Conductive Polymer Composition for Stretchable Seat Heating
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Solution Overview
Problem
Existing electrically conductive and heatable systems for seat heating in vehicles face challenges such as loss of conductivity and heating efficiency under mechanical stress, uneven heating, and high costs due to the use of high proportions of conductive fillers, which lead to issues like resistance hot spots and irreversible conductivity collapse when expanded.
Innovation Solution
A composition comprising a matrix polymer, electrically conductive particles, an organic liquid salt, and a thickener, with specific weight ratios and additives, that maintains electrical conductivity and heating efficiency even at high stretches without using organic solvents and reducing the need for expensive conductive fillers, allowing for direct application to decorative surfaces like textiles or leather.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high proportions of conductive fillers are used to maintain electrical conductivity under mechanical stress, then electrical conductivity is improved, but cost increases and resistance hot spots occur
Solution Approach 1:
The patent uses a composite material system combining a polymer matrix with conductive filler particles. The polymer matrix provides mechanical flexibility and structural support, while the conductive filler particles provide electrical conductivity. This composite approach allows the material to maintain conductivity under mechanical stress without requiring excessive amounts of expensive conductive filler, thus resolving the contradiction between reliability and cost.
2Ease of operation
If the heating system is integrated with decorative surfaces, then ease of operation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the heating function with the decorative surface by integrating the conductive polymer composition directly into the seating surface material. This combination eliminates the need for separate heating mats and decorative covers, simplifying the overall structure and ease of use while the specific formulation and application methods address manufacturing complexity.
3Adaptability or versatility
If conductive strands are arranged in wave-like or zigzag patterns to maintain elasticity, then flexibility is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the fundamental parameter of the heating element from discrete strands requiring specific geometric patterns to a continuous conductive polymer composition. This parameter change allows the heating element to inherently accommodate various shapes and movements without requiring precise wave-like or zigzag arrangements, thus improving flexibility while reducing manufacturing precision requirements.
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 composition ensures homogeneous and rapid heating with improved extensibility, maintaining conductivity and heating performance even after significant stretching, while being cost-effective and not compromising the optical properties of the surface.
Implementation Method 1
The heating effect is often based on electrically conductive strands or individual threads with a specific electrical resistance
Implementation Method 2
which heat up when a voltage is applied (electrical resistance heating)
Data Source
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AI summary
The invention relates to a composition comprising at least a matrix polymer, electrically conductive particles and at least one organic liquid salt, wherein the weight ratio between the at least one matrix polymer and the electrically conductive particles is between 4:1 and 1:5; and the weight ratio between matrix polymer and organic liquid salt is between 1000:1 and 1:1; and the sum of the weights of matrix polymer, electrically conductive particles and organic liquid salt is at least 65 % based on the total weight of the composition. The invention further relates to the production and use of such a composition.