US20250351888A1

US20250351888A1 - Heated Garments and Methods for Constructing Heated Garments

Info

Publication number: US20250351888A1
Application number: US19/209,305
Authority: US
Inventors: Simon Schmitt
Original assignee: Taylor Inventions Inc
Current assignee: Taylor Inventions Inc
Priority date: 2024-05-16
Filing date: 2025-05-15
Publication date: 2025-11-20
Also published as: CA3274005A1

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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/648,364, filed May 16, 2024, the entirety of which is incorporated herein by reference.

TECHNICAL FIELD

The disclosure relates to heated garments and methods for constructing heated garments.

BACKGROUND

Applying heat to a body part has therapeutic benefits, including the alleviation of pain. For example, the application of heat to the lower abdomen can reduce dysmenorrhea, which is pain during menstruation. Heat is often applied in the form of a heat pack that is positioned on a body part. Heat packs are typically large and cumbersome, and are therefore inconvenient to use. Usually, a user remains relatively stationary while applying the heat pack.
Other warming devices exist for keeping a user warm in a cold environment, including electrically-powered heaters. Electrically-powered heaters are often bulky and uncomfortable, and if they are powered by connection to a power main, they aren't portable. Portable battery-powered heaters exist, but they often have short run times before the battery is depleted, or they are bulky and cumbersome. Electrically-powered heaters generally don't reach temperatures high enough to provide a therapeutic benefit to the user, and are simply used for general warming of the user.

SUMMARY

In accordance with the present disclosure, there is provided 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.
The transition element may comprise 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. The heating wire may transition the fabric flex line at an angle from about 5 degrees to about 60 degrees, preferably about 5 degrees to about 40 degrees, and more preferably about 10 degrees to about 20 degrees. The heating wire may follow a tortuous path from the transition element to the fabric flex line.
The heating wire may be stitched into the fabric. The heating wire may be stitched onto a first side of the fabric without extending to the second side of the fabric. The heating wire may comprise multiple wires twisted and/or braided together.
The heated garment may further comprise a flexible thermally conductive material that is electrically resistive covering the heating wire. The thermally conductive material may comprise a thermally conductive silicone and/or a thermally conductive polyurethane.
The heated garment may further comprise a thermal insulating layer configured such that the heater array is between the thermal insulating layer and a wearer of the garment.
The heater array may be integral to the garment body. Alternatively, the heater array may be removable from the garment body. The heated garment may comprise underwear and the heating array may be arranged at the front side of the underwear.
In some embodiments, there is provided 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.
In some aspects of the disclosure, there is provided 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.
The heating wire may comprise multiple wires braided and/or twisted together. The method may further comprise braiding and/or twisting multiple wires together to form the heating wire prior to stitching the heating wire.
The method may further comprise the step of applying a thermally conductive material that is electrically insulative over the heating wire. The thermally conductive material may comprise any one of or combination of a thermally conductive silicone and a thermally conductive polyurethane. The thermally conductive material may be applied as a curable liquid that impregnates the heating section of fabric.
The method may further comprise applying a thermal insulating layer, wherein the heating wire is positioned between the thermal insulating layer and a wearer of the garment. The method may further comprise temporarily stiffening the fabric prior to stitching the heating wire.
The method may further comprise 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.
The garment may comprise underwear and the heating section may be positioned at the front side of the underwear.

BRIEF DESCRIPTION OF THE DRAWINGS

In the Detailed Description section below, one or more embodiments of the present technology are described in relation to the attached figures. These embodiments are intended to provide a better understanding of the technology, how the technology may be put into practice, and to demonstrate some of the advantages of the technology. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments of the invention. Similar reference numerals indicate similar components.

FIG. 1 is a schematic front view of a heated garment in the form of underwear, with a heater array integrally formed with the garment.

FIG. 2 is a schematic front view of a heated garment in the form of underwear, with a heater array removable from the garment.

