Heated Vehicle Interior Composite Mat With Protected Conductor Routing
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Solution Overview
Problem
Existing manufacturing methods for heatable vehicle interior components face challenges with flexible base bodies, leading to high reject rates and manufacturing costs due to damage risks of heating elements and conductor elements, especially in dimensionally stable components without flexible bases.
Innovation Solution
A method involving a fiber mat with a passage for the conductor element, allowing the heating element to be integrated within, forming a composite mat that is compressed and solidified, with the conductor element passing through the mat to prevent lateral protrusion and damage, and a decorative layer applied for aesthetic and protective purposes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a hard, non-deformable base body is used for dimensionally stable interior components, then dimensional stability is improved, but the heating element and conductor element are at risk of bending and damage at the edges during trimming and use
Solution Approach 1:
The base body is segmented into a hard base body providing dimensional stability and a separate soft protective layer (foam core) that cushions the heating element. This segmentation allows each layer to fulfill its specific function without compromising the other.
Solution Approach 2:
The heating element is bonded to the soft base body before the trimming process. This preliminary bonding ensures the heating element is protected from damage at the edges during subsequent trimming operations, as the soft base body absorbs the mechanical stress.
2Reliability
If a soft base body is used and bonded with the heating element, then the heating element is protected from damage, but the conductor elements protrude laterally and can still be bent or damaged by sharp edges
Solution Approach 1:
The conductor elements are nested within channels formed in the soft base body. This nesting arrangement protects the conductor elements from lateral bending and damage while keeping the overall structure compact and manageable.
Solution Approach 2:
The soft base body acts as an intermediary between the heating element and the hard base body. It provides a cushioning layer that protects the heating element during trimming, while the channels within it guide and protect the conductor elements from damage.
3Ease of manufacture
If the heating element is placed on a flexible base body during manufacture, then placement is simplified without risk of kinking, but this approach is not suitable for dimensionally stable components requiring hard base bodies
Solution Approach 1:
The manufacturing process is segmented into two stages: first, the heating element is placed on the soft base body where it is flexible and easy to handle; second, the hard base body is applied over the composite to provide dimensional stability. This segmentation allows both ease of manufacture and dimensional stability to be achieved.
Solution Approach 2:
The interior component uses a composite structure combining a soft base body (foam core) with a hard base body. The soft base body facilitates easy placement of the heating element, while the hard base body provides the required dimensional stability for the final product.
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 method reduces manufacturing effort and costs while enhancing the durability and quality of heatable interior components, ensuring efficient heat transfer and easy electrical connectivity, with improved resistance to damage and a visually appealing finish.
Implementation Method 1
The heating element can have one or more electric heating loops. An electric heating loop is preferably designed to generate heat and dissipate it to the environment when the electric heating loop is supplied with power.
Implementation Method 2
During forming, the composite mat can be solidified or stiffened. This can be achieved, for example, by compressing, in particular by pressing, the composite mat.
Data Source
Figure 1~2
Figure 3~4
AI summary
Process steps: Providing a fiber mat (2) and introducing a passage (3) into the fiber mat (2), creating a composite mat (7) by applying a heating element (4) to a first surface (10) of the fiber mat (2), wherein an electrical conductor element (6) of the heating element (4) is passed through the passage (3), forming the composite mat (7), and applying a decorative layer (8) to the formed composite mat (7).