Foamed Heating Element for Smooth Vehicle Surfaces
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Solution Overview
Problem
Existing heating elements for user-touchable vehicle areas face challenges in simplifying the connection of heating conductors with insulation and maintaining a seamless, user-friendly design, particularly in eliminating the palpability of the heating conductor and connections on the object's surface.
Innovation Solution
A heating element with a foamed carrier material embedding a heating conductor, where electrical connections are made inside the foam, using pressure and heat to establish conductive contact without stripping the insulation, allowing for automated production without additional intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heating conductor is embedded in foam material for user-touchable areas, then the heating element provides effective heating function, but the heating conductor and its connections become palpable on the user-facing surface
Solution Approach 1:
The patent transitions from two-dimensional foam layers to a three-dimensional encapsulation structure. The heating conductor is embedded within the foam material in such a way that the connections are positioned in a third dimension (depth) below the user-facing surface, making them imperceptible while maintaining heating functionality.
2Reliability
If the heating conductor with insulation is connected to electrical feed lines, then electrical connection is established, but the connection process becomes complex and requires additional intervention steps
Solution Approach 1:
The patent combines the heating conductor, its insulation layer, and the electrical feed line into a single integrated foam structure. The foam material simultaneously provides mechanical support, electrical insulation, and structural encapsulation, merging multiple functions into one material system.
Solution Approach 2:
The foam material automatically provides electrical insulation and structural support for the connections without requiring additional external insulation components or complex assembly steps. The connection process leverages the inherent properties of the foam material to simplify the overall manufacturing process.
3Ease of manufacture
If the heating conductor is foam-encased in traditional methods, then the heating element structure is formed, but the connection ends require labor-intensive stripping and additional processing
Solution Approach 1:
The patent positions the connection ends of the heating conductor within the foam material during the initial foam encasing process, rather than requiring subsequent stripping and reprocessing. The foam is applied in advance to encase the heating conductor while leaving connection ends accessible but protected, eliminating the need for labor-intensive post-processing.
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 solution ensures secure, insulated, and protected electrical connections within the foam, simplifying the production process and eliminating the need for labor-intensive end stripping, while maintaining a smooth user interface.
Implementation Method 1
a foamed carrier material in which at least one heating conductor is embedded, which comprises an electrical insulation
Implementation Method 2
the connection part is at least partially connected to the respective connection end of the heating conductor due to an applied pressure and/or heat, whereby the electrical insulation in the region of the connection part is at least partially destroyed
Data Source
AI summary
Heating element for user-touchable areas in a vehicle with a foamed carrier material in which at least one heating conductor, which comprises an electrical insulation, is embedded, and with connecting conductors which are electrically connected to the ends of the heating conductor via at least one connection part and form an electrical feed line. The at least one connection part is arranged within the foamed carrier material and the connection part is foam-covered in an electrically insulating manner by the carrier material. The connection part is brought into electrically conductive contact at least partially with the respective connection end of the heating conductor due to applied pressure and/or applied heat, at least partially destroying the electrical insulation in the region of the connection part. Furthermore, a method for producing such a heating element using a mold tool is indicated.