Heating element for vehicle seats and the manufacturing method (variants)

 

(57) Abstract:

The invention relates to heaters. Heating element for vehicle seats includes conductive circuit connected to the current source, and a carrier for the heating circuit. The media is breathable and made of electrically insulating flexible material, and the heating circuit is deployed on the carrier and secured in position relative to the carrier. The invention also relates to a method of manufacturing the heating element. The adhesive film is unwound continuously in the form of track material, on one side of which is applied binder, the heating circuits are deployed at the selected space between them, an additional film is unwound continuously in the form of track material and attach to the first track of the material together with located between the heating circuits. A single layer of material perforined with the formation of numerous holes throughout its surface, perform the separating cuts or instead carry out the separation of the individual heating elements. The heating element provides material savings and cost reduction and moeite the heating element for vehicle seats, in particular cars, as well as to a method of manufacturing such a heating element.

Known heating element for vehicle seats, comprising an elastic body and a plating layer containing electroconductive heating circuit connected to the current source attached to an electrically insulating, breathable layer of the medium in which the heating circuit is deployed in the form of a drawing, enabling elastic deformation in any direction (EP, A, 0331762). However, the adhesion of the plating seat in an area where such a heating element is not homogeneous, since the thickness of the element can lead to the fact that its contours become visible and tangible on the surface of the plating layer. In addition, it is necessary to take special measures to ensure bonding on both sides of the heating element.

Known, in addition, a method of manufacturing a cushion vehicle, which consists in bonding a layer of sheathing to the elastic body (EP, A, 0331762). When connecting this known method cannot be used conventional heating elements, since the heating element of this kind serves as a barrier to the penetration of the soba.

The basis of the invention the task is to create a heating element, which would provide savings of material and thus saving space and reducing costs, and could also be integrated in the seats with attached plating, and also to create a method of manufacturing such a heating element.

The problem is solved in that in the heating element for vehicle seats, comprising an elastic body and a plating layer containing electroconductive heating circuit connected to the current source attached to an electrically insulating, breathable layer of the medium in which the heating circuit is deployed in the form of a drawing, enabling elastic deformation in any direction, according to the invention between the plating layer and the heating circuit has a friction layer, forming part of the heating element, made breathable and provides sufficient friction between the heating element and the plating layer to provide mechanical transmission of the deformation layer covering the heating element, while the mechanical properties of the heating element is essentially compatible with the mechanical properties of the layer obsno layer covering a side of the heating circuit, and this film in the unmelted state would be breathable and capable of providing a sufficiently high friction relative to the surface of the plating layer for the mechanical transmission of the deformation layer covering the heating element and adapted to provide a binder impacts upon exposure to the heat.

It is possible that the adhesive film had the structure of a fine-meshed sieve.

Preferably, the layer of the device was made of a porous air-permeable foam material.

The problem is solved in that in the method of manufacturing a seat cushion of a vehicle, which consists in bonding a layer of sheathing to the elastic body according to the invention the heating element in the heating circuit and the media have between the plating layer and an elastic body and is fixed in a predetermined position by gluing, which is performed by the introduction of an adhesive film between the plating layer and the elastic body, and heating the adhesive film to achieve the effect of binding and the fact that the heating element with the carrier in the form of additional adhesive film is inserted between the plating layer and the first adhesive film, and the first different task is solved by in the method of manufacturing a heating element for seat vehicles containing elastic body and the layer of the skin, consisting in that the electroconductive heating circuit connected to the current source attached to the breathable layer media, distributing it in the form of a drawing, selected with a view to ensuring elastic deformation in any direction, according to the invention between the plating layer and the heating circuit is applied friction layer, which is breathable and provides sufficient friction between the heating element and the plating layer for mechanical transmission of the deformation layer covering the heating element.

Preferably in this case the heating element and the plating layer to be heated to achieve the binding effect of the friction layer and bonding the heating circuit addressed to him by the surface plating layer at the specified position.

