Multilayer Composite Heating With Proximity-Based Burn Prevention
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Solution Overview
Problem
Existing multi-layered composite structures used in vehicle interiors for heating purposes suffer from delayed warming due to the distance between heating wires and the surface, leading to uneven heating and potential burns from high temperatures.
Innovation Solution
A multi-layered composite structure with a heating layer formed from a thin, flexible electrically conductive layer integrated directly under the upper surface, combined with temperature and approximation sensors that monitor surface temperature and impending touch, respectively, to adjust heating power accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If heating wires are placed beneath a foam layer at a distance of more than 10 mm, then the top layer is protected from visual and tactile markings, but the heating is achieved only with a time delay
Solution Approach 1:
The patent replaces traditional wire heating elements with a thin-film heating layer that can be positioned much closer to the top layer (distance of 0.5 mm to 5 mm), enabling faster heat transfer while maintaining surface protection. The thin-film structure allows efficient thermal conduction without the need for thick foam insulation layers.
Solution Approach 2:
The patent extracts the heating function from discrete wire elements and implements it as a continuous thin-film layer, eliminating the need for large spacing between heating elements and the surface. This extraction allows the heating layer to be positioned immediately adjacent to the top layer for rapid heating.
2Ease of manufacture
If heating wires are laid with a relatively large spacing, then the structure is simpler to manufacture, but warm and cold regions are created on the surface
Solution Approach 1:
The patent uses a thin-film heating layer that provides homogeneous heat distribution across the entire surface area. The continuous film structure eliminates the discrete spacing issues of wire-based systems, ensuring uniform temperature distribution without creating warm or cold regions.
Solution Approach 2:
The patent employs composite material structures where the thin-film heating element is integrated with the multilayer composite (top layer, intermediate layer, base layer). This composite approach allows the heating layer to conform to the surface geometry and provide uniform heating while maintaining structural integrity.
3Productivity
If the heating layer is placed close to the surface for faster heating, then heating efficiency is improved, but the surface temperature can reach high levels that cause burns
Solution Approach 1:
The patent incorporates temperature sensors that continuously monitor the surface temperature and provide feedback to a control unit. When the temperature approaches unsafe levels or when proximity is detected, the control unit adjusts the heating power to prevent burns while maintaining efficient heating when safe.
Solution Approach 2:
The patent implements dynamic control of the heating layer by adjusting the heating power in real-time based on temperature conditions and proximity detection. The system transitions between different heating states (high power for rapid heating, reduced power for safety, pulsing for comfort) to optimize both heating efficiency and user safety.
4Measurement precision
If sensors are integrated close to the surface for high-resolution measurements, then measurement precision is improved, but the device complexity increases
Solution Approach 1:
The patent integrates multiple functions into the intermediate layer, including temperature sensing, proximity detection, and heating control. This multi-functional approach reduces overall device complexity by combining sensor and actuator functions within a single layer structure rather than adding separate components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables faster, more even heating of the surface while preventing burns by reducing heating power when an impending touch is detected, thus ensuring a safe and comfortable user experience.
Implementation Method 1
a heating layer (3) formed from a first electrically conductive layer, wherein current flow through the heating layer generates heat to warm the surface
Implementation Method 2
at least one temperature sensor, wherein a first sensor signal from the temperature sensor can be forwarded to an electronic computing device
Implementation Method 3
The composite structure has at least one proximity sensor, wherein a second sensor signal from the proximity sensor can be forwarded to the electronic computing device
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a system (10) comprising a multilayer composite structure (1) with a single-layer or multilayer top layer (2), a heating layer (3) formed from a first electrically conductive layer (3), and at least one temperature sensor (9), wherein a first sensor signal (S1) of the temperature sensor (9) can be transmitted to an electronic computing device (4) connected to the temperature sensor (9). The electronic computing device (4) is configured to evaluate the second sensor signal (S2) of the proximity sensor (5) and to detect an impending contact with the composite structure (1), wherein, after detecting an impending contact and exceeding a defined threshold value (S1max) of the sensor signal (S1) of the temperature sensor (9), the electronic computing device (4) is configured to output a control signal (S3) and to reduce or interrupt the heating power of the heating layer (3).