Thermoformed Vehicle Heating Mat with Embedded Elements
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Solution Overview
Problem
Existing methods for heating motor vehicle passenger compartments using hot air are slow, noisy, and inefficient in selectively heating specific areas, and integrating heating elements into thermoformed mats is challenging due to difficulties in maintaining their position during the thermoforming process.
Innovation Solution
A manufacturing method involving a stack of layers with deformable structures and heating elements, where the stack is assembled with fastening rods and thermoformed to secure the heating elements in specific locations, using thermoplastic materials and adhesives to create a single, three-dimensional heating mat with the heating elements positioned optimally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heating elements are integrated into a mat made using thermoforming method, then the mat can provide localized heating from the floor, but it is difficult to keep the heating elements in appropriate locations during the thermoforming process
Solution Approach 1:
The heating mat is divided into multiple layers (first layer, second layer, third layer) with heating elements positioned between specific layers. This segmentation allows each layer to be formed and positioned independently, ensuring heating elements remain in appropriate locations during the thermoforming process while maintaining manufacturing efficiency.
Solution Approach 2:
Heating elements are pre-positioned between layers before the final thermoforming step. The layers are stacked with heating elements in place, and then the entire assembly is thermoformed as a unit. This preliminary positioning ensures heating elements are secured in appropriate locations before the forming process begins.
2Reliability
If heating elements are positioned at driver's and/or passengers' feet locations, then the heating effectiveness is optimized, but the manufacturing process becomes more complex
Solution Approach 1:
The heating elements are arranged in a vertical stack along the stacking direction (z-axis), with different heating elements positioned at different heights between layers. This three-dimensional arrangement allows optimized positioning at driver's and passenger's foot locations while maintaining a relatively simple layered manufacturing process.
Solution Approach 2:
The layered structure with heating elements positioned between layers serves multiple functions: it provides optimized heating at specific locations, maintains structural integrity during thermoforming, and allows for efficient manufacturing. The same basic structure can be used for different vehicle configurations by adjusting the number and position of heating elements between layers.
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 efficient and effective production of a thermoformed heating mat with heating elements securely positioned, providing targeted heating while protecting the elements and improving their lifespan, and allowing for a central relief without material tearing.
Implementation Method 1
at least one of said first heating ply and said upper and lower layers comprising a thermoformable material; thermoforming the stack thus assembled, so as to secure the first heating ply and the upper and lower layers into a single piece
Implementation Method 2
the stacking step comprises depositing a layer of adhesive between the first heating ply and the upper layer and/or between the first heating ply and the lower layer, the thermoforming step activating said adhesive
Data Source
AI summary
A method for manufacturing a heating mat for a motor vehicle. The method includes the following steps: providing a heating ply having a deformable structure and two heating elements inserted into the structure, said two heating elements being separated by a deformation area of the structure; stacking the heating ply between an upper layer and a lower layer, wherein at least one of the heating ply and the upper and lower layers includes a thermoformable material; assembling the stack by at least one fastening rod; and thermoforming the stack thus assembled, so as to secure the heating ply and the upper and lower layers into a single piece; and stretching the deformation area in the stacking direction.