Textile Sheet Heating Element Production via Variable Speed Warp Knitting
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Solution Overview
Problem
Existing methods for producing sheet heating elements, such as those used in automotive seat heaters, are inefficient and require multiple steps for integrating heat and contact conductors, leading to increased production time and material waste.
Innovation Solution
A method using a warp knitting machine or Raschel machine to integrate heat conductors as warp threads and contact conductors as weft threads or groups, with adjustable production speed and pause times based on stitch formation complexity, reducing material waste and energy input while ensuring homogeneous heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If constant production speed is used in the knitting machine, then production process is simple, but production time is increased and productivity is reduced
Solution Approach 1:
The patent implements variable production speed by dynamically adjusting the knitting machine speed based on stitch formation complexity. The control system monitors stitch types and automatically varies the production speed, transforming a static constant-speed process into a dynamic adaptive process that optimizes productivity while managing complexity.
Solution Approach 2:
The patent changes the production speed parameter according to the complexity of stitch formation. By modifying this key process parameter in response to varying stitch patterns, the system achieves higher overall productivity without requiring fundamentally complex equipment changes.
2Productivity
If contact conductors are inserted continuously, then production speed is maintained, but material waste increases
Solution Approach 1:
The patent applies local quality by inserting contact conductors only in specific areas where they are needed, rather than continuously throughout the entire fabric. This localized insertion approach reduces material waste while maintaining production efficiency, as contact conductors are placed only in regions requiring electrical contact functionality.
Solution Approach 2:
The patent segments the contact conductor insertion process into discrete localized operations rather than continuous insertion. By dividing the fabric into regions that require contact conductors and regions that do not, the system eliminates unnecessary material usage while preserving overall production speed.
3Quantity of substance
If heat conductors are sparsely arranged, then material usage is reduced, but heat distribution becomes non-uniform
Solution Approach 1:
The patent transitions from sparse point-like heat conductor arrangements to a continuous multi-dimensional network formed by integrated knitting. The heat conductors are embedded throughout the fabric structure in multiple directions, creating a distributed two-dimensional heating network that achieves uniform heat distribution while using material efficiently.
Solution Approach 2:
The patent creates a composite structure where heat conductor materials are integrated with the base fabric material through the knitting process. This composite approach allows heat conductors to be distributed throughout the fabric matrix, providing uniform heat distribution while optimizing material usage through the combined structural functionality.
4Manufacturing precision
If multi-step process is used to integrate conductors, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The patent merges the integration of heat conductors and contact conductors into a single knitting process step, eliminating the need for separate multi-step integration processes. By combining these functions into one unified manufacturing operation, the system achieves precise conductor integration while dramatically reducing production time.
Solution Approach 2:
The knitting machine is designed to perform multiple functions simultaneously - producing the base fabric, integrating heat conductors, and inserting contact conductors - all in one process. This multi-functional approach eliminates the need for sequential specialized processes, reducing production time while maintaining integration precision.
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
This approach significantly streamlines production, reduces material waste, and achieves efficient energy use by varying production speed with stitch complexity, resulting in faster production times and improved contact between heat and contact conductors for enhanced heating performance.
Implementation Method 1
heat conductors inserted as warp threads form a multiple arrangement of threads lying densely adjacent to one another in the knitted material
Data Source
AI summary
A method for producing a textile sheet heating element includes forming a knitted material and, in one and the same work step, inserting heat conductors as warp threads. Contact conductors that touch the heat conductors are inserted spaced from one another as weft threads or weft thread groups. A warp knitting machine or Raschel machine is used to produce the sheet heating element. The production speed of the knitting or Raschel machine is varied as a function of stitch formation. The warp knitting machine or Raschel machine has a magazine weft insertion system with feeding chains to feed in weft threads and a weft carriage to insert weft threads. Both the feeding chain and the weft carriage are paused for preset periods as a function of stitch formation.