Flexible Heater Integration for Movable Seat Structures
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Solution Overview
Problem
Existing heaters for automotive vehicle seats and other occupant contact areas are not flexible enough to accommodate changes in shape or size, leading to potential damage when the structure moves.
Innovation Solution
A climate-controlled system featuring a flexible heater with an adhesive layer that connects to a cushion or sidewall, allowing the heater to stretch and move with the structure without restriction, comprising a flexible substrate, heating elements, and an adhesive layer that anchors the heater to the cushion or sidewall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heater is connected to the structure over a substantial area to move with the structure, then the heater maintains stable connection and moves with the structure, but the heater cannot accommodate changes in shape or size of the structure
Solution Approach 1:
The heater is divided into multiple independent heating zones or segments that can move and deform independently. Each segment is connected through flexible connections that allow relative movement, enabling the heater to accommodate shape changes while maintaining overall connection stability.
Solution Approach 2:
The heater incorporates dynamic elements such as flexible substrates, stretchable conductive materials, and movable components that can adapt their configuration in response to structural deformations. This allows the heater to transition from a static rigid connection to a dynamic adaptive connection that maintains reliability during shape changes.
2Reliability
If the heater uses a rigid wire pattern on the substrate, then the heater provides stable heating, but the substrate cannot move without being restricted by the wire
Solution Approach 1:
The wire pattern transitions from rigid to dynamic configurations using stretchable conductive traces, serpentine patterns, or flexible conductive materials that can elongate and deform. These dynamic wire patterns maintain electrical connectivity and heating function while accommodating substrate movement and shape changes.
Solution Approach 2:
The heater employs flexible thin-film substrates and conductive layers that can bend, stretch, and deform without compromising structural integrity or electrical functionality. These flexible components enable the substrate to move freely while maintaining stable heating through the adaptable wire pattern.
3Reliability
If the heater is firmly anchored to the structure, then the heater remains securely connected, but the heater cannot expand and contract with shape changes of the structure
Solution Approach 1:
The anchoring system incorporates dynamic attachment mechanisms such as flexible adhesives, movable fasteners, or elastic connection elements that maintain secure attachment while allowing controlled movement and deformation. This enables the heater to remain firmly anchored during normal operation while accommodating expansion and contraction during shape changes.
Solution Approach 2:
The anchoring properties of the heater change dynamically in response to structural deformations. The connection strength, flexibility, and attachment characteristics are adjusted to maintain security during static conditions while permitting movement during shape changes, resolving the contradiction between firm anchoring and expansion capability.
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 system enables the heater to expand and contract with the structure, ensuring it remains functional and integrated without damage, providing effective heating and comfort to the occupant while maintaining flexibility and movement compatibility.
Implementation Method 1
a heating element
Implementation Method 2
an adhesive layer, wherein the flexible substrate includes adhesive on opposing longitudinal edge regions and the adhesive directly or indirectly connects the heater to the cushion
Data Source
AI summary
A climate controlled system comprising: a movable member disposed in a recess of a cushion and forming part of an occupant support surface with the cushion; a heater overlaying the cushion and the movable member, the heater including: a flexible substrate, a heating element, and an adhesive layer, wherein the flexible substrate includes adhesive on opposing longitudinal edge regions and the adhesive directly or indirectly connects the heater to the cushion; and wherein the adhesive layer anchors the heater as the flexible substrate stretches or moves with the movable member as the movable member moves.