Embedded Carbon Veil Heating Elements for Floor Systems
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Solution Overview
Problem
Conventional heated floor systems require labor-intensive and expensive installation of bulky electrical wires or liquid tubes beneath the floor, leading to inefficient heat distribution and long lag times in reaching desired temperatures.
Innovation Solution
A heated floor system incorporating an embedded carbon veil heating element with electrically conductive veil busbars and floor busbars, connected to a controller, which allows for efficient heat production just below the flooring surface, reducing energy consumption and installation complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional electrical wires or liquid tubes are installed beneath the floor, then heating function is achieved, but installation becomes labor-intensive and expensive
Solution Approach 1:
The patent merges the heating element directly into the flooring material itself, combining the floor structure and heating function into a single integrated product. This eliminates the need for separate installation of heating wires or tubes beneath the floor, significantly simplifying installation while maintaining heating functionality.
Solution Approach 2:
The patent uses thin flexible heating films embedded within the flooring structure. These thin-film heating elements can be easily integrated into the flooring material during manufacturing, allowing for simple installation without requiring complex wiring or tube installation procedures.
2Reliability
If conventional heating systems are installed deep beneath the floor, then heating function is achieved, but heat distribution becomes inefficient with long lag times
Solution Approach 1:
The patent transitions from deep subsurface heating to surface-level heating by embedding the heating element within the flooring material itself. This dimensional change places the heat source much closer to the surface, enabling rapid and efficient heat distribution without the long lag times associated with deep subsurface heating systems.
Solution Approach 2:
The heating element is pre-integrated into the flooring material during manufacturing, positioning it optimally close to the surface before installation. This preliminary positioning ensures that once installed, the system can immediately and efficiently transfer heat to the surface without requiring deep installation or lengthy warm-up periods.
3Reliability
If conventional heating systems are installed, then heating function is achieved, but energy consumption increases
Solution Approach 1:
By moving the heat source from deep beneath the floor to within the flooring material itself, the system dramatically improves thermal efficiency. This dimensional repositioning reduces heat loss to the subfloor and enables direct, efficient heat transfer to the surface, significantly lowering energy consumption while maintaining reliable heating performance.
Solution Approach 2:
The patent converts what would traditionally be heat loss to the subfloor into a benefit by placing the heating element within the flooring structure. The previously wasted heat now contributes to surface heating, improving overall system efficiency and reducing energy consumption.
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 embedded carbon veil heating system achieves rapid heat distribution and significant energy savings by heating the floor surface efficiently, consuming approximately 42% less energy compared to traditional systems, while simplifying installation and maintaining a seamless appearance.
Implementation Method 1
a controller electrically connected to the floor busbars and configured to apply electrical current to the floor busbars sufficient to cause the carbon veil to produce heat in a portion thereof located between the veil busbars
Implementation Method 2
a temperature sensor positioned in a location operable to sense heat emitted from the section of flooring
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A heated floor system including a section of flooring including an embedded carbon veil heating element. The carbon veil heating element including at least two electrically conductive veil busbars spaced apart from one another. Also included in the system are at least two floor electrical busbars electrically connected to the at least two veil busbars, and a controller electrically connected to the floor busbars configured to apply electrical current to the floor busbars sufficient to cause the carbon veil to produce heat in a portion thereof located between the veil busbars.