Heated Garment Wire Layout for Flex-Durable Therapeutic Heating

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Solution Overview

Problem

Existing heating devices for body application are either bulky and uncomfortable (mains powered) or underpowered and heavy with short operating times (battery devices), failing to provide effective therapeutic heat levels and portability.

Innovation Solution

A lightweight, flexible, and durable heated garment with a heating wire array integrated into fabric, using a transition element to induce torsion forces and a thermally conductive material to distribute heat evenly, powered by a compact battery pack.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a heating wire is positioned directly on the fabric surface, then heat transfer to the wearer is efficient, but the heating wire is subjected to flexion forces that cause fatigue and failure

Engineering Contradiction:

Improveheating wire durabilityVSAvoidheating wire positioning complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heating wire is routed to transition over the fabric flex line at an angle (5-60 degrees) rather than perpendicular to it, creating a curved/tortuous path that subjects the wire to torsion forces instead of flexion forces, thereby improving durability while maintaining manufacturing simplicity

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

A flexible thermally conductive material layer is applied over the heating wire to protect it from mechanical damage while maintaining thermal contact with the fabric and wearer, providing both protection and heat transfer functionality

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If the heating wire follows a straight path across the fabric, then the garment construction is simple, but the heating wire experiences repeated flexion that leads to fatigue and failure

Engineering Contradiction:

Improveheating wire fatigue resistanceVSAvoidheating wire path length

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The heating wire is configured to follow a tortuous or curved path as it transitions over the fabric flex line at an angle, which increases the path length slightly but eliminates flexion-induced fatigue by converting the stress to torsion, significantly improving reliability

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

Instead of routing the heating wire in a straight line across the fabric surface, the wire is positioned to transition in three-dimensional space over the flex line, utilizing the vertical dimension to create an angled crossing that reduces mechanical stress

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Temperature

If thermally conductive material is applied over the heating wire, then heat distribution is improved, but the heating wire becomes less accessible for repair or replacement

Engineering Contradiction:

Improveheat distribution uniformityVSAvoidheating wire accessibility

Core Design Contradiction:

TemperatureVSEase of repair

Solution Approach 1:

A thin flexible thermally conductive material layer is applied over the heating wire, providing thermal contact and heat distribution while remaining thin enough to allow the heating wire to be accessed and repaired if needed, balancing thermal performance with maintainability

Inventive Principle:

Principle #30Flexible shells and thin films

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 garment provides therapeutic heat levels (above 37°C) for pain relief, is machine-washable, and offers high flexibility and durability, suitable for various body parts.

Implementation Method 1

a heating wire forming a heater array attached to a fabric that is part of the garment body or is configured for arrangement within the garment body

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a flexible thermally conductive material that is electrically resistive covering the heating wire

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250351888A1Heated Garments and Methods for Constructing Heated Garments

Publication Date: 2025.11.20 TAYLOR INVENTIONS INC

AI summary

Heated garments that are flexible, stretchable, and durable are described, along with methods for constructing such garments. The heated garments comprise a garment body, a heating wire forming a heater array stitched to a heating section of fabric, and a main current line for providing electrical current to the heating wire. A transition element is formed over the connection of the heating wire and the main current line to induce formation of a fabric flex line such that the heating wire is subjected predominately to torsion forces instead of flexion forces upon flexion at the fabric flex line. The heated garment includes a flexible thermally conductive and electrically resistive material covering the heating wire. The heater array may be integral to the garment body or may be removable.