Flexible Heating Element Grid for Uniform Heat Distribution
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Solution Overview
Problem
Existing heating elements are not flexible or stretchable after application, limiting their use in applications where material deformation is required, such as in vehicle seats or functional clothing, as they become non-stretchable and non-thermally deformable due to the binder in conductive pastes.
Innovation Solution
A flexible heating element with a grid structure made of an electrically conductive paste, comprising dispersible thermoplastic polyurethane and a conductive filler, allows for flexibility and stretchability in multiple directions, with circular or drop-shaped points of intersection to prevent hot spots and mechanical weak points, and rhombic elements for enhanced flexibility and uniform heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive paste with binder is applied to create heating element, then electrical conductivity is achieved, but flexibility and stretchability are lost after hardening
Solution Approach 1:
The paste composition is changed by using dispersible thermoplastic polyurethane instead of conventional binders, and by optimizing the conductive filler content to 60-80 wt%. This parameter change allows the paste to maintain both electrical conductivity and flexibility/stretchability after processing, resolving the contradiction between reliability and adaptability
Solution Approach 2:
The invention uses a composite material system consisting of dispersible thermoplastic polyurethane as binder and conductive filler particles. This composite structure provides both the electrical conductivity needed for heating function and the mechanical flexibility/stretchability required for adaptability to different surfaces
2Reliability
If printed conductors are used for heating element, then electrical conductivity is achieved, but surface is raised and cannot be arranged directly beneath upholstery surface
Solution Approach 1:
The heating element is constructed as a thin, flexible layer with a flat surface profile. The conductive paste is applied in a controlled manner to create a planar heating structure that does not raise the surface, allowing direct placement beneath upholstery while maintaining electrical conductivity through the distributed grid pattern
3Adaptability or versatility
If grid structure with articulated joints is used, then flexibility and stretchability are enhanced, but structural complexity increases
Solution Approach 1:
The grid structure is segmented into grid elements connected at points of intersection, allowing independent movement and deformation of each segment. This segmentation enables the structure to accommodate flexibility and stretchability requirements while maintaining a relatively simple overall design that follows conventional grid patterns
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 heating element provides uniform heat distribution and can be reshaped thermally, maintaining stretchability and conductivity, allowing for direct application under upholstery without raising the surface, enhancing comfort and efficiency in heating applications.
Implementation Method 1
The conductive filler material is admixed in such a way that the conductive particles come into contact with each other after being processed, thus bringing about the conductivity
Implementation Method 2
The thermoplastic polyurethane forms the binder of the paste and is stretchable as well as thermally deformable. Thus, the paste is still stretchable, even after being processed, and can be reshaped at any time by means of thermal shaping processes
Implementation Method 3
The matrix is electrically conductive and/or heatable
Data Source
AI summary
A heating element includes a support made of flexible material and a flexible grid structure with an electrically conductive paste disposed on the support.