FIG. 3A is a front elevational view of a heater array having a heating wire routed through a heating section in a partial circle pattern.

FIG. 3B is a front elevational view of a heater array having a heating wire routed through a heating section in a zigzag pattern.

FIG. 4A is a front elevational view of a heating wire comprising multiple wires wrapped together in a rope lay twist.

FIG. 4B is a front elevational view of a heating wire comprising multiple wires wrapped together in a lang lay twist.

FIG. 4C is a front elevational view of a heating wire comprising multiple wires braided together.

FIG. 5A is a top perspective view of heating wire stitched into fabric.

FIG. 5B is a bottom perspective view of heating wire stitched into fabric.

FIG. 5C is a side elevational view of heating wire stitched into fabric.

FIG. 6 is a front elevational view of a heater array having heated wire routed through a heated section and covered in a thermally conductive material.

FIG. 7A is a top perspective view of a transition element over the connection of a main current line and heating wire.

FIG. 7B is a top elevational view of a transition element over the connection of a main current line and heating wire.

FIG. 7C is a side elevational view of a transition element over the connection of a main current line and heating wire.

FIG. 7D is an enlarged view of section A of FIG. 7B.

FIG. 8 is a schematic front view of a heated garment in the form of underwear, comprising a thermal insulating layer.

DETAILED DESCRIPTION

Introduction

Electrical heat has historically been in the form of electrical current passed through conductive material to generate resistive heat. The ease of transporting and storing electrical energy has been challenging due to the necessary amounts of power required to provide useful levels of warming. This has led to the development of many electrical heating products for users that are derived around high voltage mains power supplied energy which is abundantly available. This energy source unfortunately is supplied with dangerous levels of electrical potential (voltage) that the user of the heating product must be protected against. This results in large heavily electrically insulated products which are neither lightweight, flexible nor conformable and require a wired connection to an outlet resulting in difficulty applying heat in an effective manner.
Alternatively, power can be derived from more portable sources such as battery packs. However, battery powered devices tend to have short operating times and be too heavy for comfortable use. To keep a long enough running time, the devices are often not warm enough to be effective for therapeutic benefits like pain relief, and function primarily for personal warming. In short, devices tend to be either bulky and uncomfortable (mains powered) or underpowered and heavy with short operating times (battery devices).
This disclosure is directed to heated garments that provide advantages over prior art devices. The heated garments are lightweight, stretchable and flexible, yet also durable and machine-washable, and can provide high enough levels of heat, for example greater than about 37° C., and more preferably greater than about 39° C., to provide a therapeutic effect to the user. These comfortable heated garments can be used as items like underwear, long underwear, including for the upper body and the lower body, sports wraps, and more. The heated garments can provide therapeutic benefits in the alleviation of pain, for example lower abdominal pain associated with menstrual cramps, back pain, joint pain, including knee or elbow pain, and more.
Various aspects of the technology will now be described with reference to the figures. For the purposes of illustration, components depicted in the figures are not necessarily drawn to scale. Instead, emphasis is placed on highlighting the various contributions of the components to the functionality of various aspects of the technology. A number of possible alternative features are introduced during the course of this description. It is to be understood that, according to the knowledge and judgment of persons skilled in the art, such alternative features may be substituted in various combinations to arrive at different embodiments of the technology.

Overview of the Heated Garment

Referring to FIG. 1 , the heated garment 10, which in this example is a pair of underwear, comprises a garment body 12 formed of fabric, a main current line 14 for providing electrical current to a heating wire that forms a heater array 20, and a transition element 30 formed at a connection point of the main current line and the heating wire. For ease of reference, the heater array 20 is shown as visible from the outside of the heated garment in FIG. 1 , however in a finished garment, the heater array would not generally be visible as it would on the inside of the garment or between layers in the garment.
The heater array 20 and transition element 30 may be formed as part of the garment body 12 or it may be formed as a separate piece 40 that is arranged within and/or connected to the garment body, as shown in FIG. 2 . The separate piece 40 may be removable from the garment body. For example, the heater array may be insertable into a pocket in the garment body.

