Multi layer heating mat for electrical floor heating or electrical wall heating
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Solution Overview
Problem
Existing electrical heating mats face high manufacturing and installation costs due to the need for high currents to achieve required heating power, which increases the cost of cables, power supplies, and other components, and they suffer from increased electrical resistance over time due to oxidation of conductive fibers.
Innovation Solution
The heating mat features a support layer with an isolating surface and a heating layer comprising multiple electrically conductive stripes, which reduces the amount of expensive conductive material needed and allows for efficient voltage distribution by connecting stripes in series and parallel, along with a controller to manage voltage bursts to maintain low resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional heating mats with low resistance are used, then heating power is achieved, but high currents are required which increase the cost of cables, power supplies, and other components
Solution Approach 1:
The heating layer is divided into multiple conductive stripes instead of using a continuous low-resistance conductive layer. This segmentation allows the system to achieve the required heating power through series-parallel connections, reducing the current requirement and associated component costs while maintaining manufacturing simplicity
Solution Approach 2:
The electrical resistance parameter of the heating layer is optimized by using multiple conductive stripes with controlled resistance values. By adjusting the number, width, and arrangement of stripes, the system achieves appropriate resistance to reduce current requirements while maintaining heating power output
2Power
If non-woven conductive fibers are used in heating mats, then heating function is provided, but electrical resistance increases over time due to oxidation of conductive fibers
Solution Approach 1:
The heating layer uses composite conductive stripes that combine conductive materials with oxidiation-resistant properties. These composite materials maintain stable electrical resistance over time while providing the necessary heating function, preventing the resistance increase problem associated with conventional non-woven conductive fibers
Solution Approach 2:
The patent employs conductive stripes designed to be replaced or reconfigured rather than relying on long-term durability of individual fiber contacts. This approach addresses the oxidation problem by using materials or designs where resistance stability is maintained through structural redundancy rather than material permanence
3Quantity of substance
If multiple conductive stripes are used instead of a continuous conductive layer, then the amount of expensive conductive material is reduced, but device complexity increases due to series and parallel connections
Solution Approach 1:
Multiple conductive stripes are electrically connected in series-parallel configurations to form a unified heating system. This merging approach reduces the total amount of conductive material needed compared to a continuous layer while the systematic connection method keeps the complexity manageable through standardized connection patterns
4Power
If high currents are used to achieve required heating power, then heating power is maintained, but the cost of cables, power supplies, relays, and other components increases
Solution Approach 1:
The electrical parameters of the heating system are changed by increasing resistance through segmented conductive stripes, which directly reduces the current requirement for a given power level (P=UI). This parameter change allows the use of lower-cost components rated for lower currents while maintaining the required heating power output
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 configuration reduces manufacturing and installation costs while maintaining efficient heating performance by minimizing the need for high currents and preventing resistance increases through controlled voltage bursts, enhancing the longevity and mechanical properties of the heating mat.
Implementation Method 1
a heating layer (20, 40), in particular comprising at least two electrically conductive stripes (20), each having a longitudinal extension and a width
Implementation Method 2
a support layer (10) with an isolating surface (12)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A heating mat 1 for a floor heating or a wall heating with a support layer 10 with an upper isolating surface 12 and a heating layer on top of the isolating surface 12 can be manufactured particularly efficient, if the heating layer comprises at least two electrically conductive stripes 20, each having a longitudinal extension and a width and if the two electrically conductive stripes 20 are horizontally spaced from each other, wherein an isolating stripe 30 extends in between of the two conductive stripes 20.