Flexible Laminate Coaxial Puncture Stitching
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Solution Overview
Problem
Existing flexible laminates with elongate electrically conductive elements, such as heating wires, are time-consuming and costly to assemble, lack secure stabilization, and struggle with uniform heat distribution on uneven surfaces, and are prone to hotspot formation and disconnection under stress.
Innovation Solution
A flexible laminate design featuring a coaxially punctured electrically non-conductive substrate, conductive element, and layer connected via a mechanical means like stitching, with a larger cross-sectional area at punctured regions to ensure secure bonding, optimal heat distribution, and enhanced tensile impact strength, using copper elements and a heat-resistant adhesive cover for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrically conductive element is connected to the substrate and layer by sewing operation with adhesive bonding, then the laminate can be assembled, but the assembly process becomes time-consuming and costly
Solution Approach 1:
The patent combines the sewing operation and adhesive bonding into a single integrated process. The adhesive is applied to the thread before sewing, so that one operation simultaneously achieves both mechanical interlocking through stitching and chemical bonding through adhesive, eliminating the need for separate bonding steps and reducing assembly time and cost
Solution Approach 2:
The adhesive-coated thread applies its own bonding agent during the sewing process, eliminating the need for separate adhesive application steps. The thread serves dual functions: mechanical fastening through stitching and chemical bonding through the adhesive it carries, making the system self-sufficient in achieving both connection methods
2Reliability
If the electrically conductive element is punctured for mechanical connection, then secure stabilization is achieved, but hotspots may form damaging the laminate
Solution Approach 1:
The patent applies local quality by creating a punctured region with enlarged cross-sectional area specifically at the connection point, while maintaining the original thin profile elsewhere. This localized thickening provides enhanced mechanical strength and heat dissipation capacity exactly where the puncture occurs, preventing hotspot formation without affecting the overall flexibility and heat distribution of the conductive element
Solution Approach 2:
The conductive element is pre-formed with an enlarged cross-sectional area at the region that will be punctured. This preliminary structural preparation ensures that when the puncture is made for mechanical connection, the element already has sufficient material volume to handle the mechanical stress and dissipate heat effectively, preventing hotspot formation before it can occur
3Reliability
If the laminate is bonded to further layers by adhesive, then the laminate can be assembled, but the process becomes time-consuming and costly
Solution Approach 1:
The patent merges the mechanical sewing operation with chemical adhesive bonding into a single integrated process. The adhesive is pre-applied to the thread, so that one sewing operation simultaneously achieves both mechanical interlocking through stitching and chemical bonding between layers, eliminating separate bonding steps and significantly improving assembly efficiency
Solution Approach 2:
The thread serves dual functions by carrying its own adhesive coating. During the sewing operation, the thread simultaneously provides mechanical fastening through stitching and chemical bonding through the adhesive it carries, making the bonding process self-sufficient and eliminating the need for separate adhesive application and curing steps
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 solution provides a cost-effective, adaptable, and durable flexible laminate that maintains uniform heat distribution and withstands stress without hotspot formation, ensuring reliable operation on various surfaces and applications.
Implementation Method 1
elongate electrically conductive in the form of a heating wire which is positioned on the substrate in a meandering shape so as to heat the laminate over full surface thereof
Data Source
AI summary
A flexible laminate (1) includes an electrically non-conductive substrate (2) with a substantially planar configuration, an electrically conductive element (3) on a surface of the electrically non-conductive substrate, and a layer (4) on a surface of the electrically non-conductive substrate (2). The electrically non-conductive substrate (2), the electrically conductive element (3) and the layer (4) are coaxially punctured forming a punctured region (6). They are connected to each other through a mechanical connection element (5) which extends through the electrically non-conductive substrate (2), the electrically conductive element (3) and the layer (4) at the punctured region (6). The cross-sectional area of the electrically conductive element (3) at the location of the punctured region (6) is larger than the cross-sectional area of the electrically conductive element (3) outside the punctured region (6).