The present invention will be described below in more detail several embodiments and with reference to the accompanying drawings, in which:

Fig. 1 - depicts a heating element in perspective corresponding to the first variant embodiment of the invention; and
Fig. 4 - in the future with the spatially separated parts of the heating element corresponding to the third variant embodiment of the invention;

Fig. 5 is a schematic, top view of the heating element corresponding to the invention;

Fig. 6 is a schematically an installation for the manufacture of the heating element in accordance with the invention;

Fig. 7 - in section of a device for the manufacture of seat cushions in accordance with the invention.

As shown in Fig. 1 and 2, the proposed heating element 1 includes a heating circuit 2 laid on the layer of the device, which in the embodiment depicted in Fig. 1 and 2, consists of a pair of layers 3, 4 of the film. The bottom layer 3 of the foil may be a carrier, but may also be connected with other material, which in this case will be a carrier. The top layer 4 of the film, as a rule, represents a protective or covering layer, which in some cases needs to be adhesive, and which in some embodiments is designed to remove prior to Assembly of the car seat. At least one film layer, preferably lower Sidney basis, which is hydrophilic. Another alternative is a polyester film, and an example of a product in this case is the film, which under the name of WW - 22 supplies company "West wood Products", California, USA. The upper layer film can consist of the same material (and lower) and, if so, it may remain secure when the Assembly is in a car seat, but, instead, may consist of a protective layer of paper or other fibrous material, non-woven textile material etc., In this case, the specified layer is used only for carrying the heating element 1 in the process of manufacturing, warehousing and transportation, and it should be removed prior to Assembly of the car seat.

Heating circuit 2 can, as is known, consist of an electrically high resistance wire, preferably stranded, so it could support a large number of bends without risk of tearing. The wire may be bare or may have a plastic insulated for keeping temperature higher than the temperature of vaporization required for the implementation of the manufacturing process (see below). The heating circuit is a closed path, elusive, to connect with the not shown power source inside the power supply system of the vehicle, including the alternator and the battery. Heating circuit 2 can be performed in various ways with the purpose of heat distribution in an optimal way and may preferably further have a known wave form.

Heating circuit 2 is fixed to at least one layer of the film by means of binders, for example a layer of glue, which also includes a binder for bonding the top layer 4 of the film with the lower layer 3 of the film. As binders can be used and the film layer due to the heating wire before deploying it on a layer of film, so there was some melting to achieve the effect of binding. As you can see from the first variant implementation, the media, at least 3 layer film is breathable, which is achieved in the present embodiment, due to the large number of holes 7 that, in the case of two layers of film, as well as in the Assembly, requires a correspondingly spaced holes in the upper layer of the film, to allow the air produced is intended for deletion holes in it optional. Preferably, the holes are not at the location of the heating circuit 2.

In Fig. 3 shows a second variant embodiment of the invention, in which the heating circuit is based on a different type lattice of the carrier, in this case representing a sieve or grid 8, made of polyamide, polyester or similar material. In addition, in this case, heating circuit 2 can be attached to the grid by means of a binder in the form of glue. In this case, there may be two layers, i.e., the lower grid and the top mesh to achieve a more reliable fastening of the heating circuit 2.

Referring to Fig. 4, note that the various component parts of the heating element 1 for clarity, is shown placed at a certain distance from each other. In the finished heating element the different parts are in contact with each other.

In this embodiment, the heating element includes a layer 30 of the carrier, on one side of which is assigned heating circuit 2 through the binder 31, shown in Fig. 4 in the form of a layer of glue. In this example, the adhesive is of oncura. As explained below, the adhesive film 3 functions as a friction layer.

