Conductive Textile Heater for Steering Wheels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric heating members, such as copper or copper-nickel-manganese alloys, fail to provide uniform heating and are noticeable in automotive applications like steering wheels, leading to thermal stress and material fatigue, while flexible foil heaters and conductive textiles face challenges in 3-D installations due to complexity and limited stretchability.
Innovation Solution
A flexible and stretchable electric heating member composed of a flat-shaped, electrically conductive textile with a layer of flexible polymeric plastic, where the textile is adhesively bonded and separated using a kiss cutting process to maintain uniform thickness and reduce visibility and tactility, utilizing polyamide or polyester materials for enhanced handling and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional heating wires (copper or copper-nickel-manganese alloys) are used, then electrical conductivity is improved, but heating uniformity deteriorates and thermal stress increases
Solution Approach 1:
The heating element is segmented into multiple independent heating zones or traces arranged in a specific pattern (e.g., serpentine, mesh, or interdigitated configuration). This segmentation allows each zone to contribute to overall heating uniformity while maintaining good electrical conductivity through the network of heating traces.
Solution Approach 2:
The heating structure transitions from one-dimensional wire to two-dimensional foil or film with distributed heating traces. This dimensional change enables broader heat distribution across the surface, improving heating uniformity while maintaining electrical conductivity through the extended trace network.
2Adaptability or versatility
If foil heater members are used for 3-D installation (e.g., steering wheel), then flexibility is improved, but installation complexity increases due to wrinkle prevention requirements
Solution Approach 1:
The heating element is constructed as a thin, flexible foil or film that can conform to curved surfaces like steering wheels. The flexible substrate allows the heater to adapt to 3-D geometries while the thin-film construction minimizes stiffness, reducing wrinkles and simplifying installation.
Solution Approach 2:
The heating element incorporates flexible or stretchable materials that can dynamically adapt to the installation surface geometry. This dynamic flexibility allows the heater to be installed on complex 3-D surfaces without requiring rigid precision alignment or complex mounting structures.
3Adaptability or versatility
If conductive textiles are used, then flexibility and stretchability are improved, but manufacturing complexity increases
Solution Approach 1:
The heating element combines conductive materials (e.g., metal traces, conductive polymers, or conductive yarns) with flexible substrate materials (e.g., polyester, polyurethane, or other polymers) to create a composite structure. This composite approach provides both stretchability and conductivity while using established manufacturing techniques like lamination, coating, or weaving.
Solution Approach 2:
The manufacturing process utilizes adjustable parameters such as print thickness (5-15 μm), material composition ratios, and layer configurations to optimize both stretchability and conductivity. By controlling these parameters, the heater achieves desired mechanical properties without requiring complex multi-step manufacturing procedures.
4Illumination intensity
If heater member thickness is reduced for low visibility, then aesthetic appearance is improved, but mechanical durability deteriorates
Solution Approach 1:
The heater is constructed as a thin flexible film or foil with distributed heating traces, providing low visibility and tactility when installed. Despite the thin overall structure, the distributed trace network and flexible substrate maintain adequate mechanical durability by distributing stress and preventing localized failure points.
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 high fault tolerance and ease of installation, ensuring uniform heating and reduced risk of kinks or bends, while maintaining low visibility and tactility, suitable for complex 3-D applications like vehicle steering wheels.
Implementation Method 1
electric heating member... electrically conductive textile member... parallel electrical heating circuit... heating traces
Implementation Method 2
layer of flexible, polymeric plastic material is adhesively bonded to one out of the upper surface and the lower surface of the textile member
Data Source
AI summary
An electric heating member, in particular for automotive application, includes an electrically conductive, flat-shaped textile member of uniform thickness and a layer of flexible, polymeric plastic material that is adhesively bonded to a surface of the textile member. The electrically conductive textile member is formed by at least two electrically conductive textile member parts that are arranged side by side and are electrically separated. At least one of the at least two textile member parts is electrically connected to electric terminals that are connectable to an electric heater power supply unit. The electric heating member is particularly intended to be used for heating a vehicle steering wheel.