Flexible Heating Element Clamp Fastening
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Solution Overview
Problem
Existing heatable flat structures in vehicles face issues with unreliable and durable electrical contact due to loose seams or inadequate pressure distribution, leading to non-uniform heating and potential damage under dynamic and climatic loads.
Innovation Solution
The use of clamps with clamping jaws that grip both the electrodes and the resistance heating element, providing a non-positive and/or positive fit to ensure consistent contact pressure and durability, eliminating the need for complex attachment methods like sewing or gluing, and allowing for flexible positioning and adaptation to various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrodes are fixed to the conductive carrier with seams, then the electrode is pressed against the conductive coating, but the contact resistance becomes dependent on seam tightness and can increase over time due to loose seams or thread fatigue
Solution Approach 1:
The patent replaces the mechanical sewing system with a clamp-based mechanical fastening system. The clamp applies continuous pressure to press the electrode against the conductive coating without requiring seams, eliminating the reliability issues associated with thread fatigue and seam loosening while maintaining uniform contact pressure across the contact area.
Solution Approach 2:
The clamp provides dynamic adaptability by allowing adjustment of contact pressure and positioning. This enables the system to compensate for variations in electrode placement and maintains optimal contact pressure under dynamic and climatic loads, ensuring uniform contact resistance throughout the electrode length.
2Force
If electrodes are pressed with clamps, then contact pressure is applied, but the contact area is limited to point support under the clamp
Solution Approach 1:
The patent extends the contact area from a single point under the clamp to a continuous linear contact zone. This is achieved by positioning the clamp to press the electrode against the conductive coating along the entire length of the electrode, effectively transforming the contact from zero-dimensional (point) to one-dimensional (line) contact, thereby increasing the effective contact area while maintaining appropriate pressure.
3Reliability
If complex attachment methods like sewing or gluing are used, then electrodes can be fixed to the resistance heating element, but the manufacturing process becomes more complex and less flexible
Solution Approach 1:
The patent replaces complex attachment methods (sewing, gluing) with a simple clamp-based mechanical fastening system. This substitution maintains attachment durability through continuous pressure while significantly simplifying the manufacturing process, eliminating the need for sewing machines, adhesives, and associated curing or assembly steps.
Solution Approach 2:
The clamp design allows for self-adjusting and self-positioning during assembly, reducing the need for precise pre-positioning and complex alignment procedures. The clamp itself provides the positioning function, making the attachment process more intuitive and less complex while maintaining reliable contact.
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 a robust, uniform, and reliable electrical contact that withstands dynamic and climatic loads, reducing contact resistance and preventing overheating, while allowing for easy adjustment and manufacturing flexibility.
Implementation Method 1
a flexible, flat resistance heating element made of electrically conductive material and at least two spaced-apart, possibly also flat electrodes connected to the resistance heating element for feeding electrical current into having the resistance heating element
Data Source
AI summary
The invention relates to a flexible flat structure having 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 and/or form-fit manner.