Conductive Functional Layer for Upholstery Heating
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Solution Overview
Problem
Existing upholstery elements for vehicles, such as motorcycle seats, face challenges with heating and sensor integration due to stiff heating foils and foam layers that reduce comfort and affect measurement accuracy, while incorporating thin wires or soft foils complicates contact, especially with complex sewing patterns.
Innovation Solution
An electrically conductive functional layer formed by printing conductor tracks on a non-conductive carrier film with conductive paste is securely applied to a molded foam body beneath the cover, allowing direct heating or sensing without additional foam and simplifying contact, regardless of seam arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If wire mesh or heating foils are integrated into the covering material, then heating function is achieved, but seating comfort is reduced and heating efficiency is lowered due to additional foam layers required
Solution Approach 1:
The patent uses a flexible heating foil with integrated conductor tracks that can be directly integrated into the covering material without requiring additional foam layers. The thin film structure maintains comfort while enabling efficient heating.
Solution Approach 2:
The patent creates a composite structure by integrating the electrically conductive functional layer directly into the covering material, combining the textile substrate with conductive paste traces to form a unified heating element that eliminates the need for separate foam cushioning layers.
2Ease of operation
If thin wires or soft electrical functional films are integrated into the covering material, then comfort is improved, but contacting becomes difficult especially with complex stitching patterns
Solution Approach 1:
The patent transitions from integrating conductive elements within the three-dimensional foam structure to applying a two-dimensional functional layer on the surface of the covering material. This surface-level integration simplifies contacting while maintaining comfort.
3Ease of operation
If a foam layer is placed between the heating element and the surface to be heated, then comfort is improved, but heating efficiency and sensor measurement accuracy are reduced
Solution Approach 1:
The patent extracts the heating function from the interior foam structure and places it directly on the covering material surface, eliminating the insulating foam layer that previously reduced heating efficiency while still providing comfort through the flexible foil design.
4Ease of manufacture
If electrodes are arranged on the cover for contacting the heating element, then electrical contact is achieved, but design freedom is restricted particularly regarding seam lines
Solution Approach 1:
The patent moves the contacting interface from the surface level (where electrodes would be arranged on the cover) to the edge or boundary level, allowing the functional layer to be contacted at the periphery without interfering with seam line design or aesthetic considerations.
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 solution enables efficient, low-energy heating and accurate sensing with minimal design restrictions, as the conductive layer is thin and elastic, eliminating the need for extra foam and allowing flexible conductor track layouts that adapt to the body's contour without considering seam patterns.
Implementation Method 1
wire mesh is incorporated into or beneath the cover, which, when an electric current is applied, acts as a resistance heater and heats up
Implementation Method 2
an electrically conductive functional layer is applied in an adhesive manner to the body formed from a molded foam below the cover
Data Source
Figure 1
AI summary
The invention relates to a cushioning element (1) comprising a body (10) formed from a molded foam, which is covered on its visible side with a cover (12), wherein an electrically conductive functional layer (11) is bonded to the body (10) beneath the cover (12). This functional layer is contactable by means of electrodes and is formed from an electrically non-conductive carrier film and conductive traces printed onto the carrier film and cured by drying, consisting of at least one electrically conductive paste. A method for manufacturing such a cushioning element and its use are also described.