Below a more detailed description of each part of the heating element 1. The layer 30 of the carrier in this case is composed of a porous air-permeable foam material. In this example implementation used polyethylene (polyethene foam, having a thickness of 2 mm and a density of 30 kg/m3. It is important that the heating element 1 was as flexible and amenable to stretching, as the casing 26 of the seat depicted in Fig. 7. This is necessary in order to pass the heating element of the dimensional changes that occur in the layer of skin under the influence of the profile of the tool during manufacture, in order to avoid wrinkling and other unwanted morphogenesis. The profile of the car seat can be relatively complex, resulting in a possible three-dimensional deformation of various parts of the heating element. Because the layer 30 of the carrier is a dimensional dominant part of the heating element 1, it is particularly important that this part will meet all the requirements of flexibility. Moreover, a major advantage of using foam material for the layer is, a thin layer of foamed material of approximately the same thickness as the layer of the device. Thus, the mechanical and thermal properties of the heating element as a whole are based on mechanical and thermal properties of the layer 26 covering, because the layer 3 film (media) mainly determines the overall properties of the material of the heating element 1, such as rigidity, flexibility, and thermal expansion. The importance of these properties to a large extent compatible with the properties of the layer 26 covering, will be apparent from the brief description of the process of manufacturing seat cushions hire from glued layers of skin below in this description. For use of the heating element 1 in the process of manufacturing high permeability element. In this case, the layer of the device is a layer of porous foam material with very good permeability that allows the heating element 1 to reduce the ability of the seat to "breathe" due to its design.

Heating circuit 2 is made of wire, such as a known conductive wire of high resistance. This wire can be neizolirovannyj heating circuit 2 is deployed in the corresponding figure, providing the possibility of elastic deformation in an arbitrary direction, so that the circuit can withstand a large number of twists and sprains without risk of tearing. A closed circuit provided with two connecting pins 32, 33, which preferably ends in a not shown connecting device for connection with a not shown power source inside the power supply system of a motor vehicle comprising the alternator and the battery. Heating circuit 2 can be deployed in various ways in order to optimally distribute the generated heat, preferably in the form of a figure like waves.

Heating circuit 2 are fixed to the layer 30 of the carrier by means of binders, for example a layer 31 of the adhesive, as shown schematically in Fig. 4. Suitable could be a layer 31 of the adhesive, consisting of molten adhesive, adapted to reduce the permeability of the heating element 1.

Between the layer 26 covering and heating circuit 2 applied friction layer 3. The friction layer has a high permeability and provides a relatively high friction between the heating circuit 2 and the inner side of cloudentine the manufacture of car seats with the pasted layer plating, described below.

As will be seen from the variant embodiment of the invention, which is depicted in Fig. 4, the friction layer 3 included in the heating element 1 as part of this element and consists of an adhesive film deposited on the side of the heating circuit 2, which is converted to a layer 26 covering. The adhesive film is adapted, in principle, to provide an adhesive effect only after it is subjected to heating, and in this embodiment is attached to the rest of the heating element 1 by means of the same adhesive that secures and heating circuit 2 to the layer 30 of the carrier.

However, some adhesive effect may be present in the friction layer 3 from the very beginning, so that this layer will be slightly glued to the inner side of the cladding layer 26.

In the finished heating element 1 all layers shown in Fig. 4, compressed into one unit and are held together by a layer 31 of the adhesive and adhesive film 3, the remaining unmelted and, therefore, provides in itself a limited prikleivayas impact. In unmelted form the adhesive film 3 breathable and provides a relatively high friction with about the specific item 1.

To ensure a high permeability and a high coefficient of friction between the contacting surfaces, the adhesive layer 3 has, for example, to have a loose structure with a fine-meshed sieve. In this embodiment, the material of the adhesive film is a polyamide adhesive substance with a name SH 2402 and supplied by Applied Extrusion Technologies Ltd, Bristol, United Kingdom of great Britain and Northern Ireland.