Heating Wire

Referring to FIG. 3A, the heating wire 22 is a conductive wire that heats up when an electric current flows through the wire. The heating wire is arranged as a heater array 20 that forms a loop throughout a heating section 24 of fabric which may be part of the garment body or a separate piece of fabric that is configured within the garment body.
The heating wire 22 is routed through the heating section to provide a desired amount of heat throughout the heating section. FIG. 3A illustrates an example configuration wherein the heating wire is routed in a partial circle pattern. FIG. 3B illustrates another example configuration wherein the heating wire is routed in a zigzag pattern. The heating wire is preferably routed in a closely spaced configuration throughout the heating section, such that spaces 22 a between adjacent heating wire are small, which provides adequate heat and reduces temperature variation throughout the heater array. The heating wire is preferably spaced apart from about 3 mm to about 20 mm, and more preferably about 4 mm to about 7 mm.
The heating wire 22 comprises one or more thin flexible metal wires. Multiple wires may be wrapped together to form the heating wire to increase fatigue resistance. Preferably, there are 3 to 40 wires wrapped together, and more preferably 12 to 20 wires. The multiple wires may be wrapped together in a variety of ways, for example in a rope lay twist as shown in FIG. 4A, a lang lay twist as shown in FIG. 4B, or a braid as shown in FIG. 4C. The diameter of the one or more wires forming the heating wire is preferably less than about 36 AWG, more preferably less than about 40 AWG, and more preferably less than about 44 AWG.
The heating wire 22 preferably has a conductivity of about 35×10⁶S/m to about 64×10⁶S/m, preferably about 40×10⁶S/m to about 64×10⁶S/m, and more preferably about 50×10⁶S/m to about 59×10⁶S/m. Examples of suitable wire materials include copper, copper-silver alloys, silver, and high-tension copper alloys.
Referring to FIGS. 5A, 5B, and 5C, the heating wire 22 may be routed through the heating section 24 by stitching the heating wire onto the inner side 24 a of the heating section of fabric. The heating wire may be stitched in a manner to avoid extending to the outer side 24 b of the fabric. This can be accomplished using known sewing techniques where a thread 26 extends from the outer side 24 b of the fabric through the fabric to the inner side 24 a where it forms loops 26 a around the heating wire to secure the heating wire to the fabric. In a sewing machine, the heating wire would be on the bobbin and the thread on the needle.
Preferably, the heating wire is stitched onto the fabric using a short stitch length to prevent bunching or kinking of the heating wire when the fabric is folded. The stitch length is preferably from about 1 mm to about 5 mm, and more preferably from about 1.2 mm to about 2.0 mm.
The fabric may be a highly stretchable fabric, including fabric with 4-way stretch, in which case the fabric may be temporarily stiffened or supported during stitching for accurate stitch placement. The fabric may be stiffened using a dissolvable or otherwise removable material or chemical compound. For example, the fabric may be impregnated with a removable compound like a water-soluble starch or glycerine solution. In another example, a dissolvable film may be applied to the fabric to stiffen the fabric during stitching.
The heating wire may be attached to the heating section in other manners, for example by thermal bonding or ultrasonic welding.

