Method for attaching a heating wire to a textile and textile with a heating wire
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Solution Overview
Problem
Existing methods for attaching heating wires to textiles in resilient interior parts of vehicles, such as seats and armrests, result in damage or destruction due to deformation under load, leading to local resistivity changes and hotspots, compromising the functionality of the heating elements.
Innovation Solution
Attaching the heating wire as the upper or lower thread during a sewing process using stretch stitches like zigzag, elastic, or jersey stitches, allowing the wire to adapt to textile deformation without additional threads or specialized equipment, ensuring even temperature distribution and reduced risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the heating wire is arranged in a meander or serpentine fashion in the textile to provide even temperature distribution, then the temperature uniformity is improved, but the heating wire becomes more susceptible to damage during endurance loading tests due to local deformation and elongation
Solution Approach 1:
The heating wire is replaced by a conductive thread that is integrated into the textile structure, allowing it to dynamically adapt to textile deformation. The conductive thread is woven or knitted together with the textile fibers, enabling it to stretch and deform elastically with the textile during loading cycles, thereby preventing wire breakage while maintaining electrical conductivity for heating function.
Solution Approach 2:
The invention uses a composite structure where conductive material is combined with textile fibers to create a conductive thread. This composite thread integrates the electrical conductivity needed for heating with the mechanical flexibility and elasticity of the textile, allowing the heating element to withstand repeated deformation without damage while maintaining even temperature distribution.
2Ease of manufacture
If traditional sewing methods are used to attach the heating wire to the textile, then the attachment process is simple, but the heating wire is damaged or destroyed by deformation during endurance loading tests
Solution Approach 1:
The heating function and the textile structure are merged into a single integrated component. The conductive thread serves dual purposes: it provides the electrical pathway for heating while simultaneously being structurally integrated into the textile through weaving or knitting. This eliminates the need for separate attachment processes and ensures the heating element moves with the textile during deformation.
Solution Approach 2:
The invention changes the physical state and properties of the conductive element from a rigid wire to a flexible conductive thread with elastic properties matching the textile. This parameter change allows the heating element to undergo repeated stretching and deformation without permanent damage or breakage, while maintaining electrical conductivity.
3Ease of operation
If the heating wire is used in resilient interior parts like seats or armrests, then passenger comfort is improved, but the heating wire is subjected to high loads and repeated deformation that cause local resistivity changes and hotspots
Solution Approach 1:
The conductive thread is designed to dynamically respond to the deformation of resilient interior parts during use. When passengers sit or lean on seats or armrests, the textile and integrated conductive thread deform together, maintaining electrical continuity and preventing localized stress concentrations that would cause hotspots or performance degradation.
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 method provides a cost-effective and durable attachment of heating wires to textiles, enhancing stretchability and reducing the risk of damage during deformation, ensuring consistent performance and longevity of the heating elements.
Implementation Method 1
The heat generated by the electric resistance is used to heat the interior part
Implementation Method 2
attaching the heating wire as upper thread or lower thread to the textile by stitching with the sewing machine
Data Source
Figure 1a~1b
Figure 2a~2f
Figure 3
AI summary
The present invention relates to a method for attaching a heating wire (12) to a textile (30), comprising the steps of - providing a textile (30), - feeding the heating wire (12) as upper thread (62) or lower thread (64) to a needle (52) of a sewing process, and - attaching the heating wire (12) as upper thread (62) or lower thread (64) to the textile (30) by stitching with the sewing process. Beyond that the present invention relates to a device for attaching a heating wire (12) to a textile (30), the device being embodied as a sewing machine (50) comprising a needle (52), the heating wire (12) being fed as upper thread (62) to the needle (52) of the sewing machine (50) and textile (30) of an interior part of a means of passenger transport, in particular a vehicle, the textile (30) comprising a heating wire (12) being attached to the textile (30) in form of stitches provided by a sewing machine (50).