Method for producing a heat module

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Solution Overview

Problem

Existing heat modules suffer from air pockets that accumulate condensed water, leading to earth leakage risks and lower mechanical impact resistance due to excessive weight from massive rubber or polyurethane construction.

Innovation Solution

A method for producing a heat module involves arranging a stepping plate and a base plate with a spacing in between, attaching heat elements along the stepping plate, and filling the spacing with a flowable water-impermeable insulator, which is cured by heating the insulator with the attached heat elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If heat modules are made of massive rubber or polyurethane, then mechanical strength is improved, but weight increases

Engineering Contradiction:

Improvemechanical strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The heat module is divided into distinct functional layers: a flexible support layer (rubber or polyurethane) providing mechanical strength, and a separate filling material (flowable water-impermeable insulator) providing insulation and water protection. This segmentation allows each layer to be optimized for its specific function without the weight penalty of a monolithic massive construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heat module employs a composite structure combining flexible support material (rubber/polyurethane) with a flowable water-impermeable insulator filling. This composite approach achieves both mechanical strength from the support layer and water protection/insulation from the filling material, eliminating the need for excessive material thickness.

Inventive Principle:

Principle #40Composite materials

2Reliability

If heat modules are made of massive rubber or polyurethane, then water protection is improved, but weight increases

Engineering Contradiction:

Improvewater protectionVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The water protection function is extracted from the structural support function. Instead of using massive rubber or polyurethane for both support and water protection, the invention uses a thin flexible support layer combined with a flowable water-impermeable insulator filling that specifically provides the water protection and insulation functions.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The flowable water-impermeable insulator filling creates a porous or cellular structure that provides water protection through its impermeable nature while maintaining low weight. This filling material occupies the space between the support layer and heating elements, providing both insulation and water barrier functions without the weight of solid massive construction.

Inventive Principle:

Principle #31Porous materials

3Ease of manufacture

If air pockets are present in the module, then manufacturing is simplified, but water accumulation risk increases

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwater accumulation risk

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention changes the physical state and properties of the filling material from air (compressible, permeable) to a flowable water-impermeable insulator (liquid or semi-liquid state, impermeable). This parameter change eliminates air pockets while maintaining manufacturing simplicity, as the flowable filling automatically fills all voids and conforms to the module geometry during the filling process.

Inventive Principle:

Principle #35Parameter changes

4Strength

If stepping plate thickness is increased for load bearing, then mechanical strength is improved, but weight increases

Engineering Contradiction:

Improveload bearing capacityVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The flexible support layer (stepping plate) is designed to perform multiple functions: providing mechanical strength for load bearing, serving as a barrier layer, and working in conjunction with the filling material to provide insulation and water protection. This multi-functionality allows the stepping plate to be thinner than traditional single-function designs, reducing weight while maintaining load bearing capacity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This solution prevents water accumulation, reduces weight and thickness, enhances mechanical impact resistance, and minimizes the risk of earth leakage by effectively isolating the heat elements from the environment.

Implementation Method 1

connecting the at least one heat element to a power source for heating the insulator so that the insulator is curing

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS12324063B2Method for producing a heat module

Publication Date: 2025.06.03 EQON AS

AI summary

A heat module for a flooring. The heat module has a stepping plate having a first side and a second side, at least one heat element arranged along the first side of the stepping plate, and a water impermeable insulator at the first side of the stepping plate. The at least one heat element is attached to the first side of the stepping plate so that emitted heat is directly conducted to the stepping plate.