In Fig. 6 schematically shows an example of apparatus for manufacturing the proposed heating element. This example is based on the option corresponding to the first variant of the invention, with two layers of film. One layer of film is stored in a cassette storage 9 located at one end of the device. The device further comprises a position 10 applying the binder, for example by spraying glue on the upper side of layer 3 films. This is followed by item 11 deployment of the heating circuit in accordance with a given pattern. Thus, the layer film to form a continuous track, based on the conveyor belt 12 extending between the various positions. The second film layer 4 is also provided in the form of Drogheda with the changing direction of the second film layer 4 and is attached to the first layer of film together with in between the heating circuit. In addition, there is a perforating device 15 containing, for example, perforating roller 16 and perforating knife 17. At the end of the device there is a bobbin 18 to winder constructed and connected in the form of tracks of the heating elements.

Manufacturer of heating elements in accordance with the embodiment depicted in Fig. 6, is therefore as follows:

With bobbin storage 9 bottom 3 layer film is continuously wound and cover, for example, by sputtering, a layer of glue on item 10 of the application of the binder, and then deploy heating circuit 2 at positions 11 and attached by bonding to a layer of film with a layer of glue. The second film layer 4 is also wound continuously with its bobbin storage 13 and is attached by means of a conducting roller 14 after you expand the heating circuit to the lower layer film together with in between the heating circuit. Then the layers of the film any punching perforating roller 16, and it also creates edges of the perforation by a perforation cutter 17, spaced apart by a distance equal to the distance between two opposite edges of the heating elements which can be a cutting knife for cutting the heating elements into separate blocks, are put in boxes for transport to the plant for Assembly of seat cars. As mentioned above, the adhesive effect between loop 2 and layer 3 of the film can be provided by the initial heating of the wire forming the heating circuit so that the 3 layer film is partially melted in a sticky mass. In this case, the application of a separate adhesive layer can be eliminated.

In Fig. 7 schematically shows an example of a section of the device for the manufacture of seat cushions, i.e., back pillows and seat cushions designed for seat cars. Device and method apply to known gluing plating layer on an elastic body seat. For example, you can use the technology in more detail disclosed in the European patent N 0227202, therefore there was no need to describe here the technology, such as this detail. The device contains a form 19, having a cavity, the inner surface 20 which has the same shape as the pillow in question. The device also includes a thrust plate 21, is arranged to move in the direction of the arrow 22, and in the opposite direction, by means not shown doers the pressure to an already decorated elastic body 23, forming the core of the pillow and having after forming the same surface as the inner surface 20 of the form. The core may consist of a conventional material, usually plastic foam, such as pineforest or polyurethane foam. Into the mold cavity are a large number of channels 24, which in the depicted example are located in the lower part of the form and communicated with a vacuum device and a heating device that may be included in the channels 24. In the space between the surface 25 of the elastic body 23 and the surface of the mold 20 is a layer 26 covering made of breathable textile material, for example on the basis of the layer of breathable foam, and its facing the inside surface has adhesive film 27, which may be of the same type and preferably is made exactly from the same material as the carrier, at least one of the layers 3 film heating element. Of course, the thickness of the layers may vary. When using such technology layer 3 carrier, which in this case is an adhesive film and adhesive film 27, which covers the entire cavity forms shall be such that the binding effect of an adhesive film should not manifestation is postema higher operating temperature, while the adhesive film should melt at a temperature which is below the maximum allowable temperature of all other parts of pillows, such as the elastic body 23, the layer 26 of the casing, and a heating circuit 2. Accordingly, the adhesive film is a layer which, due to the properties of the material from which it is made, at least at a certain temperature, has a binding effect without the necessity to use a separate additional layers of glue. An example of an adhesive film is a film of polyurethane, which when heated has a binding effect.

In accordance with the invention, the heating element 1 is placed between the layer 26 covering and adhesive film 27, and so it has either a single layer which is an adhesive film, thus covering layer is removed, or two layers of adhesive film located between the heating circuit.

