A heating module and method of manufacturing thereof
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Solution Overview
Problem
Conventional heating arrangements for floor areas, such as buildings and transportation means, are complex and costly to install and maintain, requiring significant disruption for repairs due to embedded heating cables.
Innovation Solution
A heating module comprising a first and second conductive layer with an intermediate insulating layer having a channel for a heating cable, filled with conductive material and sealed with a conductive adhesive, allowing for easy installation and repair by modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating cables are embedded in floor area (concrete), then heating function is achieved, but installation and maintenance become complex and costly
Solution Approach 1:
The heating arrangement is divided into modular heating modules that can be independently installed and replaced. Each module contains a heating cable section enclosed in a protective structure with insulating material, allowing the system to be segmented into discrete units rather than requiring embedding throughout the entire floor area.
Solution Approach 2:
The heating modules are pre-assembled with heating cables, protective layers, and insulating material before installation. This preliminary preparation eliminates the need for complex on-site embedding procedures and allows for straightforward placement and connection of complete functional units.
2Reliability
If heating cables are embedded in floor area, then heating function is achieved, but repair requires breaking and remaking floor area
Solution Approach 1:
By segmenting the heating system into separate modular units, individual modules can be accessed and replaced without disturbing the entire floor area. Damaged modules are simply removed and replaced with new ones, eliminating the need to break and remake the floor structure.
Solution Approach 2:
The heating cable and its protective structure are extracted as a complete removable module from the floor area. This allows the heating function to be maintained while enabling easy removal and replacement of damaged components without permanent installation.
3Reliability
If heating cables are embedded in material below finished floor, then heating function is achieved, but installation procedure becomes complex and costly
Solution Approach 1:
All components including heating cables, protective layers, and insulating material are assembled into complete modules before installation. This preliminary assembly simplifies the installation procedure to merely placing and connecting pre-fabricated units, eliminating complex on-site construction work.
Solution Approach 2:
Multiple components (heating cable, protective layer, insulating material) are merged into a single integrated module. This combination simplifies handling and installation by reducing the number of separate installation steps and materials required on-site.
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 modular heating arrangement simplifies installation and maintenance, providing efficient heat distribution while keeping floor areas dry and non-slippery, and can be easily repaired by replacing individual modules without extensive renovation.
Implementation Method 1
the heating arrangement is electrically coupled to an electrical power source for allowing electricity to pass though the heating cables for warming the floor area
Implementation Method 2
an intermediate insulating layer positioned between the first and the second conductive layers
Data Source
Figure 1
Figure 2
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AI summary
Disclosed is a heating module and a method of manufacturing thereof. The method comprises arranging a first conductive layer on a first surface of an intermediate insulating layer; making a channel on a second surface of the intermediate insulating layer; arranging a heating cable in the channel; filling the channel with a conductive filling material to cover the heating cable arranged in the channel; and attaching a second conductive layer to the second surface of the intermediate insulating layer with a conductive adhesive coating.