Cordless Heated Roller With Flex-Resistant Heating Layer

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Foam rollers with integrated heat sources face inefficiency due to the insulating nature of foam, which reduces the effectiveness of heat transfer to the user's muscles, and existing heat mesh materials fail to maintain electrical conductivity upon flexing, leading to broken electrical paths.

Innovation Solution

A portable heated roller with a re-chargeable inner core, a flex-resistant resistive heating layer, and a therapeutic foam overmold, featuring a multi-path electrical structure and carbon-filled polymer or carbon fiber heating elements to maintain conductivity during flexing, and an outer foam layer for efficient heat distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a heat source is placed within the foam roller, then heat relief is provided to muscles, but the insulating foam layer prevents effective heat transfer to the user

Engineering Contradiction:

Improveheat transfer effectivenessVSAvoidheat loss through insulation

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The heating element is extracted from the traditional foam-embedded configuration and positioned in a dedicated channel or groove within the foam roller structure. This allows the heating element to be separated from the insulating foam material, enabling direct thermal contact with the user's body while the foam provides structural support rather than thermal isolation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A thermal conductor or heat transfer medium is introduced as an intermediary between the heating element and the user's body. This intermediary material facilitates efficient heat transfer from the heating element to the user while allowing the foam roller to maintain its insulating properties for structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If a resistive heating mesh is placed near the surface of the foam layer, then heat transfer efficiency is improved, but repeated flexing breaks the electrical paths in the mesh

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidelectrical path continuity

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The heating element is constructed using flexible heating materials such as flexible heating wires, flexible heating ribbons, or flexible heating membranes that can withstand repeated flexing without breaking electrical paths. These flexible heating structures are designed to bend and flex with the foam roller while maintaining continuous electrical conductivity.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

A composite heating structure is used that combines flexible conductive materials with reinforcing elements. The composite structure includes flexible heating wires or ribbons embedded in a flexible substrate or mounted on a flexible circuit board, creating a durable assembly that maintains electrical integrity through repeated flexing cycles.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If foam is used as the outer layer for comfort and therapy, then user comfort is improved, but the insulating property minimizes the effect of heat/cold sources

Engineering Contradiction:

Improveuser comfortVSAvoidthermal effect delivery

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The foam roller is segmented into distinct functional zones: an outer foam layer for comfort and structural support, a middle layer containing the flexible heating element, and an inner core for additional support. This segmentation allows each layer to perform its specific function without interfering with the others, enabling both comfort and effective heat delivery.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The foam roller is designed with varying foam density or thermal conductivity in different regions. The outer foam layer maintains insulating properties for structural integrity, while localized areas have reduced insulation or enhanced thermal conductivity to facilitate heat transfer from the heating element to the user's body, creating different thermal zones within the same structure.

Inventive Principle:

Principle #3Local quality

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 consistent and penetrating heat relief to muscles, enhancing muscle recovery and usability with a durable heating system that maintains electrical conductivity even upon flexing, thus overcoming the inefficiencies of traditional foam rollers.

Implementation Method 1

carbon-filled polymer or carbon fiber heating elements to maintain conductivity during flexing

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

provides consistent and penetrating heat relief to muscles

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11951063B2ARAY heated roller

Publication Date: 2024.04.09 EMANUELLI EDUARDO

AI summary

A cordless portable composite foam roller generates and applies heat and/or cold to muscles, and operates using an internal rechargeable power source combined with a flex-proof heating layer when in use. The cordless foam roller includes an elongated cylindrically-shaped body having a sandwich of heating layer(s) and textured exterior surface, and an inner cavity for hosting the rechargeable power source components.