Conductive Paper Structure for Molded Fiber Heating
Solution Overview
Problem
Existing methods for heating large areas, such as in vehicles, require high installation effort and cost, and struggle with condensation issues, while heated surfaces offer a more energy-efficient alternative but face challenges in integrating conductive paper structures with electrical connections.
Innovation Solution
A molded fiber part with an electrically conductive paper structure featuring conductor tracks connected to electrical lines, where the conductive paper is embedded in a composite body and connected to power sources through integrated electrical lines within a mold, allowing for secure and invisible electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conductive paper structures are used for large-area heating, then heating efficiency and energy consumption are improved, but the complexity of connecting electrical conductors and the installation effort increase
Solution Approach 1:
The patent combines the conductive paper structure with the electrical conductors into a single integrated unit. The conductive traces are printed directly on the paper structure, and electrical connectors are attached to these traces, merging the heating element and electrical connection system into one component. This eliminates separate wiring harnesses and reduces installation complexity while maintaining large-area heating efficiency.
Solution Approach 2:
The patent introduces intermediate electrical connectors that serve as mediators between the power source and the conductive paper structure. These connectors are attached to the conductive traces on the paper and provide standardized connection points, simplifying the interface between the heating element and the electrical power distribution system.
2Reliability
If conductive traces are applied to paper structures, then current distribution across the surface is improved, but the visibility of traces in the finished composite material becomes problematic
Solution Approach 1:
The patent embeds the conductive traces within layers of the composite material structure. The traces are printed on the paper, which is then laminated or复合 with additional layers that cover and conceal the traces. This nesting approach maintains the electrical functionality while hiding the visual appearance of the traces in the finished product.
Solution Approach 2:
The patent applies conductive traces only in specific locations where electrical connection is needed, rather than uniformly across the entire surface. By concentrating the conductive material in functional areas and using decorative or protective layers in visible areas, the design maintains current distribution reliability while achieving aesthetic appearance in the finished composite material.
3Ease of manufacture
If electrical conductors are exposed and connected to power sources, then electrical connection is achieved, but the installation effort and cost increase
Solution Approach 1:
The patent performs electrical connections during the manufacturing process rather than during installation. Electrical connectors are attached to the conductive traces on the paper structure before the final composite assembly is completed. This preliminary action eliminates the need for separate field installation steps, reducing installation time and labor costs while ensuring proper electrical connections.
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 reduces the effort and cost of connecting conductive paper structures to power sources, provides a design-friendly integration of electrical lines, and results in a finished product that is ready for use with integrated, hidden electrical connections.
Implementation Method 1
the electrically conductive paper structure (2) has at least two conductive traces (3) extending along its length and the conductive traces (3) are each connected to an electrical conductor (4) suitable for contacting a power source
Implementation Method 2
the adsorption of matrix fibers onto the inner surfaces of the lower mold (10) and/or the upper mold (11) until the mold is filled
Implementation Method 3
the bonding of the matrix fibers by means of the added binder, thereby solidifying the lower fiber mold section (13) and/or the upper fiber mold section (13)
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to a molded fiber part (14) comprising an electrically conductive paper structure (2) with an upper main surface and a lower main surface, wherein the electrically conductive paper structure (2) has at least two conductor tracks (3) extending along the paper structure (2) and the conductor tracks (3) are each connected to an electrical conductor (4) suitable for contacting a power source, wherein the upper main surface of the electrically conductive paper structure (2) has an upper molded fiber section (13) and/or the lower main surface of the electrically conductive paper structure (2) has a lower molded fiber section (13) in order to form a composite body, wherein the molded fiber section (13), optionally both the upper and the lower molded fiber section (13), is based on matrix fibers bonded with an admixed binder.