Composite panel with integrated heater system and associated methods for manufacturing
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Solution Overview
Problem
Conventional resistance heaters in vehicles are inflexible, expensive, and difficult to integrate into composite panels, especially those with non-planar shapes, and often add weight, complexity, and cost due to separate temperature regulation and protection systems.
Innovation Solution
A composite panel with an integrated heater system, featuring a resistance heater and capacitive sensor between non-conductive layers, along with a heater control module, allowing for flexible, non-planar integration and self-regulating temperature control.
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 difficult to integrate into composite panels with non-planar shapes
Solution Approach 1:
The patent applies flexible thin films by printing the heater circuit pattern directly onto a flexible substrate that can conform to non-planar surfaces. This printed heater circuit on flexible substrate allows the heater to be integrated into composite panels with complex geometries, solving the inflexibility issue of conventional rigid heaters while maintaining ease of manufacture through printing processes.
Solution Approach 2:
The patent merges the heater circuit with the composite panel manufacturing process by integrating the heater pattern printing into the same production line. The heater is co-formed with the composite panel layers, eliminating separate integration steps and making the process suitable for non-planar shapes that are formed during composite curing.
2Reliability
If conventional resistance heaters with separate temperature regulation and protection systems are used, then temperature control is provided, but weight and complexity increase
Solution Approach 1:
The patent combines the temperature regulation and protection functions directly into the heater circuit pattern itself. By printing the heater circuit with integrated control elements on the same flexible substrate, the system eliminates separate temperature regulation and protection devices, reducing overall system complexity and weight while maintaining reliable temperature control.
Solution Approach 2:
The patent changes the physical state and properties of the heater material to achieve self-regulating temperature control. The printed heater circuit uses materials with specific electrical resistance characteristics that inherently provide temperature regulation and protection without requiring additional control systems, thereby reducing device complexity while maintaining reliability.
3Reliability
If conventional resistance heaters with protection circuits are used, then overheating prevention is provided, but cost increases
Solution Approach 1:
The patent combines the protection circuit functions with the heater circuit pattern by printing both onto the same flexible substrate in the same manufacturing process. This integration eliminates the need for separate protection circuit components and assembly steps, reducing manufacturing cost while maintaining overheating prevention capability through the integrated circuit design.
Solution Approach 2:
The patent uses inexpensive printed conductive ink and flexible substrate materials to create the heater circuit with integrated protection, replacing expensive conventional heater components. The printed circuit approach allows for cost-effective manufacturing while the integrated design ensures overheating prevention is built into the basic structure rather than requiring additional expensive protection 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
The solution provides a lightweight, cost-effective, and flexible heating solution for vehicles, with integrated temperature regulation and protection, suitable for non-planar surfaces, reducing complexity and weight.
Implementation Method 1
When current flows through the first portion of the layer of conductive ink and the layer of PTC conductive ink, the layer of PTC conductive ink provides resistance to the current flow and increases in temperature
Implementation Method 2
the layer of PTC conductive ink provides resistance to the current flow and increases in temperature
Data Source
Figure 1
Figure 2
Figure 3A
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.