Stretchable Heating Mat for Curved Composite Surfaces
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Solution Overview
Problem
Existing heating mats struggle to conform to curved shapes and are costly to manufacture, lacking the necessary elasticity to efficiently apply heat to complex surfaces like fiber composite structures without laborious adaptation during production.
Innovation Solution
A heating mat with a reversibly stretchable flat carrier and a heating element that can be embroidered or sewn onto the carrier, featuring directional changes and a two-dimensional or three-dimensional design, allowing for significant elongation and embedding in a 2K silicone mat for enhanced flexibility and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid heating mat is used, then manufacturing precision is improved, but adaptability to curved surfaces deteriorates
Solution Approach 1:
The heating mat uses a flexible polymer film as its structural base, allowing it to conform to curved and complex surfaces while maintaining structural integrity. The heating elements are embedded within this flexible matrix, enabling the entire assembly to bend and adapt to various geometries without compromising manufacturing precision or structural stability.
Solution Approach 2:
The heating mat employs composite construction by integrating heating elements (conductive materials) into a flexible polymer matrix. This composite structure combines the dimensional stability and precision of manufactured heating elements with the adaptability and flexibility of the polymer material, resolving the contradiction between structural precision and surface conformability.
2Adaptability or versatility
If a heating mat is custom-adapted to curved shapes, then adaptability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The flexible polymer film base allows the heating mat to be manufactured in a standard planar form that can then be easily adapted to curved surfaces during application. The inherent flexibility eliminates the need for complex custom manufacturing processes for each curved surface, reducing device complexity while maintaining high adaptability to various geometries.
3Adaptability or versatility
If a heating mat is made highly elastic, then adaptability to curved surfaces is improved, but manufacturing precision and structural stability deteriorate
Solution Approach 1:
The composite structure embeds rigid or semi-rigid heating elements within a flexible polymer matrix. The polymer provides the necessary elasticity and flexibility for conforming to curved surfaces, while the embedded heating elements maintain structural stability and manufacturing precision. The composite design allows each material to contribute its optimal properties without compromising the other.
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 efficient heating of multiply curved surfaces and complex shapes, such as fiber composite structures, without the need for autoclaves, while maintaining cost-effectiveness and reliable temperature control through embedded sensors and induction heating.
Implementation Method 1
at least one heating element made of a wire-shaped or fibrous element connected to the support... The at least one heating element exhibits changes in direction along its length that deviate from a straight path on the support
Implementation Method 2
DE 102016115284 A1 describes a repair device for a workpiece made of a plastic material, comprising an induction heating device which is arranged on the workpiece
Data Source
AI summary
The invention relates to a heating mat (100) with a sheet-like support (10) and at least one heating element (50, 52, 54, 56, 58) comprising an element (51, 53, 55, 57, 59) which is in the form of a wire or in the form of a fibre and is connected to the support (10). The support (10) is designed to be reversibly stretchable and has at least one region (20, 21, 22) with the at least one heating element (50, 52, 54, 56, 58) in which the at least one heating element (50, 52, 54, 56, 58) has along its length (30) a change of direction on the support (10) deviating from a straight path. The support (10) is designed to be reversibly stretchable with an elongation at break in at least one direction of at least 50%. The at least one heating element (50, 52, 54, 56, 58) is stitched or sewn on the support (10) and has at least two-dimensional stability and reversibly follows an elongation of the support (10).