In the manufacture of seat cushion in accordance with the invention, the following occurs:

Layer 26 covering is placed in a mold and it may consist of cut pieces or to form part of the track material, which breaks leaned forward over the cavity f is completed to continue the intermittent feed. Due to the impact of vacuum through channels 24, the layer 26 covering and adhesive film 27 stick and are in direct contact with the inner wall of the form. This occurs despite the fact that the adhesive film has a porous structure with a large number of microscopic holes, as these openings are substantially restrict the passage of air. Then the heating element 1 is placed in a specified position on the upper surface of an adhesive film. After that, the elastic body 23 is placed in a mold and exert countervailing pressure by the thrust plate 21, the purpose of which is to press the elastic body to said layers and located between the heating element. Then warm, feeding the hot air through the channels 24, until a temperature exceeding the melting point of the adhesive film 27, which gives the right to assert that the adhesive film is converted into droplets and diffuses into the adjacent layers, i.e. in the elastic body, and the layer 26 covering. The same thing happens with the carrier in the heating element 1, which is melted and converted into drops and diffuses into the adjacent layers, indicating that the heating circuit kleiverda flow of air - due to the heating element, which is breathable. After you turn off the vacuum and heat, and after hardening of the adhesive cushion ready for final finishing of edges, etc.

The invention is not limited to the embodiments of the disclosure above and depicted in the drawings, but may vary within the framework of the attached claims. For example, the installation of the heating element is not limited to the technology disclosed in the above source, or may be used in connection with other methods of bonding the layers of the skin to the elastic bodies with the purpose of the seat cushions of the car. Alternatively, the layers of the perforated film and screen structures, the carrier may have a different structure, for example, can be made of a porous material, which is breathable and thereby allowing vacuum to pass and be distributed in the application process by means of a vacuum device, and to distribute the incoming hot air.

1. Heating element for vehicle seats, comprising an elastic body and a plating layer containing electroconductive heating circuit, podklyuchenny circuit is deployed in the form of a drawing, enabling elastic deformation in any direction, characterized in that between the plating layer and the heating circuit has a friction layer, forming part of the heating element, made breathable and provides sufficient friction between the heating element and the plating layer to provide mechanical transmission of the deformation layer covering the heating element, while the mechanical properties of the heating element is essentially compatible with the mechanical properties of the plating layer.

2. Item under item 1, characterized in that the friction layer formed adhesive film on the facing layer covering a side of the heating circuit, and this film in the unfused condition is breathable and capable of providing a sufficiently high friction relative to the surface of the plating layer for mechanical transmission of the deformation layer covering the heating element and adapted to provide a binder impacts upon exposure to the heat.

3. Item under item 1 or 2, characterized in that the adhesive film has the structure of a fine-meshed sieve.

4. Item under item 1, characterized in that the layer wear the ears of the vehicle seat, which consists in bonding a layer of sheathing to the elastic body, characterized in that the heating element in the heating circuit and the media have between the plating layer and an elastic body and is fixed in a predetermined position by gluing, which is performed by the introduction of an adhesive film between the plating layer and the elastic body, and heating the adhesive film to achieve the effect of binding the heating element with the carrier in the form of additional adhesive film is inserted between the plating layer and the first adhesive film, and the first and the additional adhesive film is heated to effect bonding.

6. A method of manufacturing a heating element for seat vehicles containing elastic body and the layer of the skin, consisting in that the electroconductive heating circuit connected to the current source attached to the breathable layer media, distributing it in the form of a drawing, selected with a view to ensuring elastic deformation in any direction, characterized in that between the plating layer and the heating circuit is applied friction layer, which is breathable and provides sufficient friction between the heating element is 7. The method according to p. 6, characterized in that the heating element and the plating layer is heated to achieve the binding effect of the friction layer and bonding the heating circuit addressed to him by the surface plating layer at the specified position.

Priority points:

28.10.92 under item 1;

26.08.93 on PP.5 and 6.

 

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