Flexible Flat Heating Element With Clip-Clamped Electrodes
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Solution Overview
Problem
Existing heatable flat structures with electrically conductive elements face challenges in secure and durable electrode connections, leading to inconsistent contact resistance and potential damage under dynamic and climatic loads, particularly in applications like vehicle seat heating where uniform heating is required.
Innovation Solution
The use of clips or clamps with clamping jaws to securely connect electrodes to a flexible resistance heating element, providing force-fitting or form-fitting engagement, ensuring consistent pressure and resistance across the electrode length, and allowing for flexible positioning and robust assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stitching is used to connect electrodes to the resistance heating element, then the electrode is pressed against the conductive coating, but the contact resistance becomes non-uniform and the connection is not durable under dynamic loads
Solution Approach 1:
The connection system is segmented into distinct functional components: the electrode, the resistance heating element, and the clip fastener. This segmentation allows each component to be optimized independently, with the clip providing uniform distributed pressure without the localization issues of stitching points.
Solution Approach 2:
The stitching mechanism (thread-based mechanical fastening) is replaced with a clip-based clamping system. This substitution eliminates the intermittent contact characteristic of stitches and provides continuous uniform pressure across the entire electrode-contact interface, ensuring consistent electrical contact resistance.
2Power
If high current is fed into the resistance heating element, then heating effect is achieved, but the contact areas are prone to damage and overheating
Solution Approach 1:
The clip fastener serves as a protective element that pre-establishes a robust mechanical and electrical connection before high current flows. This beforehand securing prevents contact area damage by ensuring the electrode is firmly held against the conductive coating with uniform pressure, distributing the thermal and mechanical stresses that occur during high-power operation.
Solution Approach 2:
The contact pressure parameter is optimized through the clip design to provide sufficient force for low contact resistance while distributing this force uniformly across the electrode length. This parameter optimization allows high current transmission without localized overheating, as the pressure is sufficient to maintain good electrical contact but distributed to prevent damage.
3Reliability
If stitching is used to fix electrodes, then connection is achieved, but the stitching may come undone due to thread fatigue or damage
Solution Approach 1:
The clip fastener is designed as a simple, robust, and potentially replaceable component that provides secure connection without the complexity of threaded fasteners. While individual clips may be simple in construction, the overall connection system achieves extended lifespan through the clip's ability to maintain constant pressure and be easily replaced if needed, avoiding the progressive degradation of thread materials.
Solution Approach 2:
The clip fastener provides a dynamic connection that can accommodate movement and deformation of the flexible heating element during use. Unlike rigid stitching that may break under dynamic loads, the clip design allows for some movement while maintaining continuous contact pressure, ensuring the connection remains secure throughout the product's service life.
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 provides secure, durable, and uniform electrical contact, reducing the risk of overheating and damage, while maintaining consistent heating performance under varying loads, and is adaptable for diverse applications including vehicle interiors and floor heating systems.
Implementation Method 1
a flexible, flat resistance heating element of electrically conductive material... intended for feeding electric current into the resistance heating element
Implementation Method 2
Fasteners being either clips or clamps, for connecting the electrodes to the resistance heating element. The fasteners having clamping jaws acting against one another... and pressing the respective electrode onto the resistance heating element
Data Source
AI summary
A flexible flat structure has a flexible, flat resistance heating element that is connected to electrodes that are spaced apart from one another for supplying electrical current that is pressed on to the resistance heating element by staples or clamps in a force-fit manner and/or a form-fit manner and provides a more flexible connection.