PCM Floor Mat Heating System for Industrial Vehicle Cabin
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Solution Overview
Problem
Existing heating systems for industrial vehicle cabin floors lack efficient temperature control and high efficiency, leading to discomfort and increased fuel consumption due to inconsistent heating and prolonged operation times.
Innovation Solution
A heating system utilizing a serpentine heat exchanger, Phase Change Material (PCM) floor mats, and a two-position control valve to manage thermal energy storage and release, ensuring consistent cabin temperature through a feedback control mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional heating systems are used without thermal energy storage, then the heating system can operate continuously to maintain cabin temperature, but fuel consumption increases and the system cannot provide consistent temperature control
Solution Approach 1:
The system pre-heats the PCM thermal energy storage elements during periods when heating is needed, storing thermal energy in advance. This preliminary action allows the system to release stored heat later, maintaining consistent cabin temperature without continuous operation and reducing fuel consumption.
Solution Approach 2:
The invention changes the physical state parameter of the PCM material between solid and liquid phases to store and release thermal energy. By utilizing phase change transitions, the system can accumulate and discharge large amounts of thermal energy, enabling consistent temperature control while reducing the need for continuous heating operation.
2Reliability
If the heating system operates continuously to maintain consistent temperature, then temperature control is improved, but the runtime increases leading to higher fuel consumption
Solution Approach 1:
The system utilizes phase transitions of PCM materials (solid-liquid transitions) to store thermal energy during heating operation and release it during cooling periods. This allows the heating system to operate intermittently rather than continuously, reducing runtime and fuel consumption while maintaining consistent cabin temperature through the thermal buffer provided by the phase-changing material.
3Productivity
If no thermal energy storage is implemented, then the system structure remains simple, but the heating efficiency is low and temperature control is poor
Solution Approach 1:
The PCM thermal energy storage elements act as an intermediary between the heating system and the cabin environment. They absorb excess heat during heating operation and release it during cooling, mediating temperature fluctuations and improving heating efficiency. This intermediary component enhances system performance without requiring complex control mechanisms.
Solution Approach 2:
The invention integrates PCM materials with the floor mat structure, creating a composite thermal energy storage system. The PCM is encapsulated within the floor mat assembly, combining structural and thermal storage functions in a single integrated component. This approach improves heating efficiency while minimizing additional structural complexity.
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 provides enhanced comfort by maintaining a constant floor temperature, reduces fuel consumption by minimizing heating system runtime, and extends the off-time of the heating system, thereby optimizing energy efficiency.
Implementation Method 1
the mat 16 contains a plurality of energy-storing elements 17 made of a PCM material that changes its aggregation state from solid to liquid (Phase Change Material) by receiving heating energy from the serpentine 13 thus storing thermal energy; the stored thermal energy in the material is given back towards the exterior of the floor mat 16 when the material changes its aggregation state from liquid to solid
Implementation Method 2
The serpentine 13 is placed over a floor of the cabin an lies in a substantially flat plane... receiving heating energy from the serpentine 13
Data Source
Figure 1
Figure 2~4
AI summary
Heating system for a floor of a cabin of an industrial vehicle, wherein a control valve (11) interposed along a return conduct (9) of a cabin heating system (4) is movable between a first position establishing a direct return of the fluid and a second position where at least part of the fluid flowing thought the control valve (11) is diverted to an input (13-a) of a serpentine (13) placed over a floor of the cabin and integrated with a cabin floor mat (16) and containing a plurality of energy-storing elements (17) made in a material that changes its aggregation state from solid to liquid and vice versa by receiving/delivering heating energy. The control valve (11) is set in the second position when a detected mat temperature Tmat falls below a first limit Tlow so that a first energy storing phase is realized and the thermal energy of the fluid flowing in the serpentine (13) is transferred to said energy-storing elements (17) changing their aggregation state from solid to liquid. The control valve (11) is set in the first position when the detected mat temperature Tmat overcomes a second upper limit Thigh so that a second energy delivery phase is realized and the thermal energy previously stored in the energy-storing elements (17) is supplied to the exterior of the mat (16) when the energy-storing elements (17) change their aggregation state from liquid to solid.