Vehicle Seat Heat Mat Assembly for Consistent Conductive Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing heating devices for vehicle components lack efficiency and effectiveness in providing consistent conductive heat to occupants.
Innovation Solution
A method of manufacturing a heat mat for vehicle seats involves conveying a carrier sheet to a coating station, applying a conductive-particle based fluid, forming a conductive pad, attaching a conductor harness, and applying a protective sheet to create a heat mat that provides conductive heat to occupants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing methods for manufacturing heating devices are used, then the manufacturing process is simpler, but the efficiency and effectiveness in providing consistent conductive heat deteriorates
Solution Approach 1:
The heating device is divided into distinct functional layers: a carrier sheet, a conductive-particle based fluid layer, and a protective sheet. This segmentation allows each layer to be optimized independently for its specific function while maintaining manufacturing efficiency through a systematic assembly process.
Solution Approach 2:
The conductive-particle based fluid is applied to the carrier sheet in advance during the manufacturing process, forming a pre-prepared conductive pad structure. This preliminary action ensures consistent conductive heat properties are established before final assembly, improving reliability without adding complex post-manufacturing steps.
2Reliability
If a conductive-particle based fluid is applied to form a conductive pad, then the conductive heat provision is improved, but the manufacturing steps increase
Solution Approach 1:
The conductor harness attachment and protective sheet application are merged into a single integrated step. The protective sheet is applied over the entire assembly including the conductor harness, simultaneously completing both the electrical connection protection and the final device encapsulation, thereby reducing the number of discrete manufacturing steps.
Solution Approach 2:
The carrier sheet serves as an intermediary substrate that facilitates the application of the conductive-particle based fluid and provides a stable base for subsequent conductor harness attachment. This intermediary structure simplifies the manufacturing process by providing a standardized platform for assembling the heating device components.
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 method enables the production of heat mats that efficiently provide conductive heat to vehicle occupants, enhancing comfort and usability in various climatic conditions.
Implementation Method 1
a conductive layer coupled to the mat foundation and arranged to lie between the top cover and the bottom cover
Implementation Method 2
The heat mat may further include a conductor harness configured to couple the conductive layer to a power source
Data Source
AI summary
A heat mat is configured to provide conductive heat to an occupant in a vehicle. The heat mat includes a mat foundation, a conductive layer coupled to the mat foundation, and a conductor harness configured to couple the conductive layer to a power source. The heat mat is configured to be installed on a vehicle component. A method includes assembling the mat foundation, the conductive layer, and the conductive harness together.