Heating Conductive Wire Structure for Flex Life and Hot-Spot Prevention
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Solution Overview
Problem
Existing car seat heating systems face challenges in achieving long lifetime, reliable operation, and preventing hot-spots due to dynamic bending forces, while maintaining cost-effectiveness and avoiding the difficulties of applying uniform lacquer coatings on fine metallic filaments.
Innovation Solution
A heating conductive wire-like element is designed with a synthetic fiber core twisted in one direction and conductive wires wound around it in a different direction, individually covered with non-conductive material, and optionally wrapped with non-conductive filaments or tapes, to enhance flex life and prevent hot-spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the diameter of metallic filaments is decreased to increase flex life, then flex endurance is improved, but production costs increase exponentially
Solution Approach 1:
The patent replaces expensive fine metallic filaments with cheaper, coarser heating conductive wires that are individually insulated. This substitution allows the use of lower-cost materials while maintaining the required flex life through the combination of individual insulation and protective sheathing, thereby resolving the contradiction between durability and manufacturing cost.
Solution Approach 2:
The heating element is segmented into multiple individually insulated heating conductive wires rather than using a single continuous filament or bundle of uninsulated filaments. This segmentation allows each wire to be independently protected, preventing hot-spot formation while using coarser, cheaper wire diameters, thus reducing production costs while maintaining flex life.
2Reliability
If individual lacquer coating is applied to metallic filaments to prevent hot-spots, then hot-spot formation is resolved, but manufacturing difficulty increases due to inability to apply uniform coating on fine filaments
Solution Approach 1:
The patent changes the physical parameters of the heating conductive elements from fine metallic filaments to coarser wires with larger diameters. This parameter change makes the surface more accessible and easier to coat uniformly with insulating lacquer, thereby enabling effective hot-spot prevention through manufacturable coating processes while maintaining reliability.
Solution Approach 2:
The patent uses composite construction combining heating conductive wires with insulating lacquer coating and an additional protective polymer sheath. This multi-layer composite structure ensures uniform coverage and effective hot-spot prevention, while the layered approach allows each material to perform its specific function optimally, making the overall manufacturing process more feasible.
3Reliability
If high grade polymer coatings are used to protect metallic filaments from corrosion and increase flex life, then protection and durability are improved, but cost and manufacturing difficulty increase
Solution Approach 1:
The protective system is segmented into two distinct layers: an inner insulating lacquer coating that provides corrosion protection and electrical insulation, and an outer polymer sheath that provides mechanical protection and enhances flex life. This segmentation allows each layer to be optimized for its specific function and applied using appropriate manufacturing processes, reducing overall complexity and cost compared to using a single high-grade coating for all functions.
Solution Approach 2:
The patent employs a composite protective structure with inner lacquer coating and outer polymer sheath. This composite approach allows the use of lower-cost, easier-to-apply materials for each individual layer while achieving the combined benefits of corrosion protection, electrical insulation, and enhanced durability that would require expensive high-grade coatings if applied as a single layer.
4Power
If metallic filaments are used for heating, then heating function is achieved, but hot-spot formation occurs when filaments are damaged or broken
Solution Approach 1:
The patent introduces an insulating lacquer coating as an intermediary layer between the heating conductive wires and each other. This intermediary insulation prevents direct contact and electrical arcing between adjacent wires, thereby eliminating hot-spot formation when wires are damaged or broken, while maintaining the heating capability of the conductive wires themselves.
Solution Approach 2:
The patent uses thin film insulation in the form of lacquer coating on each heating conductive wire and an additional flexible polymer sheath surrounding the assembly. These flexible insulating layers provide continuous protection against hot-spot formation while allowing the heating element to maintain its flexibility and heating function throughout its operational life.
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 flexible heating element with improved flex life and effective hot-spot prevention, ensuring reliable operation and reduced production costs by using a balanced 'S' and 'Z' torque structure and lower-grade polymer coatings.
Implementation Method 1
electrical heating cables are subjected to dynamic bending forces... the heating cable is connected to a power feeding unit that delivers current, whereby the element can be heated to a suitable temperature
Data Source
Figure 1~3
AI summary
The invention provides a heating conductive wire-like element comprising a core made from synthetic fibers a plurality of heating conductive wires around said core. The core is twisted in a predetermined direction X and the plurality of heating conductive wires are wound in a predetermined direction Y. The predetermined direction X is different from the predetermined direction Y. A predetermined number of said heating conductive wires are individually covered with a non- electrically conductive material.