Parallel-Wire Heating Product for Low-Resistance, Uniform Heating
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Solution Overview
Problem
Existing heating garments with continuous conductive yarns face issues of high electrical resistance, requiring larger power sources, exposure to wear and tear, oxidation, and non-uniform heat distribution, leading to safety concerns and reduced reliability.
Innovation Solution
A composite heating product with parallel arranged electrically conductive wires, thermally conductive cording yarns, and thermally conductive layers for uniform heat distribution, combined with a flexible and lightweight design to reduce electrical resistance and ensure safe, efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If continuous conductive yarns are spread across a large heating area, then the heating coverage is improved, but the overall electrical resistance increases
Solution Approach 1:
The continuous conductive yarn is divided into multiple separate conductive yarns, each covering a portion of the heating area. These segmented yarns are arranged in parallel configuration, which reduces the overall electrical resistance while maintaining comprehensive heating coverage across the desired area.
2Power
If more electrical current is supplied to generate heat in large area, then the heating effectiveness is improved, but the power source size and weight increase
Solution Approach 1:
The heating system uses multiple conductive yarns arranged in parallel, which reduces the overall electrical resistance. This allows the system to generate the required heating power with lower current, enabling the use of a smaller and lighter power source while maintaining effective heating across the large area.
3Ease of manufacture
If conductive yarns are exposed to external environment, then the manufacturing simplicity is improved, but the reliability decreases due to oxidation and wear
Solution Approach 1:
A flexible protective layer is applied over the conductive yarns to shield them from oxidation and mechanical wear. This protective shell maintains the electrical conductivity of the yarns while protecting them from environmental damage, ensuring long-term reliability without significantly complicating the manufacturing process.
4Ease of manufacture
If continuous conductive yarns are used, then the manufacturing process is simple, but the heat distribution uniformity deteriorates
Solution Approach 1:
The single continuous conductive yarn is segmented into multiple separate yarns that are distributed across the heating area in a parallel arrangement. This segmentation enables more uniform heat distribution across the surface while maintaining a relatively simple manufacturing process through automated placement techniques.
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 safer, more reliable heating with reduced power requirements, uniform temperature distribution, and improved durability, ensuring thermal comfort and therapeutic benefits without skin damage.
Implementation Method 1
a plurality of electrically conductive wires (122) arranged electrically in parallel to each other, the wires (122) being connectable to a power source for conducting an electrical current through the wires (122), thereby generating heat in the wires (122)
Implementation Method 2
thermally conductive cording yarns (124) that attach each wire (122) to the base layer (110) by cording embroidery, the cording yarns (124) extending along and cording around the respective wire (122)
Implementation Method 3
at least one thermally conductive layer (140) formed on the base layer (110), wherein the at least one thermally conductive layer (140) is arranged for substantially uniform heat transfer from the heating layer (120)
Data Source
Figure 1~2
Figure 3
Figure 4~5B
AI summary
Disclosed herein is a heating product that includes a base layer; a heating layer formed on the base layer, the heating layer formed from: a plurality of electrically conductive wires arranged electrically in parallel to each other; and thermally conductive cording yarns that attach each wire to the first fabric layer by cording embroidery, the cording yarns extending along and cording around the respective wire; and at least one thermally conductive layer formed on the base layer, wherein the wires are connectable to a power source for conducting an electrical current through the wires, thereby generating heat in the wires; and wherein the at least one thermally conductive layer is arranged for substantially uniform heat transfer from the heating layer.