Fine Heating Wire with Poly Aramid Core for Flexible Wearables
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Solution Overview
Problem
Conventional heating wires are too thick for subminiature products, causing a foreign body sensation, increasing volume, and reducing thermal efficiency, while being prone to damage and electric hazards when bent.
Innovation Solution
A fine heating wire with a small diameter is created by braiding poly aramid fiber strands for tensile strength and spirally winding a copper or copper alloy coil, allowing for dense installation and flexibility, with a resistance value that maintains high thermal efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional heating wire is used, then heating function is provided, but diameter is large causing foreign body sensation and increased volume
Solution Approach 1:
The heating wire is segmented into multiple fine heating wires (e.g., 7-19 wires per bundle) bundled together. Each fine heating wire has a small diameter (0.1-0.5mm) that can be densely arranged, while the bundled structure provides overall strength and flexibility, resolving the contradiction between small individual wire diameter and bundle durability.
Solution Approach 2:
The heating wire uses a composite structure combining fine heating wires (copper or copper alloy) with poly aramid fiber coating. This composite design allows the heating element to maintain small diameter for dense installation while the poly aramid fiber provides tensile strength and flexibility, preventing damage during bending operations.
2Loss of energy
If conventional heating wire is used, then heating function is provided, but thermal efficiency per unit area is extremely decreased
Solution Approach 1:
By segmenting the heating function into multiple fine heating wires that can be densely arranged, the heating area is significantly increased per unit length. This dense arrangement improves thermal efficiency per unit area while using lower power per wire, reducing the danger of electric shock.
Solution Approach 2:
The invention changes the diameter parameter of the heating wire to a very small range (0.1-0.5mm), enabling dense installation. This parameter change increases the number of wires per unit area, improving thermal efficiency while reducing power consumption per wire and associated electric shock risks.
3Adaptability or versatility
If conventional heating wire is bent, then adaptability is improved, but heating wire is damaged causing electric leakage and short circuit
Solution Approach 1:
The poly aramid fiber coating creates a composite structure that provides flexibility allowing the heating wire to be bent without damage. The fine diameter (0.1-0.5mm) combined with the flexible coating enables adaptability to curved surfaces while maintaining electrical safety by preventing wire damage, short circuit, and contact failure during bending.
4Quantity of substance
If heating wire diameter is reduced, then dense installation is enabled, but tensile force is weakened
Solution Approach 1:
The heating system is segmented into multiple fine wires (0.1-0.5mm diameter) bundled together in groups (7-19 wires per bundle). This segmentation allows dense installation of individual fine wires while the bundled configuration maintains overall tensile strength through the collective strength of multiple wires and the poly aramid fiber coating.
Solution Approach 2:
The composite structure of fine heating wires combined with poly aramid fiber coating provides both the small diameter needed for dense installation and the tensile strength required for durability. The poly aramid fiber specifically contributes high tensile strength to compensate for the reduced diameter of individual heating wires.
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 fine heating wire provides high thermal efficiency with low power consumption, durability, and safety by maintaining tensile force and resistance even when bent, suitable for miniature products like gloves and mats, with controlled temperature and power management.
Implementation Method 1
a coil 12 made of copper or a copper alloy spirally wound around the outer portion of the core 11
Implementation Method 2
braids and connects fine poly aramid fiber strands to form a core, and a coil having a small diameter is spirally wound around the outer portion of the core, thereby securing firm tensile force even with the small diameter
Data Source
Figure 1~2
Figure 3
Figure 4a
AI summary
The present invention relates to a fine heating wire, applied to various products by having a small diameter and being bendable and densely installed, and having high thermal efficiency, which includes a core formed with synthetic fiber material and a coil spirally wound around the outer portion of the core, wherein the core connects one or more pairs of poly aramid fiber units, each formed by braiding dozens to hundreds of fine poly aramid fiber strands, to maintain the diameter within 200-600 denier, and the coil is formed of copper or copper alloy to have a temperature rising up to 60° within five minutes when 3.7-12V power is supplied to maintain a resistance value equal to or greater than 0.5 Ω/m. The fine heating wire has a minimized diameter to be installed inside slim fiber, and is bendable and densely installed to be applied to gloves, socks, etc.