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I've done a bit more work on a heated glove I started last winter. The carbon heating rope frays very easily and weave is forced open when closing my hand. Having the heating elements touch each other could also create a short which would be bad causing localized heating in excess of 100C. To deal with those issues and ensure permanent attachment I coated the carbon with a flowable silicone. The silicone is stretchy but does make the glove somewhat stiff. A lower viscosity silicone would be ideal as I could achieve a thinner coating. Now that I think about it, pre-coating the rope with silicone then wiping most of it off would probably yield a better result as long as I could keep both ends of each of the 3 loops free of silicone to make the electrical connection.
The carbon rope I'm using is 3 mm wide which is extreme overkill for the application. I just noticed that the rope is made from a loose weave of 12 bundles of fibers which I should be able to separate. The pair of heated gloves I bought last year appear to use just a single one of those bundles. So for my 2nd glove I'm going to use just 1 or 2 of the 12 which should be a lot easier to work with and I can use much less silicone.