Thermally Conductive Material

Referring to FIG. 6 , the heater array 20 may be covered or impregnated with a thermally conductive material 18 to more evenly spread heat throughout the heating section 24. The thermally conductive material may cover the entire heater array 20, including the heating wire 22 routed throughout the heating section and the tortuous path 22 b of the heating wire extending from the transition element 30 across the fabric flex line, which is discussed in further detail below. In FIG. 6 , the heater array 20 is visible through the thermally conductive material for ease of reference, but generally the heater array would not be visible through the thermally conductive material 18 that overlays it. This is more apparent in FIGS. 5A, 5B, and 5C where thermally conductive material 18 is shown covering a section of the heating wire 22.
There may be variations in temperature throughout the heater array when in use. For example the temperature directly on the heating wire would be higher than the temperature in the spaces 22 a between the heating wire. Using a thermally conductive material provides less temperature variation throughout the heater array, for example a temperature variation of less than about 2° C., and more preferably less than about 1° C. The thermally conductive material may also be an electrical insulator to insulate the user from the heating wire 22, therefore improving the safety of the device.
The thermally conductive material may be applied as a layer over the heater array, causing heat to evenly spread throughout the thermally conductive layer from the underside of the thermally conductive material that is in contact with the heater array to the upper surface of the thermally conductive layer that faces the user of the heated garment. The thermally conductive material is preferably a thin layer that is flexible and stretchable. The thermally conductive material may just cover the heating wire or be slightly thicker than the heating wire. Suitable thicknesses include from about 0.4 mm to about 2 mm, and preferably from about 0.5 mm to about 1.2 mm.
The thermally conductive material may be part of a backing material that is applied to the fabric of the heating section 24 over the heater array 20. In some embodiments, the thermally conductive material may impregnate the fabric in the heating section. For example, the thermally conductive material may be applied in liquid form to the fabric in the heating section, wherein the liquid penetrates the fabric pores. The thermally conductive material is then cured to a solid state. During curing, heat may optionally be applied. Preferably, the impregnated fabric remains flexible and stretchable. In some embodiments where a stiffening compound is used to stiffen the fabric prior to attaching the heating wire 12, the stiffening compound is removed prior to applying the thermally conductive material.
The layer of thermally conductive material, whether it applied as a backing and/or impregnates the fabric, preferably has a thermal conductivity of at least about 0.35 w/mK, and preferably at least about 0.5 w/mK.
Various techniques may be used to apply the thermally conductive material, for example screen printing methods or mold injection methods. In one example, a frame is laid over the heating section, the frame having a frame border positioned around the perimeter of the heating section area and an open interior where the heater array is. The frame border may have a height matching the desired thickness of the thermally conductive material. The thermally conductive material is dispensed in liquid form into the open interior of the frame. The material may be dispensed to reach the height of the frame border and any excess liquid material may be removed using a squeegee action such that the liquid thermally conductive material has a smooth upper surface equaling the height of the frame border. This may be done, for example, by positioning a semi-rigid bar parallel with the thermally conductive material and dragging it along the upper surface of the frame border and the thermally conductive material from one end of the frame to the other, causing any excess liquid thermally conductive material to be removed from the frame interior. The thermally conductive material is then cured to a solid state, after which the frame is removed.
In some embodiments, the thermally conductive material may be applied using a mold injection. For example, the heating section 24 of fabric with the heater array 20 is inserted into a mold such that the fabric lays flat against one side of the mold, with a void space between the fabric comprising the heater array and the opposite side of the mold.
The inside edges of the mold align with the edges of the heating section 24. The thermally conductive material in liquid form is injected into the void space in the mold to fill the void space, thereby filling the spaces 22 a between the heating wire of the heater array and impregnating the fabric of the heating section 24. The thermally conductive material is then cured to a solid state and the mold removed. The layer of the thermally conductive material would have a thickness equal to the thickness of the void space in the mold, and thus the dimensions of the thermally conductive layer is easily controlled.
Suitable thermally conductive materials include thermally conductive silicone and thermally conductive polyurethane, both of which are also electrical insulators. Thermally conductive silicone and thermally conductive polyurethane comprise one or more additives having high thermal conductivity. Suitable additives include ceramic additives, including boron nitride, aluminum oxide, and other electrically insulative high thermal conductive materials. The additives may comprise from about 10 wt % to about 70 wt %, and more preferably from about 20 wt % to about 60 wt % of the thermally conductive material.

