or more or less. The cover layer may have an elongation of about 40% (MD) or more or less, 60% (CD) or more or less, per ASTM 5034-95. The cover layer may have a film adhesion of 180G or more or less. The bonding pattern of the film to the nonwoven may be any pattern, including diamond shaped.

[0137] The cover layers may be connected together and surround the heating layer and the insulating layer. The heating layer and/or the insulating layer may be connected to the one or more cover layers, to each other, or both. The cover layers may form an envelope, pocket, pouch, and/or bag structure within which the heating layer and or the cover layer are located.

[0138] In some instances, the cover (i.e., top layer and/or bottom layer) may be separated from the rest of the heating blanket. This may be advantageous to wash or sterilize the cover layer(s) or to replace one or both of the cover layers in the event they are damaged, without having to dispose of the entire blanket. [0139] The heating blanket may include one or more insulation layers. An insulation layer may be located adjacent to the heating layer. An insulation layer may be located adjacent to the base or carrier layer of the heating layer. An insulation layer may have protective layer or material to restrict or prevent liquids (disinfectants, blood, etc.) from being absorbed.

[0140] An insulation layer may be made of a material comprising of polypropylene, low-density polymethylene (LDPE) polypropylene, fleece, non-woven fleece, polymeric foam or film, a thermally insulating material, a high-loft fibrous non-woven material, foam, compressible foam, or a combination thereof.

[0141] An insulating layer may function to retain heat generated by the heating layer. An insulating layer may function to protect a user or patient from electric shock hazards, burning due to excessive or elevated temperatures generated by the heating layer. An insulating layer may function to add comfort, softness, and/or weight to the heating blanket.

[0142] A heating blanket comprising a first heating segment comprising a first heating section and a first sensing section, each of the first heating section and first sensing section comprise a foil layer supported on a base layer, the foil layer in the first heating section comprises one or more heating elements and the foil layer in the first sensing section comprises one or more sensing elements, wherein the first heating section is folded over the first sensing section, or the first sensing section is folded over the first heating section such that the first sensing section overlays the first heating section. The one or more heating elements are one or more resistors that are integrally formed on the foil layer in the first heating section. The one or more heating elements are one or more resistors that are attached to the foil layer in the first heating section. The one or more sensing elements are temperature sensors that are integrally formed on the foil layer in the first sensing section. The one or more sensing elements are temperature sensors that are attached to the foil layer in the first sensing section. Prior to folding, the first heating section and the second heating section are arranged in a common plane. The heating blanket comprises a second heating segment comprising a second heating section and a second sensing section, wherein the second sensing section overlays the second heating section. The second heating section is folded over the second sensing section, or the second sensing section is folded over the second heating section. The second heating section is folded over the second sensing section at a second divider or the second sensing section is folded over the second heating section at the second divider, the first heating section is folded over the first sensing section at a first divider or the first sensing section is folded over the first heating section at the first divider, and the first divider is connected to the second divider to couple together the first heating segment and the second heating segment. The first divider and the second divider are arranged along a longitudinal axis of the heating blanket. [0143] The first divider and/or the second divider is electrically conductive. The heating blanket comprises a third heating segment comprising a third heating section and a third sensing section, the third heating segment is coupled to the first heating segment. The heating blanket comprises a fourth heating segment comprising a fourth heating section and a fourth sensing section, the fourth heating segment is coupled to the second heating segment and to the third heating segment. The third heating section is folded over the third sensing section at a third divider or the third sensing section is folded over the third heating section at the third divider, the fourth heating section is folded over the fourth sensing section at a fourth divider or the fourth sensing section is folded over the fourth heating section at fourth third divider, and the third divider is connected to the fourth divider to couple together the third heating segment and the fourth heating segment. The third heating section is juxtaposed to the fourth sensing section, and the fourth heating section is juxtaposed to the third sensing section. [0144] A heating blanket comprising: a first heating segment comprising a first heating section and a first sensing section, the first heating section comprises one or more heating elements and the first sensing section comprises one or more sensing elements, a second heating segment comprising a second heating section and a second sensing section, the second heating section comprises one or more heating elements and the second sensing section comprises one or more sensing elements, the first heating segment and the second heating segment are connected together such that the first heating section of the first heating segment is juxtaposed to the second sensing section of the second heating segment, and the second heating section of the second heating segment is juxtaposed to the first sensing section of the first heating segment. The first heating section and the first sensing section are arranged in a common plane. The second heating section and the second sensing section are arranged in a common plane. The first heating segment comprises a foil layer supported on a base layer, and the one or more heating elements are integrally formed on the foil layer. The first heating segment comprises a foil layer supported on a base layer, and the one or more heating elements are connected to the foil layer. The first sensing segment comprises a foil layer supported on a base layer, and the one or more sensing elements are integrally formed on the foil layer. The first sensing segment comprises a foil layer supported on a base layer, and the one or more sensing elements are connected to the foil layer.

[0145] 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. [0146] 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.

[0147] 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. [0148] The disclosure of "a" or "one" to describe an element or step is not intended to foreclose additional elements or steps.

[0149] 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 or section. 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.

[0150] 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. [0151] The disclosures of all articles and references, including patent applications and publications, 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.