Composite panel with integrated heater and associated methods for manufacturing
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Solution Overview
Problem
Conventional resistance heaters used in vehicles are inflexible, heat intolerant, and expensive, making them unsuitable for integration into composite panels, and they require additional temperature regulation and protection systems that increase weight, complexity, and cost, while conventional composite panels lack integrated heaters, especially for non-planar shapes.
Innovation Solution
A composite panel with an integrated resistance heater, where the heater is printed onto a non-conductive material layer using conductive and positive temperature coefficient inks, allowing for flexible and non-planar configurations, and eliminating the need for external temperature regulation systems by using self-regulating PTC ink.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional resistance heaters are used in vehicles, then heating function is provided, but the heaters are inflexible and heat intolerant making them unsuitable for integration into composite panels
Solution Approach 1:
The patent changes the material parameters by using temperature-resistant flexible materials such as silicone rubber or fluoropolymer coatings instead of conventional inflexible heater materials. This allows the heater to withstand curing temperatures (up to 120°C or higher) and maintain flexibility for integration into composite panels with non-planar shapes
Solution Approach 2:
The patent employs composite material structures where the heater element is integrated within a composite panel consisting of multiple layers including flexible non-conductive materials. This composite structure provides both the heating functionality and the required flexibility and heat resistance for vehicle integration
2Reliability
If conventional resistance heaters with protection circuits and thermostats are used, then temperature regulation is achieved, but weight and complexity increase
Solution Approach 1:
The patent implements self-regulating heating elements that automatically control their own temperature without requiring external thermostats or protection circuits. The heater material inherently limits its operating temperature through material properties, eliminating the need for additional regulation components and reducing overall system complexity and weight
Solution Approach 2:
The patent extracts and eliminates the protection circuits and electronic temperature regulating controllers from the heating system. By using inherently safe, self-regulating heater materials, the complex regulatory subsystem is removed entirely, leaving only the essential heating function integrated into the composite panel
3Reliability
If conventional resistance heaters are used, then heating function is provided, but cost increases due to expensive materials and additional systems
Solution Approach 1:
The patent merges the heater element directly into the composite panel structure during the panel manufacturing process. By combining the heating function with the existing composite panel layers using techniques like co-forming or post-manufacturing integration, separate heater components and their associated mounting hardware are eliminated, reducing material costs and simplifying production
Solution Approach 2:
The patent creates a multi-functional composite panel that simultaneously provides structural support, thermal insulation, and heating capabilities. The same composite panel layers serve multiple purposes, eliminating the need for separate heater assemblies and reducing overall system cost
4Strength
If conventional composite panels are used, then structural requirements are met, but integrated heating functionality is lacking
Solution Approach 1:
The patent combines the heating functionality directly into the composite panel structure by integrating heater materials within the panel layers. This merging allows the panel to maintain its structural integrity while gaining heating capability, eliminating the need for separate heater installations that would add weight and complexity
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 provides a lightweight, cost-effective, and flexible composite panel with integrated heaters that can be shaped non-planarly, reducing weight and complexity by integrating the heating functionality directly into the panel, thus enhancing vehicle components like side walls, floors, and seats.
Implementation Method 1
a second ply applied onto the first ply and made from an electrically conductive ink
Implementation Method 2
a third ply applied onto the second ply and made from a switching-type positive temperature coefficient ink
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. Further, the composite panel includes a second layer adjacent the resistance heater, the resistance heater being positioned between the first layer and the second layer. The second layer is made from an electrically non-conductive material.