Heated Interior Cladding with One-Sided Back-Foamed Heating Mat

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing interior cladding parts with heating elements, such as in vehicles, face issues where heating coils protrude on the visible side due to the use of fleece with heating coils, leading to increased process and material costs or impaired heating performance when foam-encapsulating the heating element.

Innovation Solution

A method involving a foam mat with embedded heating elements, where the heating element is back-foamed only on one side, avoiding foam encapsulation on both sides and ensuring the heating elements are flush or recessed, thus preventing foam from reaching the visible side and maintaining heating performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If heating coils are applied on fleece for interior cladding parts, then heating function is achieved, but heating coils protrude on the visible side increasing process and material expense

Engineering Contradiction:

Improveheating function implementationVSAvoidadditional cut foam and constructive measures

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The heating coils are merged with the foam material to form an integrated heating foam element. The foam serves both as structural material and as the medium in which heating coils are embedded, eliminating the need for separate fleece layers and additional cut foam measures.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heating coils are nested within the foam material structure. The foam acts as a container that holds and protects the heating coils, with the coils positioned inside the foam body rather than on the surface, preventing protrusion on the visible side.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Shape

If foam-encapsulating of flat heating element is used, then heating element is covered, but heating performance is impaired due to additional foam-material layer on visible side

Engineering Contradiction:

Improveheating element coverageVSAvoidheating performance

Core Design Contradiction:

ShapeVSTemperature

Solution Approach 1:

The foam application is segmented into two distinct sides: the first side (visible side) is kept free of foam to maintain heating performance and aesthetic appearance, while the second side (back side) is foam-encapsulated for structural support and element retention. This selective foam application resolves the contradiction between coverage and heating efficiency.

Inventive Principle:

Principle #1Segmentation

3Shape

If additional cut foam is provided between fleece and decorative material, then heating coils are hidden, but process and material expense increases

Engineering Contradiction:

Improveheating coils concealmentVSAvoidprocess and material expense

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

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 reduces material costs and enhances the appearance by avoiding foam insulation, ensuring efficient heating while maintaining a smooth, non-protruding heating element on the visible surface, improving the material appearance and heating efficiency.

Implementation Method 1

a first foam material is introduced into the foaming tool on a second flat side, opposite the first flat side, of the flat heating element such that the flat heating element is back-foamed only on the second flat side

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 2

a flat heating element for the heating of the visible side

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20240399630A1Method for the manufacturing of a heated interior cladding part

Publication Date: 2024.12.05 LISA DRAXLMAIER GMBH

AI summary

A method for the manufacture of an interior cladding part with a visible side and a flat heating element includes arranging of the flat heating element as foam mat in a foaming tool such that the flat heating element abuts with a first flat side, which is facing the visible side of the interior cladding part to be manufactured, against an interior surface of the foaming tool, and introducing a first foam material into the foaming tool on a second flat side, opposite the first flat side, of the flat heating element such that the flat heating element is only back-foamed on the second flat side. The first foam material connects with the carrier element and the flat heating element.