Heated Composite Panel With Embedded Carbon Fiber Layer
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Solution Overview
Problem
Existing heated panels for transit conveyances lack efficient integration of carbon fiber heating elements with reinforced phenolic materials, leading to suboptimal heat distribution and increased panel thickness due to exposed electrical components.
Innovation Solution
A composite panel design incorporating a carbon fiber heating element embedded within a reinforced phenolic skin, with recessed pockets for electrical components to maintain panel thickness and facilitate easy connection to a voltage source, using a manufacturing method that saturates the carbon fiber heating element with liquid phenolic resin and cures it within the panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If carbon fiber heating element is embedded in reinforced phenolic skin, then heat distribution efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The heating element is integrated directly into the phenolic skin during the molding process, merging two previously separate components (heating element and panel structure) into a single unified structure. This eliminates the need for separate installation steps and reduces overall manufacturing complexity while maintaining effective heat distribution.
Solution Approach 2:
The patent combines carbon fiber material with reinforced phenolic material to create a composite heating structure. The carbon fiber provides heating functionality while the phenolic material provides structural integrity and thermal distribution, creating a synergistic composite that achieves both heating efficiency and manufacturing feasibility.
2Length of stationary object
If electrical components are recessed into pockets, then panel thickness is maintained, but closeout complexity increases
Solution Approach 1:
The closeout is divided into multiple segments including recessed pockets that accommodate electrical components. This segmentation allows the closeout to perform multiple functions: sealing the panel perimeter and housing electrical connections, thereby maintaining panel thickness without requiring additional external components.
Solution Approach 2:
The closeout structure serves dual purposes: it provides the sealing function for the panel perimeter and simultaneously houses the electrical components through integrated recessed pockets. This multi-functionality eliminates the need for separate electrical component housings, reducing overall complexity despite the added recessed features.
3Ease of operation
If terminal blocks are integrated into closeouts, then connection ease is improved, but manufacturing precision requirements increase
Solution Approach 1:
Terminal blocks are pre-integrated into the closeout structure during the molding process, with recessed pockets precisely formed to accommodate them. This preliminary integration ensures proper positioning and alignment before final assembly, making electrical connections easier while the molding process itself handles the precision requirements.
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 efficient heat distribution while maintaining a standard panel thickness, allowing for flexible heat output and modular design, and ensuring easy conversion between heated and non-heated panels.
Implementation Method 1
a heating element adjacent the interior face of the panel, the heating element including carbon fiber material extending between and electrically coupling two opposed electrical buses
Implementation Method 2
embedding the carbon fiber heating element within the first reinforced phenolic skin by saturating the carbon fiber heating element in at least one layer of liquid phenolic resin, placing a reinforcement layer over the carbon fiber heating element, saturating the reinforcement layer with at least one additional layer of liquid phenolic resin, and jointly curing all of the liquid phenolic resin layers
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A panel has an exterior face thereof adapted for attachment to a support frame and an interior face thereof adapted for defining a boundary of a compartment. The panel includes a core encapsulated within a panel frame of reinforced phenolic material, the core having first and second faces thereof, and a periphery. The panel frame includes first and second skins attached to the first and second faces of the core. One or more closeouts are disposed between the skins about the periphery of the core, with the one or more closeouts being attached to the first and second skins. A heating element is adjacent the interior face of the panel. The heating element includes carbon fiber material extending between and electrically coupling two opposed electrical buses. An electrical wire is coupled to each of the electrical buses of the heating element for introducing a voltage across the heating element.