Softening Device for Heating Element Insulation
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Solution Overview
Problem
The existing methods for sewing electrical heating metallic wires onto vehicle heating cushions often result in damage to the insulating skin due to bending, leading to potential short circuits and reduced product life, especially when dense patterns are used.
Innovation Solution
A softening device and method that heats the electrical heating element with hot air to a specific temperature, allowing it to be bent into complex patterns without damaging the insulating layer, using a sewing apparatus with a softening device that includes a body with gas and feeding passages, and a connecting tube with a spiral spring to maintain warmth and prevent damage during sewing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electrical heating metallic wire is sewn onto the carrier in a high density pattern to improve heating performance, then the heating performance is improved, but the insulating skin may be broken due to multiple bending, resulting in short circuit and reduced product life
Solution Approach 1:
The patent applies parameter changes by heating the electrical heating metallic wire to a specific temperature range (80-150°C) before sewing. This temperature change modifies the physical properties of the insulating skin, making it more flexible and resistant to cracking during bending and sewing operations, thereby maintaining both high-density pattern capability and insulating skin integrity
Solution Approach 2:
The patent implements preliminary action by pre-heating the electrical heating metallic wire before the sewing process. This preliminary thermal treatment softens the insulating skin in advance, allowing it to withstand the multiple bending operations required for high-density sewing patterns without cracking or breaking, thus preventing short circuits and ensuring product reliability
2Strength
If the insulating skin is made of relatively hard material to protect the electrical heating wire, then the protection is improved, but the insulating skin cannot be multiple bent with sharp angles without breaking
Solution Approach 1:
The patent changes the temperature parameter of the insulating skin from room temperature to elevated temperature (80-150°C) before bending operations. This parameter change transforms the insulating skin from a rigid, brittle state to a more flexible, ductile state, enabling it to be bent into sharp angles and complex patterns while maintaining its protective function and preventing cracks
Solution Approach 2:
The patent utilizes a phase transition-like effect where the insulating skin transitions from a hard, brittle phase at room temperature to a soft, flexible phase when heated. This thermal softening allows the insulating skin to undergo multiple sharp bends without breaking, after which it can be set in the desired shape, effectively combining protection and adaptability
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
Enables the electrical heating element to be securely sewn onto a cushion without damaging the insulating layer, allowing for complex patterns with small radii without short circuits or reduced product life, while maintaining operational integrity.
Implementation Method 1
the softening device comprises: a body, wherein the body is provided with a gas passage, a feeding passage, and an open cavity, wherein hot air is able to be driven through the gas passage, and the elongate electrical heating element is able to be conveyed through the feeding passage
Implementation Method 2
the electrical heating element is able to be heated by said hot air to a heat softening temperature at which said electrical heating element is capable of being formed with a bending
Implementation Method 3
a connecting tube by which the electrical heating element discharged out of the body is kept warm
Data Source
AI summary
The present application discloses a softening device (200) by which an outer insulating layer of an elongate electrical heating element (121) to be secured onto a cushion, especially a vehicle seat or rest cushion is able to be softened, the softening device (200) comprising: a body (210), wherein the body is provided with a gas passage, a feeding passage (211), and an open cavity (213), wherein hot air is able to be driven through the gas passage, and the elongate electrical heating element (121) is able to be conveyed through the feeding passage (211), wherein the gas passage and the feeding passage (211) are isolated from each other but both of them open into the open cavity (213), wherein after passing through the feeding passage (211) and the open cavity (213), the electrical heating element (121) is able to be discharged out of the body (210). The present application also discloses an electrical heating element (121), a sewing apparatus comprising the softening device, and a method for controlling the softening device.