Flexible Heating Mat With Integrated Cooling for Composite Repair
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Solution Overview
Problem
Existing heating mats for laminates and repair pieces in plastic materials face limitations in efficiently achieving high processing temperatures without damaging the material, and they lack effective cooling mechanisms to extend their service life and enable cost-effective, mobile repairs and manufacturing processes.
Innovation Solution
A tooling device with a flexible heating mat incorporating inductive heating elements and integrated cooling lines, along with insulating elements, allows for controlled heating and cooling to manage temperature effectively, preventing overheating and extending the service life of the heating mat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heating mats are used to achieve high processing temperatures for laminates and repair pieces, then heating efficiency is improved, but the heating mat material may be damaged due to excessive temperature
Solution Approach 1:
The heating system is segmented into distinct functional layers: a heating element layer and a protective insulating layer. This segmentation allows the heating function to operate at high temperatures while the insulating layer protects the heating mat material from thermal damage, resolving the contradiction between achieving high processing temperatures and maintaining heating mat durability.
Solution Approach 2:
An insulating layer acts as an intermediary between the heating element and the heating mat material. This intermediary layer blocks excessive heat from reaching the heating mat, preventing material damage while allowing the heating element to achieve the necessary high processing temperatures for laminates and repair pieces.
2Duration of action of stationary object
If heating mats without cooling mechanisms are used, then device complexity is reduced, but service life is limited due to overheating and material degradation
Solution Approach 1:
The insulating layer serves as a thermal barrier that mediates between the heating element and the heating mat material, reducing heat accumulation and slowing material degradation. This simple intermediary structure extends service life without requiring complex active cooling systems.
Solution Approach 2:
The insulating layer changes the thermal parameters of the heating mat system by reducing heat transfer to the mat material. This passive parameter modification allows the heating mat to operate longer at high temperatures without active cooling, extending service life while maintaining simple device architecture.
3Ease of operation
If conventional heating mats are used for mobile repairs, then ease of operation is improved, but cost-effectiveness is reduced due to frequent replacement and material damage
Solution Approach 1:
The insulating layer, which might seem to add complexity or cost, actually converts the potential harm of high temperature into a benefit by protecting the heating mat material. This extends the lifespan of the heating mat, making mobile repair operations more cost-effective despite the initial addition of the insulating layer.
Solution Approach 2:
The insulating layer provides beforehand cushioning against thermal damage to the heating mat material. By protecting the heating mat from excessive heat before damage occurs, the system extends service life and reduces replacement costs, improving overall cost-effectiveness for mobile repair applications.
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 efficient heating of laminates and repair pieces at high temperatures while protecting the heating mat and workpiece, facilitating cost-effective, mobile repairs and manufacturing processes, especially for fiber-reinforced composites.
Implementation Method 1
at least one inductive heating element with at least one cooling element
Implementation Method 2
the heat-generating elements are inductively heated by the heating element
Implementation Method 3
at least one cooling element having at least one cooling line
Implementation Method 4
an insulating element having a thickness of at least 5 mm and a heat-generating element are arranged between the object to be heated and the heating mat
Data Source
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AI summary
The invention relates to a tool device (100), more particularly a portable tool device, comprising at least one flexible heating mat (10) which has at least one heating element (12) with at least one cooling element (14) that has at least one cooling line (15), said heating element being provided for heating an object (44), more particularly a laminate (42) and or a repair piece (34). The at least one cooling line (15) has at least one flexible hose. The at least one cooling line (15) of the cooling element (14) is arranged, at least in regions, in intermediate spaces (52) between heating wires (13) of the heating element (12). The invention also relates to a repair method for a workpiece (30) made of a plastic material, wherein a tool device (100), comprising at least one flexible heating mat (10), which comprises at least one heating element (12), with which an object (44), more particularly a laminate (42) and/or a repair piece (34), is heated, positioned at a repair region (32) of the workpiece (30). The heating mat (10) is actively cooled, at least some of the time, while the object (44) is being heated.