Fluid conditioning device

Abstract

A heating element includes a plurality of folded surfaces which can be resistively heating using electrical current. The heating element can advantageously function both as a heating source and a heat transfer device, as the need for separate fins or other heat dissipation members is eliminated. In some embodiments, the heating element can be included in a fluid heating system. The fluid heating system can include a fluid transfer device configured to deliver a volume or ambient air or other fluid through the heating element. As air moves past the heated folded surface of the heating element, it is heated. Heated air can then be discharged to one or more desired locations.

1 . A heating element comprising:
 a chamber having and an inlet and an outlet and defining a flow direction that extends from the inlet to the outlet;   a resistive material and at least one substrate positioned within the chamber, wherein a combination of the resistive material and the at least one substrate are folded into a plurality of folds that extend substantially parallel to the flow direction;   the resistive material disposed on the substrate; and   at least one electrical lead operatively coupled to the resistive material such that an electrical current can be delivered through the resistive material.   
     
     
         2 . The folded heating element of  claim 1 , wherein the plurality of folds comprise a series of folds in which a fold direction of adjacent folds are opposite to each other. 
     
     
         3 . The folded heating element of  claim 1 , wherein at least a portion of the resistive material comprises a Positive Temperature Coefficient (PTC) material. 
     
     
         4 . The folded heating element of  claim 1 , wherein at least a portion of the resistive material comprises a coiled resistance wire. 
     
     
         5 . The folded heating element of  claim 5 , further comprising at least one spacer positioned between at least two adjacent folded portions. 
     
     
         6 . The folded heating element of  claim 1 , wherein a portion of the resistive material comprises a copper, nickel-chromium, stainless steel or conductive carbon. 
     
     
         7 . The folded heating element of  claim 1 , wherein a portion of the resistive material comprises a flexible and formable material. 
     
     
         8 . The folded heating element of  claim 1 , further comprising a backing member, the backing member being configured to help the folded heating element maintain a desired folded shape. 
     
     
         9 . The folded heating element of  claim 1 , wherein the heating element comprises first and second conductive members and a conductive layer electrically connecting the first and second conductive members, the heating element generally positioned on a base member comprising first and second electrical buses, the first electrical bus being in electrical communication with the first conductive member of the heating element, and the second electrical bus being in electrical communication with the second conductive member of the heating element; and
 wherein an electrical voltage difference applied across the first and second electrical buses causes current to flow from the first conductive member to the second conductive member through the conductive layer; and   wherein such current flow is configured to generate heat along a surface of the heating element to selectively heat a volume of fluid passing thereby.   
     
     
         10 . A heating element comprising:
 a chamber having and an inlet and an outlet and defining a flow direction that extends from the inlet to the outlet;   a resistive material positioned within the chamber, wherein the resistive material is generally folded into a plurality of folds that extend substantially parallel to the flow direction; and   at least one electrical lead operatively coupled to the resistive material such that an electrical current can be delivered through the resistive material;   wherein the resistive material is configured to heat when electrical current is delivered therethrough; and   wherein at least a portion of the heat generated by the resistive material can be transferred to a fluid passing through the chamber.   
     
     
         11 . A climate controlled seat assembly comprising:
 a heating element comprising a resistive material configured to receive an electrical current, wherein the heating element is generally folded into a plurality of folds, wherein the heating element is configured to produce heat when an electrical current is delivered through the resistive material;   a fluid transfer device configured to selectively transfer fluids through or in the vicinity of the plurality of folds of the heating element; and   a control system configured to control the operation the heating element or the fluid transfer device;   wherein fluids transferred toward the heating element are heated before being directed to an occupant of the seating assembly.   
     
     
         12 . The seat assembly of  claim 11 , wherein the heating element is positioned downstream or upstream of the fluid transfer device. 
     
     
         13 . The seat assembly of  claim 11 , wherein heated fluids are conveyed to at least one fluid distribution member positioned on or within a cushion of the seat assembly. 
     
     
         14 . The seat assembly of  claim 11 , wherein the fluid transfer device comprises a blower or fan. 
     
     
         15 . The seat assembly of  claim 11 , wherein the resistive material comprises copper, nickel-chromium, stainless steel or conductive carbon. 
     
     
         16 . The seat assembly of  claim 11 , wherein the heating element is positioned within a housing. 
     
     
         17 . The seat assembly of  claim 11 , wherein the seat assembly comprises a vehicle seat. 
     
     
         18 . The seat assembly of  claim 11 , wherein the seat assembly comprises a bed. 
     
     
         19 . The seat assembly of  claim 11 , wherein the heating element further comprises at least one temperature sensor, the temperature sensor configured to measure a temperature of the heating element or a heated fluid in the vicinity of the temperature sensor.