Heating Mat With Discrete Parallel Circuits for Field Trimming
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Solution Overview
Problem
Existing electric heat mats are not adjustable in the field, cannot withstand heavy loads, and lack the ability to adjust power distribution after being cut, limiting their versatility and functionality.
Innovation Solution
A vinyl-based heat mat with a multilayer construction including poly vinyl chloride, polyethylene terephthalate, metal alloy heating circuits, and a polymer liquid adhesive, allowing for field trimming and adjustable power distribution through a thermostatic control circuit with a variable-resistance temperature sensor and MOSFET power controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the heat mat is manufactured as a single continuous circuit, then the thermostatic control can regulate temperature effectively, but the mat cannot be trimmed or cut in the field to different lengths
Solution Approach 1:
The heating element is divided into multiple discrete parallel circuits instead of a single continuous circuit. Each discrete circuit is electrically independent and connected in parallel between the line and neutral conductors. This segmentation allows the mat to be cut at predefined locations between circuits while maintaining electrical continuity through the remaining parallel circuits, thus enabling field adaptability without sacrificing reliability.
2Adaptability or versatility
If the heat mat is designed with fixed dimensions, then the manufacturing process is simplified, but the mat cannot be adjusted to fit different application areas
Solution Approach 1:
The heating element is divided into multiple discrete parallel circuits instead of a single continuous circuit. Each discrete circuit is electrically independent and connected in parallel between the line and neutral conductors. This segmentation allows the mat to be cut at predefined locations between circuits while maintaining electrical continuity through the remaining parallel circuits, thus enabling field adaptability without sacrificing reliability.
3Reliability
If the heating element is made as a single continuous wire, then the construction is simple, but the mat stops functioning when the wire is damaged by puncture or heavy loads
Solution Approach 1:
The heating element is divided into multiple discrete parallel circuits instead of a single continuous circuit. Each discrete circuit is electrically independent and connected in parallel between the line and neutral conductors. This segmentation allows the mat to be cut at predefined locations between circuits while maintaining electrical continuity through the remaining parallel circuits, thus enabling field adaptability without sacrificing reliability.
Solution Approach 2:
The system incorporates predefined cut points between discrete circuits that serve as safety features. If damage occurs to one circuit, the parallel configuration and predefined separation points allow the system to continue functioning through remaining circuits, providing beforehand protection against total system failure from punctures or heavy load damage.
4Adaptability or versatility
If the heat mat is cut in the field to reduce size, then the mat can fit different areas, but the power supplied cannot be adjusted to control watts per square inch
Solution Approach 1:
The system incorporates a thermostatic control with a variable-resistance temperature sensor and MOSFET power controller that dynamically adjusts the power supplied to the heating elements. This dynamic control allows the power output to be varied to maintain appropriate watts per square inch ratios regardless of the mat's final size after field cutting, thus maintaining ease of operation alongside field cut capability.
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
Enables the heat mat to be cut to various lengths, withstand heavy loads, and adjust power output per square inch, ensuring continuous functionality and improved adaptability in different applications.
Implementation Method 1
a third layer comprising a metal alloy with a polymer liquid adhesive... The metal alloy is configured as discrete parallel connected individual heating circuits
Implementation Method 2
a variable-resistance temperature sensor in a vinyl-based heat mat
Implementation Method 3
a polymer liquid adhesive used in the construction delaminates a polyethylene terephthalate film at temperatures above about 300 degrees F., which functions as a fuse severing the resistance heating wire
Data Source
AI summary
A heating pad with a plurality of parallel connected heating circuits that are provided with a temperature control circuit. The parallel connected heating circuits are longitudinally separated from each such that a user may cut or sever the heat mat along predetermined cut points that are indicated on the exterior surface of the heat mat. In this way, the length of the heat mat can be adjusted in the field based on the application by simply cutting the heat mat along a predefined cut point.