Heating mat for use in a floor structure, floor structure, and method for producing same
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Solution Overview
Problem
Existing aircraft floor heating systems are susceptible to corrosion, especially in moist areas like aircraft doors and galleys, leading to costly and complex replacements when the heating elements fail, resulting in unavailable underfloor heating until the cabin is overhauled.
Innovation Solution
A heating mat with a layered structure comprising a wear-resistant protective layer, an electrically conductive ground fault detection layer, electrical insulation layers, a flat electrically conductive heating varnish layer, and a further wear-resistant protective layer, which is designed to be flat and filled with an electrically conductive heating varnish that emits heat mainly as infrared radiation, and includes a ground fault detection system to prevent electrical shock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heating wire is integrated into the base plate, then the heating function is achieved, but the susceptibility to corrosion increases
Solution Approach 1:
The heating system is segmented into modular heating mats that can be independently replaced. Each heating mat consists of separate functional layers (heating element, insulation, protective layers) that are factory-assembled, allowing the heating function to be isolated from the base plate structure and replaced without corroding the entire floor assembly.
Solution Approach 2:
An intermediary modular heating mat structure is introduced between the base plate and the floor covering. This intermediary contains the heating element and protects it from moisture through multiple protective layers, preventing direct contact between the heating function and corrosive environmental factors.
2Reliability
If the heating element is integrated into the base plate, then the heating function is achieved, but the complexity of replacement increases
Solution Approach 1:
The heating system is divided into independent modular heating mats that can be removed and replaced as complete units. This segmentation eliminates the need to disassemble the entire floor structure, reducing replacement complexity from system-level to module-level operations.
Solution Approach 2:
The heating element is extracted from the base plate and packaged as a separate removable module. This extraction allows the heating function to be independently replaced without affecting the base plate or floor covering, significantly simplifying the replacement process.
3Reliability
If the heating wire is exposed in moist areas, then the heating function is achieved, but the risk of electrical shock increases
Solution Approach 1:
Multiple intermediary protective layers are introduced between the heating element and the environment: an electrical insulation layer directly surrounding the heating element, and a protective layer providing additional barrier protection. These intermediaries isolate the electrical component from moisture and prevent electrical shock risks.
Solution Approach 2:
The heating mat uses a composite layered structure combining different materials with specific properties: heating element (electrically conductive), insulation layer (electrically insulating), and protective layer (moisture-resistant). This composite structure simultaneously provides heating function and electrical safety in moist environments.
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 durable and efficient heating solution that minimizes corrosion risks, allows for easy replacement of heating elements, and maintains floor temperature consistency without the need for complete floor structure overhaul, making it suitable for retrofitting and reducing maintenance costs.
Implementation Method 1
a planar electric heating element comprising a planar, electrically conductive heating paint layer
Implementation Method 2
designed to be flat and filled with an electrically conductive heating varnish that emits heat mainly as infrared radiation
Implementation Method 3
an electrical insulating layer; and d) a planar electric heating element comprising a planar, electrically conductive heating paint layer; e) a further electrical insulating layer
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a heating mat (1) for use in a floor structure (10), in particular in aircraft (20), to a floor structure (10) having a corresponding heating mat (1), and to a method for producing a floor structure (20). The heating mat (1) has a layer structure having the following layers, permanently bonded to each other: a) walkable protection layer (5) made from an unfinished floor covering material made of fiberglass-reinforced and/or aramid fiber-reinforced plastic; b) electrically conductive ground fault detection layer (4); c) electrical insulation layer (3); and d) flat, electrical heating element (2) comprising an electrically conductive heating varnish layer. The floor structure (10) which can be produced by the method according to the invention comprises - an unfinished floor (11) having a recess (17) for a heating mat (1), - a heating mat (1) according to the invention inlaid therein, and - a floor covering (12) laid on the unfinished floor (11) and over the heating mat (1), wherein the recess (17) in the unfinished floor is adjusted to the width, length and thickness (90) of the heating mat (1).