Insulating Layer

The heated garment may include one or more thermal insulating layers to improve the energy efficiency of the garment by reducing heat loss from the heater array to the external environment. The one or more thermal insulating layers are positioned such that the heater array is between the wearer's body and the thermal insulating layer. FIG. 8 illustrates a thermal insulating layer 16 on the outer side 12 a of the garment body 12 corresponding to the area in the garment where the heater array is positioned. The thermal insulating layer may be an intermediate layer between the heater array and the garment body outer side, or it may be integral to the heating section of the fabric. FIGS. 5B and 5C illustrate a thermal insulating layer 16 configured on the outer side 24 b of the heating section 24 of fabric.
The thermal insulating layer may be electrically insulative. The thermal insulating layer may comprise silicone or polyurethane that does not contain thermally conductive additives, thereby providing a thermally and electrically insulative layer. The thermal insulating layer is preferably a thin layer that is flexible and stretchable. In some embodiments, the thermal insulating layer has a thermal conductivity less than about 0.5 W/mK, and preferably less than about 0.35 W/mK.
In some embodiments, the thermal insulating layer is applied to the heating section of fabric on the opposite side of the fabric from the heater array, for example as shown in FIGS. 5B and 5C. The thermal insulating layer may be applied as a backing material on the fabric using a suitable technique. In some embodiments, the thermal insulating layer may impregnate the fabric, with the fabric preferably remaining flexible and stretchable. In some embodiments, the thermal insulating layer comprises a layer that impregnates the fabric as well as a backing material that is applied on top of the impregnated fabric. The backing material may have a greater thermal insulation value than the impregnated fabric.
The thermal insulating layer may be applied using similar methods that are used to apply the thermally conductive material. For example, using a frame with a frame border and an open interior to position a thermal insulating layer in liquid form on the desired section of fabric, then curing it to a solid state before removing the frame. In another example, a mold injection technique can be used by inserting the desired section of fabric into a mold and injecting the thermal insulating composition into a void space in the mold, then curing it to a solid state before removing the mold.
In one example, the thermally insulative layer 16 comprises a silicone that is thermally insulative, and the thermally conductive layer 18 comprises a silicone with one or more additives that are thermally conductive. Both layers may applied to the heating section of fabric in one step by using a composition comprising silicone and a thermally conductive additive, wherein the thermally conductive additive comprises particles larger than the silicone particles. To apply the thermally insulative layer and the thermally conductive layer in one step, the composition is applied in liquid form to the inner side 24 a of the fabric on top of the heater array 20. Some of the composition impregnates the fabric under the heater array, and some of the composition remains on top of the inner side of the heating section 24 of fabric, in the spaces 22 a between the heating wire 22 and on top of the heating wire. Due to the larger particle size of the thermally conductive additive particles compared to the silicone particles, the composition impregnating the fabric may have a lower concentration of thermally conductive additive particles compared to the composition remaining on top of the fabric. Thus, when the composition cures, the layer of silicone below the heater array that has impregnated the fabric is more insulative, while the layer of silicone on top the fabric and in between and on top the heating wire is more thermally conductive. In this example, the silicone may be replaced by polyurethane or another suitable material. Optionally, there may be a second thermal insulating layer on top the fabric side with the thermally insulative layer that has impregnated the fabric. For example, the second thermal insulating layer may comprise a layer of insulative material such as fleece.

