Vehicle Interior Heater Lamination for Hidden Wire Adhesion
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Solution Overview
Problem
Current methods for producing vehicle interior components with heater elements are inefficient and do not effectively integrate the heater elements with foam materials and substrates, leading to issues with adhesion and visibility of the heating wires.
Innovation Solution
A method involving the use of a forming tool with a removable liner and adhesive web, where the heater element is attached to the liner with temporary adhesion, allowing the foam material to flow into the adhesive web's pores, and a cover layer is applied to conceal the heating wires, ensuring strong adhesion and visual imperceptibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the heater element is directly attached to the substrate, then the manufacturing process is simplified, but the adhesion strength and integration with foam material are insufficient
Solution Approach 1:
An adhesive web is introduced as an intermediary layer between the heater element and the substrate. The adhesive web comprises a first adhesive layer for bonding to the heater element and a second adhesive layer for bonding to the substrate, providing enhanced adhesion strength and proper integration while maintaining manufacturing efficiency
Solution Approach 2:
The adhesive web is constructed as a composite material system with multiple adhesive layers designed for different bonding purposes. The first adhesive layer is optimized for bonding to the heater element while the second adhesive layer is optimized for bonding to the substrate, creating a composite structure that achieves both strong adhesion and proper integration
2Ease of manufacture
If the heating wires are visible on the surface, then the manufacturing process is simpler, but the aesthetic appearance and comfort are reduced
Solution Approach 1:
A cover layer is applied over the heater element and foam material assembly. This thin film layer conceals the heating wires from view while allowing the heater element to function properly, achieving visual imperceptibility without compromising manufacturing simplicity
3Object-affected harmful factors
If the foam material is applied before the heater element, then the substrate is protected, but the heater element integration and adhesion are compromised
Solution Approach 1:
The heater element is pre-positioned on the substrate with the adhesive web before the foam material is applied. This preliminary action ensures proper integration and adhesion of the heater element to the substrate, while the foam material is subsequently applied to provide cushioning and complete the assembly
4Strength
If a permanent adhesive is used to attach the heater element, then strong adhesion is achieved, but the ability to apply foam material and cover layer is restricted
Solution Approach 1:
The adhesive system is segmented into multiple functional layers: the adhesive web with first and second adhesive layers for strong bonding to heater element and substrate, and a separate foam material layer for cushioning. This segmentation allows each layer to perform its specific function without restricting the overall manufacturing process
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 enables the production of vehicle interior components with integrated heater elements that provide even heat distribution while maintaining a smooth, visually imperceptible surface, enhancing occupant comfort and manufacturing efficiency.
Implementation Method 1
the foam material to flow into the adhesive web's pores
Implementation Method 2
The step of applying adhesive to the heater element may comprise forming temporary adhesion between the heater element and the liner
Data Source
AI summary
A method of producing a component for a vehicle interior may comprise placing a liner in a forming tool, placing a heater element on the liner, applying a foam material, and forming the heater element on a substrate. Adhesive may be applied to the heater element and liner. The liner may comprise a tool liner configured to facilitate removal of the component from the forming tool. The tool liner may remain in the forming tool when the component is removed from the forming tool. The tool liner may be re-usable. The adhesive/tape may comprise a pressure-sensitive adhesive with suitable adhesion for the heater element/mat without requiring activation; the adhesive/tape may comprise a side with lower adhesion to the mold liner (temporary adhesion) and with higher adhesion to the body of the heater element/mat (permanent adhesion). A pre-fix tool may be used.