Flexible Conductive Element Shaping for Complex Curved Surfaces

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Solution Overview

Problem

Flexible flat resistors face challenges in coating complex geometries, such as small radii of curvature, leading to creases, ripples, and potential breakage of the metal track during deformation.

Innovation Solution

A method of plastic deformation for flexible conductive elements, involving arranging the element around a device that expands to a predetermined volume, allowing the element to be plastically deformed and then separated, enabling optimal coating of complex shapes like a steering wheel without breakage or ripples, with specific design features like serpentine metal tracks and radial branches for uniform heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a flexible flat resistor is wrapped around an item with small radii of curvature, then the item can be coated with a heating element or sensor, but numerous creases or ripples are formed and the metal track is subject to breakage

Engineering Contradiction:

Improvecoating capability on complex geometriesVSAvoidmetal track integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The flexible flat resistor is pre-deformed into a toroidal shape before coating the item. This preliminary deformation adapts the resistor to complex geometries in advance, so that when wrapped around items with small radii of curvature, it does not form creases or ripples and the metal track does not breakage during the wrapping process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flexible flat resistor is given a toroidal (curved) shape instead of remaining flat. This curvature allows the resistor to conform to items with small radii of curvature without creating stress concentrations that would cause metal track breakage or surface defects like creases and ripples

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Manufacturing precision

If the flexible flat resistor is deformed to adapt to complex geometries, then coating quality improves, but the metal track may break during deformation

Engineering Contradiction:

Improvecoating qualityVSAvoidmetal track strength

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The resistor is pre-deformed into a toroidal shape with controlled dimensions before being applied to the item. This preliminary action ensures that the deformation is performed under controlled conditions where the metal track geometry is optimized to prevent breakage while achieving the desired coating quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The metal track geometry is specifically designed with stretches oriented at angles between 45° and 135° relative to the deformation direction, and the track width and spacing are controlled to ensure that during toroidal deformation, the metal track undergoes elastic deformation within safe stress limits, preventing breakage while achieving high coating quality

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the flexible flat resistor remains flat, then the metal track is less likely to break, but it cannot optimally coat items with complex geometries

Engineering Contradiction:

Improvemetal track integrityVSAvoidcoating capability on complex geometries

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The resistor is pre-deformed into a toroidal shape before use. This preliminary deformation prepares the resistor to conform to complex geometries in advance, enabling optimal coating of items with small radii of curvature while the controlled deformation design prevents metal track breakage

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The resistor is transformed from a flat configuration to a toroidal (curved) configuration. This curvature enables the resistor to adapt to complex geometries and coat items effectively, while the specific toroidal dimensions are designed to keep metal track stress within safe limits, preventing breakage

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 method allows for homogeneous and localized deformation of flexible resistors, ensuring optimal coating of complex items like steering wheels with minimized defects, improved reproducibility, and reliability, suitable for mass production.

Implementation Method 1

a method of plastic deformation to deform a substantially flat flexible conductive element

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentEP3654352B1Flexible conductive element and shaping method thereof

Publication Date: 2024.01.24 I R C A S P A IND RESISTENZE CORAZZATE E AFFINI

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AI summary

A flexible conductive element (1) comprising at least one insulating layer (2) and at least one conductive track (4) fixed to the at least one insulating layer (2), wherein the conductive track (4) has a plurality of stretches (3), and wherein the adjacent stretches of said plurality of stretches (3) have a different orientation one another, and wherein said insulating layer (2) is made of a thermoplastic polymeric material; wherein there is provided a plurality of branches (5) of a thermally conductive material extending from the conductive track (4).