Transition Element

Referring to FIGS. 7A, 7B, 7C, and 7D, the transition element 30 is configured at the connection point between the main current line 14 and the heating wire 22. The transition element prevents flexion at the connection point and induces formation of a fabric flex line 32 that the heating wire crosses. By controlling where and how the heating wire flexes, the durability of the heating wire and thus the heated garment is increased.
The heating wire is configured to transition the fabric flex line such that it is subjected predominantly to torsion forces instead of flexion forces upon flexion at the fabric flex line. This means that the heating wire crosses the fabric flex line at an angle θ, which is preferably about 5 degrees to about 60 degrees, preferably about 5 degrees to about 40 degrees, and more preferably about 10 degrees to about 20 degrees.
The heating wire preferably follows a tortuous path 22 b between the transition element 30 to the fabric flex line 32 to cause the heating wire to cross the fabric flex line at an angle θ. One example of a tortuous path 22 b is shown by the zig zag configuration of the heating wire 22 in FIGS. 7A, 7B, and 7D. The heating wire in the zigzag section may be stitched into the fabric like it is for the rest of the heater array as described above. As the heating wire forms a loop from the main current line throughout the heating section, it crosses the fabric flex line twice, both at an angle to cause the heating wire to be subjected predominantly to torsion forces instead of flexion forces.
The transition element 30 is preferably rigid or semi-rigid and comprises a housing 30 a having two outward extensions 30 b. The housing preferably forms an overmolding on top of the connection point of the main current line 14 and the heating wire 22 to protect the connection point and prevent the heating wire from bending at the connection point. The connection point may be disconnectable, for example using a quick barrel connector, such that the main current line can be disconnected and removed from the heater array.
The outward extensions 30 b preferably extend alongside either side of the heating wire 22. A line passing by the ends 30 c of the outward extensions defines the fabric flex line 32. The outward extensions may splay outwards from the housing 30 a towards the ends 30 c. The outward extensions may taper down from the housing 30 a towards the ends 30 c, i.e. tapering towards the fabric, as shown in FIG. 7C. This downward taper provides for a smoother flexing of the fabric at the fabric flex line 32.
The transition element may be on the same side of the fabric as the heater array, or it can be on the opposite side of the fabric, i.e. the transition element may be on the outer side of the fabric and the heater array on the inner side of the fabric. In the case where the transition element is on the opposite side of the fabric of the heater array 20, the heating wire 22 can transition from the inner side 24 a of the fabric to the outer side of the fabric between the heater array 20 and the transition element 30, for example at transition point 34 shown in FIG. 3A and FIG. 6 .

Power Supply

The main current line 14 is preferably connected to a power-supply control unit for providing power to the main current line and controlling the operation and temperature of the heater array 20. Power may be provided in the form of a battery or by connection to a wall adaptor for plugging in to an electrical socket. For example, the garment may operate using a 5-V battery pack or connect to a standard 5V USB-C wall adaptor.
The power-supply control unit can adjust the temperature of the heater array using a pulse-width-modulated (PWM) voltage chopper. The heater array is preferably controllable from a temperature of about 37° C. to about 44° C. The higher temperature ranges, for example from about 39° C. to about 44° C. provide sufficient heat such that the garment can provide a therapeutic benefit to the user without causing a long-term burn risk to the user. The heated garment is constructed in an energy-efficient manner to provide high temperature output at low voltage. This allows the heated garment to have a compact battery pack that can be arranged within the garment to provide a portable and comfortable garment.

OTHER FEATURES AND PROPERTIES

The heated garment is illustrated as underwear with the heater array arranged at the front side of the underwear, corresponding to a user's lower abdomen. However the heater array may be arranged in any section of the garment, and the garment may be any type of garment, for example a long underwear top, long underwear bottoms, shorts, socks, mittens, pants, leggings, shirts, hats, body wraps for elbows, knees, ankles, etc., and more.
The composition, arrangement and manner of forming the heated garment as described herein provides a thin, highly flexible, stretchable and fatigue resistant heated garment. Preferably, the heated garment has a stretch of at least about 10% in both directions, and preferably at least about 25%, and more preferably at least about 50%. In some embodiments, the heated garment has a stretch of at least about 90% in one direction and/or at least about 60% in another direction. When quantifying stretch, a stretch of 100% means that the heated garment can double in length.
Once disconnected from a power supply, the heated garment, including the heater array, thermally conductive material, thermally insulative material and transition element may be machine washable.
Although the present technology has been described and illustrated with respect to preferred embodiments and preferred uses thereof, it is not to be so limited since modifications and changes can be made therein which are within the full, intended scope of the technology as understood by those skilled in the art.

Claims

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.