Heating device and method for manufacturing same
Solution Overview
Problem
Heated floor panels for aircraft interiors face issues with mechanical damage and overheating, as well as vulnerability to moisture penetration, which can lead to malfunctions and reduced operational safety.
Innovation Solution
A heating device with a mechanically resilient support structure and a thermally conductive cover structure, featuring a heating layer made of positive temperature coefficient (PTC) resistive material, which is self-regulating and protected from mechanical and environmental influences, ensuring reliable operation and extended service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional heating wire is used in the heated floor panel, then the heating function is achieved, but the system is susceptible to mechanical damage and overheating
Solution Approach 1:
The patent changes the physical state and properties of the heating element by using a PTC resistive heating layer instead of conventional heating wires. The PTC material's electrical resistance increases with temperature, providing self-regulating heating that prevents overheating and mechanical damage while maintaining reliable heating function.
Solution Approach 2:
The patent employs a composite structure consisting of a PTC resistive heating layer integrated between a support structure and a deck structure. This composite design combines the heating functionality with mechanical protection and thermal management, creating a more reliable system that resists mechanical damage and overheating.
2Ease of operation
If the heating element is exposed to the environment, then the heating function is accessible, but it is vulnerable to moisture ingress and mechanical damage
Solution Approach 1:
The patent implements a nested structure where the PTC resistive heating layer is positioned between the support structure and the deck structure. This nesting provides inherent protection from moisture ingress and mechanical damage while maintaining heating functionality, as the heating element is enclosed within the sandwich structure.
Solution Approach 2:
The patent introduces intermediate protective layers (support structure and deck structure) between the heating element and the external environment. These intermediary structures act as barriers against moisture and mechanical damage while allowing the heating function to operate effectively.
3Temperature
If electronic temperature control is added to prevent overheating, then temperature regulation is improved, but device complexity increases
Solution Approach 1:
The patent employs a self-service mechanism where the PTC resistive heating layer automatically regulates its own temperature through its inherent positive temperature coefficient property. As the temperature increases, the electrical resistance increases, naturally limiting power consumption and preventing overheating without requiring external electronic control systems.
Solution Approach 2:
The PTC material provides inherent feedback control where the temperature rise directly affects the electrical resistance, which in turn regulates the power consumption. This automatic feedback mechanism eliminates the need for complex electronic temperature control systems while maintaining precise temperature regulation.
4Strength
If a mechanically resilient support structure and thermally conductive deck structure are used, then mechanical strength and thermal conductivity are improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the heating device into distinct functional segments: a mechanically resilient support structure, a PTC resistive heating layer, and a thermally conductive deck structure. This segmentation allows each component to be optimized for its specific function while simplifying the overall manufacturing process through modular assembly.
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 solution provides a mechanically and electrically robust, self-regulating heating system that is resistant to overheating and mechanical damage, ensuring high operational safety and reliability by using a PTC heating layer integrated between a support and cover structure, which is thermally conductive and protected from environmental factors.
Implementation Method 1
a heater (104) for converting electrical energy into thermal energy... When an electric current flows through the resistive material, it heats up due to its electrical resistance
Implementation Method 2
the heater (104) has a heating layer (108) made of a resistance material with a positive temperature coefficient... The resistive material's positive temperature coefficient causes the electrical resistance of the resistive material to increase with rising temperature
Implementation Method 3
a mechanically resilient and thermally conductive deck structure (106)... heat conduction through an aluminum honeycomb (112) directly above the heater (104)
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
The invention relates to a heating device (100) for the interior of an aircraft. Said heating device (100) comprises a mechanically loadable support structure (102), a mechanically loadable, heat-conducting top structure (106), and a heater (104) for converting electric energy into thermal energy; the heater (104) is placed between the support structure (102) and the top structure (106) and includes a heating layer (108) made of a resistive material that has a positive temperature coefficient.