Flexible Conductor Device with Substrate Cut-outs for Seat Comfort

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Solution Overview

Problem

Flexible conductor devices in vehicle seats face issues with reduced comfort due to thickness differences and stiffness, noise generation, and impaired air and moisture regulation, which affect seating adaptability and user experience.

Innovation Solution

Incorporating incisions or cut-outs through the full thickness of the flexible carrier substrate to enhance deformation adaptability, reduce noise, and improve air and moisture regulation, with cut-outs covering at least 30% of the substrate area to allow greater movement and ventilation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a serpentine circuit is used to cover the seat surface, then heating coverage is improved, but local thickness differences occur which impair seating comfort

Engineering Contradiction:

Improveheating coverage areaVSAvoidseating comfort

Core Design Contradiction:

Area of stationary objectVSEase of operation

Solution Approach 1:

The serpentine circuit is divided into multiple independent heating zones or segments that can be controlled separately, allowing different areas to be heated at different intensities, thus maintaining comfort while achieving comprehensive coverage

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating circuit uses varying trace widths or spacing in different regions to create local variations in heating intensity, with lower heating density in areas requiring higher comfort (contact areas) and higher density in areas requiring less direct contact

Inventive Principle:

Principle #3Local quality

2Strength

If the carrier substrate is made stiff to maintain structural integrity, then mechanical strength is improved, but adaptability to body contours and deformation capability deteriorate

Engineering Contradiction:

Improvestructural integrityVSAvoidadaptability to body contours

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The carrier substrate incorporates dynamic elements such as flexible hinges, accordion structures, or progressive collapse zones that allow controlled deformation under body weight while maintaining structural integrity and returning to original shape after load removal

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The carrier substrate uses composite material structures combining rigid and flexible layers, or materials with anisotropic properties that provide strength in certain directions while allowing deformation in others, enabling both structural integrity and body contour adaptability

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If the flexible conductor device is deformed during use, then adaptability to seat contours is improved, but noise generation and cracking sounds increase

Engineering Contradiction:

Improveadaptability to seat contoursVSAvoidnoise generation

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The conductor traces are pre-stressed or pre-formed with built-in flexibility compensation features that absorb deformation stresses before they reach critical levels, preventing cracking sounds and reducing noise during seat adjustment or body movement

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Reliability

If the flexible conductor device is made closed and continuous for electrical connectivity, then electrical reliability is improved, but air circulation and moisture regulation are impaired

Engineering Contradiction:

Improveelectrical connectivityVSAvoidmoisture accumulation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The carrier substrate or insulation layers incorporate porous structures or micro-perforations that allow air and moisture vapor to pass through while maintaining electrical isolation, enabling moisture regulation without compromising electrical connectivity of the conductor traces

Inventive Principle:

Principle #31Porous materials

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 flexible conductor device achieves enhanced adaptability to body contours, minimizes noise during deformation, and improves air and moisture regulation, maintaining comfort and uniform heating or lighting effects.

Implementation Method 1

By providing an electric current at the connectors located at the opposite ends of the circuit, a heating effect is obtained

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS10602609B2Flexible electrical conductor device

Publication Date: 2020.03.24 ALT TECH

AI summary

A flexible conductor device (1) includes an electrically insulating flexible carrier substrate (2) and a printed electrical conductor (12) situated on the flexible carrier substrate. The electrical conductor is defined by at least one elongate circuit (3) which extends between opposite ends (6). The carrier substrate (2) is provided with at least an incision or cut-out (4) extending through the full thickness of the carrier substrate (2) so as to provide enhanced flexibility.