Mat with a heel pad
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Solution Overview
Problem
The high cost and limited versatility of high frequency welding (HFW) tools for manufacturing vehicle mats with heel pads, which require a different tool for each vehicle make and model, leading to excessive investment and potential heel interference issues due to standard rectangular heel pad designs.
Innovation Solution
A method of securing a universal heel pad across the full width of the base mat using high frequency welds along opposite edges and additional welds between them, with converging edges and a brass die forming a continuous weld, allowing for a single tool to accommodate various vehicle configurations while preventing heel pad ballooning and interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a standard rectangular HFW heel-pad is used, then the investment in tooling is reduced, but the heel pad may not provide comprehensive wear protection and could cause heel interference
Solution Approach 1:
The heel pad shape is changed from a static rectangular form to a dynamic contour that converges towards one side edge of the base mat. This converging shape adapts to different vehicle configurations and driving positions, providing comprehensive wear protection while preventing heel interference, all while being manufactured with a single HFW tool.
2Reliability
If a near-full-width heel pad is produced with conventional HFW tools, then comprehensive wear protection is achieved, but a different HFW tool is required for each vehicle make and model, leading to enormous investment
Solution Approach 1:
A single HFW tool is designed with a die that can accommodate multiple vehicle makes and models by forming welds along opposite edges and additional welds between them. The converging heel pad shape provides universal applicability across different vehicle configurations, eliminating the need for multiple specialized tools while maintaining comprehensive wear protection.
3Stability of the object's composition
If additional high frequency welds are made between opposite edges, then heel pad ballooning is prevented, but the welding process complexity increases
Solution Approach 1:
The welding process is segmented into distinct weld lines: welds extending along opposite edges of the heel pad and additional welds between those edges. This segmentation allows each weld to serve a specific function in preventing ballooning and ensuring stable attachment, while the modular nature of the segmented welds actually simplifies the overall welding process by providing clear, repeatable welding paths.
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 tooling investment and minimizes heel interference by ensuring comprehensive wear protection and an aesthetically pleasing design with a single HFW tool, suitable for multiple vehicle models, while maintaining effective attachment and preventing heel pad lifting.
Implementation Method 1
a heel pad secured to an upper surface of the base mat by high frequency welding
Implementation Method 2
high frequency welding (HFW) is a technique which has been known for many years
Data Source
Figure 1
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Figure 3
AI summary
A mat includes a base mat (1) and a heel pad (10) secured to an upper surface of the base mat by high frequency welding (HFW). The base mat has a pair of opposite side edges (4) and (5) and the heel pad (10) extends up to those side edges and any overhanging portions of the heel pad are trimmed off after the high frequency welding process has taken place.