Pliable Pallet Heating Wrap With Insulation for Asphalt Patch Warming
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Solution Overview
Problem
Cold weather conditions pose a challenge in maintaining asphalt patches at the required temperature for effective application, as they need to be heated to adhere properly to potholes in asphalt driving surfaces.
Innovation Solution
A modular heating unit designed to cover the entire perimeter of a pallet, including insulation and a heat generating element, which spreads heat efficiently and maintains a consistent temperature using a thermostat and heat spreading elements like graphite-based materials, ensuring the asphalt patch remains warm and usable in cold conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heating unit is used to maintain asphalt patch temperature, then the asphalt patch can be properly applied in cold weather, but the device complexity increases
Solution Approach 1:
The heating unit is divided into multiple independent heating elements that can be arranged in a grid pattern around the pallet. Each heating element operates independently and can be controlled separately, allowing the system to maintain temperature without requiring a single complex heating mechanism. The segmented design enables modular assembly and easier maintenance.
Solution Approach 2:
The patent introduces a controller as an intermediary component that manages the heating elements based on temperature sensor feedback. This intermediary layer simplifies the overall system by automating temperature regulation, eliminating the need for manual intervention, and coordinating multiple heating elements to work together efficiently.
2Temperature
If heating elements are distributed around the pallet perimeter, then heat coverage is improved, but the device complexity increases
Solution Approach 1:
The heating system is segmented into multiple identical heating elements positioned at regular intervals around the pallet perimeter. This segmentation provides uniform heat distribution across all sides of the pallet, ensuring consistent temperature maintenance for asphalt patches applied at different locations.
Solution Approach 2:
Each heating element is positioned to provide localized heating at specific areas around the pallet, with the density and positioning of elements optimized for local heat requirements. The controller adjusts individual element operation based on local temperature conditions, providing targeted heating where needed most.
3Loss of energy
If insulation material is added to retain heat, then energy efficiency is improved, but the device complexity increases
Solution Approach 1:
The insulation material is merged with the heating unit structure itself, forming an integrated assembly where the heating elements, insulation, and support structure become a single unified component. This merging eliminates the need for separate insulation installations and simplifies the overall device while maintaining heat retention effectiveness.
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 modular heating unit effectively maintains the asphalt patch at the necessary temperature, ensuring it remains pliable and can be properly applied to potholes even in cold weather, addressing the issue of temperature maintenance and application efficiency.
Implementation Method 1
The heating unit includes a heating element which provides heat and spreads the heat over the surface of at least portions of the heating unit
Implementation Method 2
The heating unit may also include an insulation layer to prevent heat from being lost to an environment external to the pallet
Implementation Method 3
maintains a consistent temperature using a thermostat and heat spreading elements like graphite-based materials
Data Source
AI summary
A heating unit for use in heating buckets or barrels. The heating unit includes a first pliable cover layer and a second pliable cover layer. A pliable electrical heating element is disposed between the first and the second cover layers and configured to convert electrical energy to heat energy and to distribute the heat energy. The pliable electrical heating element includes a heat generating element for converting electrical current to heat energy and a heat spreading element comprising carbon thermally coupled to the heat generating element. The heating unit further includes a thermal insulation layer. The heating unit includes a receiving power connector electrically connected to the heat generating element. The heating unit further includes one or more fasteners allowing the heating unit to be wrapped around a bucket or barrel and secured by the one or more fasteners.