PTC Heated Floor Panel Structure for Impact and Ink Waste Reduction

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Solution Overview

Problem

Traditional heated aircraft floor panels made with carbon-based positive thermal coefficient (PTC) materials face issues with ink wastage, impact resistance, and knife cut vulnerability due to screen printing methods, which are inefficient and inadequate for withstanding repeated impacts and cuts.

Innovation Solution

A heater panel design featuring a core with a PTC heater layer sandwiched between dielectric layers and structural facings, using direct writing to minimize ink waste and enhance impact resistance, with carbon fiber-reinforced resin and impact layers for improved durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If screen printing is used to apply PTC ink, then the heating element pattern can be formed, but excessive ink is wasted and requires disposal

Engineering Contradiction:

Improveheating element pattern formationVSAvoidink waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent replaces the screen printing mechanical system with a direct write system that deposits PTC material directly onto the dielectric layer. This substitution eliminates the need for screens and excess ink application, achieving precise material placement without waste while still forming the required heating element pattern

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The direct write system applies PTC material only where needed on the dielectric layer before assembly, rather than applying excess material and removing it later. This preliminary precision placement prevents ink waste from the outset while ensuring the heating element pattern is correctly formed

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If traditional surface layer materials are used in composite panels, then the panel structure is simple, but the panel cannot withstand repeated or high load impacts and knife cuts

Engineering Contradiction:

Improvepanel structureVSAvoidimpact and knife cut resistance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent employs a composite structure with multiple specialized layers: a PTC heater layer for heating, dielectric layers for electrical insulation, and a polyurea impact layer for mechanical protection. This composite material approach provides superior impact and knife cut resistance compared to traditional single-material surface layers, while the layers are integrated through bonding to maintain structural coherence

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The polyurea impact layer is applied beforehand to the structural facing to provide protective cushioning against impacts and knife cuts. This pre-applied protective layer absorbs and distributes impact forces before they reach the underlying structural components, enhancing the panel's overall reliability without significantly increasing complexity

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If the heater/dielectric layer is bonded directly between the core and structural facing, then assembly is simplified, but the PTC heater layer must withstand direct mechanical bonding forces

Engineering Contradiction:

Improveassembly processVSAvoidPTC heater layer durability under bonding forces

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent introduces a close-out layer as an intermediary between the PTC heater/dielectric assembly and the structural facing. This close-out layer serves as a mediator that bonds to both the dielectric layer and the structural facing, protecting the PTC heater layer from direct exposure to mechanical bonding forces while enabling simplified assembly through this intermediate bonding interface

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution reduces ink waste, enhances impact and knife cut resistance, allows for contoured designs, and results in lighter, more robust, and longer-lasting heated panels.

Implementation Method 1

Positive thermal coefficient (PTC) materials increase in electrical resistance as their temperature rises. PTC materials are useful in heating panels such as used in heating air craft floors, due to their intrinsic limits on temperature.

Methodology Applied

Scientific EffectPositive thermal coefficient (PTC): Thermal Expansion

Implementation Method 2

The heater layer can be formed by direct writing a heating element pattern onto a dielectric layer bonded to the core.

Methodology Applied

Scientific EffectDirect writing: 3D Printing

Implementation Method 3

The heater/dielectric layer is bonded directly between the core and the structural facing.

Methodology Applied

Scientific EffectBonding: Adhesive

Data Source

PatentUS11499724B2Heated floor panels

Publication Date: 2022.11.15 GOODRICH CORP

AI summary

A heater panel includes a core and a heater/dielectric layer including a positive thermal coefficient (PTC) heater layer between a pair of dielectric layers. A structural facing is included, wherein the heater/dielectric layer is bonded directly between the core and the structural facing. A second structural facing can be bonded to the core opposite the heater/dielectric layer. An impact layer can be bonded to the structural facing, e.g., the first structural facing described above, opposite the heater/dielectric layer. The heater layer can be formed by direct writing a heating element pattern onto a dielectric layer bonded to the core.