Metal Braid Spacer Fabric for Seat Heaters

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Solution Overview

Problem

Conventional knitted spacer fabrics used for seat heaters have high energy and heat losses due to low specific resistance and high metal content, making them economically non-competitive for widespread use.

Innovation Solution

A knitted spacer fabric with both layers and spacer yarns composed of metal braid for enhanced laminar electrical and thermal conduction, utilizing copper or copper alloys for improved conductivity and reduced production costs, along with polymeric monofilament yarns for elasticity, forming a highly conductive and flexible structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a knitted layer is composed entirely of metal braid for heating purposes, then electrical and thermal conduction is improved, but specific resistance becomes too low causing energy and heat losses in leads and contact points

Engineering Contradiction:

Improveelectrical and thermal conductionVSAvoidenergy and heat losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent applies local quality by using metal braid only in specific regions where conduction is needed (knitted layers and spacer yarns) rather than throughout the entire fabric structure. This allows optimal electrical and thermal conduction at connection points while maintaining acceptable resistance overall, resolving the contradiction between high conduction reliability and energy loss reduction.

Inventive Principle:

Principle #3Local quality

2Reliability

If high metal content is used in the spacer fabric for resistance heating, then heating effect is achieved, but material cost increases significantly

Engineering Contradiction:

Improveheating effectVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention uses metal braid locally in the knitted layers and spacer yarns rather than throughout the entire fabric. This localized metal content provides sufficient heating effect while dramatically reducing material costs compared to fully metallic fabrics, making the solution economically competitive.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining metal braid with non-metallic yarns in the spacer fabric structure. This composite approach achieves the required heating effect through strategic metal placement while using cost-effective non-metallic materials for the remainder of the structure, resolving the cost contradiction.

Inventive Principle:

Principle #40Composite materials

3Reliability

If metal braid is used in spacer yarns for laminar conduction, then electrical and thermal conductivity is improved, but flexibility and elasticity may be reduced

Engineering Contradiction:

Improveelectrical and thermal conductivityVSAvoidflexibility and elasticity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent uses composite materials by combining metal braid with flexible non-metallic yarns in the spacer construction. The metal braid provides laminar electrical and thermal conduction while the non-metallic components maintain the flexibility and elasticity needed for the spacer to function properly, resolving the contradiction between conductivity and flexibility.

Inventive Principle:

Principle #40Composite materials

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 fabric achieves optimal electrical and thermal conductivity with reduced resistance, enabling efficient heat dissipation and reduced weight and cost, suitable for various applications including heat sinks and flexible electrical contacts.

Implementation Method 1

laminar and transverse electrical and thermal conduction is provided by the metal braid of the knitted layers and of the spacer yarns

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

laminar and transverse electrical and thermal conduction is provided by the metal braid of the knitted layers and of the spacer yarns

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

intended only for seat heaters for electrical resistance heating

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11242628B2Spacer fabric

Publication Date: 2022.02.08 MULLER TEXTIL GMBH

AI summary

A knitted spacer fabric has two transversely spaced knitted layers and first and second spacer yarns extending transversely between and connecting the knitted layers. Both knitted layers are formed by metal braid that is arranged such that laminar electrical and thermal conduction is provided by the metal braid in both knitted layers, and the first spacer yarns are also formed by metal braid.