Vehicle Heat Mat Assembly for Consistent Conductive Heating
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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 a conductive-particle based fluid is applied to a carrier sheet and formed into a conductive pad, then the heat mat can provide conductive heat to occupants, but the manufacturing process becomes complex requiring multiple steps including coating, forming, attaching conductor harness, and applying protective sheets
Solution Approach 1:
The manufacturing process is divided into distinct sequential steps: conveying the carrier sheet, applying conductive-particle based fluid at a coating station, forming the conductive pad, attaching the conductor harness, and applying protective sheets. This segmentation allows each operation to be optimized independently while maintaining overall process reliability for producing functional heat mats with consistent conductive heating performance.
2Reliability
If multiple components (conductive layer, conductor harness, protective sheets) are assembled to create a functional heat mat, then the heating device can effectively provide conductive heat, but the manufacturing time and production complexity increase
Solution Approach 1:
The conductor harness is pre-assembled with the conductive pad and protective sheets are prepared in advance before final assembly. The carrier sheet is conveyed through a automated coating station where the conductive-particle based fluid is applied and formed into the conductive pad pattern before the harness is attached. This preliminary preparation of components streamlines the final assembly process and improves manufacturing efficiency while ensuring proper functionality of the heat mat.
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 temperature conditions.
Implementation Method 1
a conductive layer coupled to the mat foundation and arranged to lie between the top cover and the bottom cover... 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.