Composite panel with integrated heater system and associated methods for manufacturing
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Solution Overview
Problem
Conventional composite panels for vehicles lack integrated heater systems, and conventional resistance heaters are inflexible, expensive, and add weight and complexity due to their materials and temperature regulation systems.
Innovation Solution
A composite panel with an integrated heater system, comprising a non-conductive material layer, a resistance heater, a capacitive sensor, and a heater control module, where the resistance heater and capacitive sensor are positioned between two non-conductive layers, allowing for flexible and non-planar shapes, and a system control module for temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional resistance heaters are used in vehicles, then heating function is provided, but weight and complexity increase due to protection circuits and temperature regulation systems
Solution Approach 1:
The patent combines the heater element, temperature sensor, and control circuitry into a single integrated heating assembly. The temperature sensor is positioned in thermal contact with the heater element, and the control circuitry is integrated with both components, eliminating the need for separate protection circuits and regulation systems that would otherwise be required.
Solution Approach 2:
The integrated heating assembly serves multiple functions simultaneously: the heater element provides heating, the temperature sensor monitors temperature for both control and protection purposes, and the control circuitry performs both regulation and safety functions. This multi-functionality reduces the overall system complexity compared to conventional separate components.
2Temperature
If conventional resistance heaters are made from inflexible materials, then heating function is provided, but integration into composite panels becomes difficult
Solution Approach 1:
The heater element is constructed as a flexible assembly that can be integrated into composite panels of various shapes. The flexible nature of the heater assembly allows it to conform to the panel geometry and be manufactured using composite panel fabrication processes, making integration straightforward.
3Reliability
If temperature regulation and protection systems are added to conventional resistance heaters, then safety is improved, but cost increases
Solution Approach 1:
The control circuitry is integrated directly with the heater element and temperature sensor, combining regulation and protection functions into a single compact assembly. This integration eliminates the need for separate protection circuits and reduces overall system cost while maintaining safety and temperature regulation capabilities.
4Shape
If conventional composite panels are manufactured, then panel structure is created, but integrated heater systems cannot be incorporated
Solution Approach 1:
The heating assembly is designed and prepared in advance as a complete integrated unit containing the heater element, temperature sensor, and control circuitry. This preliminary preparation allows the heating assembly to be incorporated into composite panels during the panel manufacturing process itself, enabling integration without requiring post-manufacturing modifications.
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
The solution enables flexible, cost-effective integration of heaters into composite panels, reducing weight and complexity while providing efficient temperature control, allowing for customizable heating based on passenger input and monitoring health conditions of the heater system.
Implementation Method 1
The resistance heater is configured to generate heat at least partially in response to input sensed by the capacitive sensor
Implementation Method 2
a capacitive sensor applied onto the first layer. The capacitive sensor is operably coupled with the resistance heater
Data Source
AI summary
Described herein is a composite panel that includes a first layer made from an electrically non-conductive material. The composite panel also includes a resistance heater printed onto the first layer and a capacitive sensor applied onto the first layer. The capacitive sensor is operably coupled with the resistance heater. The composite panel additionally includes a second layer adjacent the resistance heater and the capacitive sensor. The resistance heater and the capacitive sensor are positioned between the first layer and the second layer. Furthermore, the second layer is made from an electrically non-conductive material. The resistance heater is configured to generate heat at least partially in response to input sensed by the capacitive sensor.