Deformable Heating Mat with Undulating Filament Cavities
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Solution Overview
Problem
Conventional heating mats for composite material manufacturing are not extensible or formable to complex geometries, leading to inadequate heat distribution and a high risk of damage when trying to conform to parts with complex shapes or angles.
Innovation Solution
A deformable and formable heating mat with an elastic matrix containing cavities with an undulating layout to accommodate zigzag or spiral-shaped heating elements, allowing for greater flexibility and adaptability to complex shapes without risking damage to the mat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional heating mats with resistive filaments are used, then heating function is provided, but the mat cannot be extended or deformed to complex geometries without risking damage to the filaments
Solution Approach 1:
The heating element is segmented into multiple discrete resistive filaments that are independently movable within separate cavities. This segmentation allows each filament to move independently without constraining the others, enabling the mat to be extended and deformed to complex geometries while maintaining filament integrity and preventing breakage.
2Adaptability or versatility
If the heating mat is extended beyond 30% deformation, then adaptability to complex shapes improves, but the resistive filaments may break
Solution Approach 1:
Cavities made of flexible material serve as intermediaries between the resistive filaments and the elastic matrix. These cavities allow the filaments to move and deform within a protected space, accommodating large extensions of the mat while preventing direct stress and strain on the filaments that would cause breakage.
3Manufacturing precision
If the heating mat is pressed to fit complex contours, then contact with the part improves, but the resistive filaments may break due to pressure
Solution Approach 1:
The resistive filaments are nested within cavities that are themselves embedded in the elastic matrix. This nested structure allows the filaments to remain protected within their cavity compartments while the outer surface of the mat conforms to complex contours under pressure, achieving accurate contour following without transmitting damaging forces to the filaments.
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 heating mat can be elastically deformable through 90° and extend at least twice its length without compromising the functionality of the resistive filaments, enabling effective heat distribution on complex-shaped parts without risk of damage.
Implementation Method 1
heating resistors in the form of resistive filaments circulate
Implementation Method 2
matrix made of elastic material (for example silicone)
Data Source
AI summary
A silicon heating mat, the mat being formable and deformable and including a matrix made of elastic material, in which at least one cavity is arranged that fully passes through the matrix, the at least one cavity being intended to accommodate a resistive filament connected to a heating cycles management unit. Furthermore, the at least one cavity has an undulating layout, with each resistive filament being able to move inside said at least one cavity, and each resistive filament having a zigzag or spiral shape.