PTC Heater Layers Embedded in Construction Materials
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Solution Overview
Problem
Conventional heating methods require significant space and additional installation steps, and existing integrated heating solutions, like printed heater foils, are inflexible and require pre-configuration of the room layout.
Innovation Solution
Integration of a Positive Temperature Coefficient (PTC) material-based heating element into construction materials such as floor, wall, and ceiling elements, allowing for space-efficient, flexible, and simplified installation by embedding a PTC composition layer and busbars within the construction materials, which can be activated by voltage to provide heating without additional space or visible components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional heating methods (water radiators, stoves, electrical heaters) are used, then heating function is provided, but they take up a lot of space and are always visible
Solution Approach 1:
The heating element is merged with the construction material (floor, wall, or ceiling) by integrating the PTC composition layer directly into the material structure. This combining eliminates the need for separate heating devices and reduces the space they occupy, while the construction material itself serves as the housing and mounting structure.
Solution Approach 2:
The construction material serves multiple functions: it provides structural support, insulation, and simultaneously acts as the housing for the heating element. The PTC composition layer integrated into the construction material performs both the heating function and the structural function of the floor/wall/ceiling.
2Volume of moving object
If water based floor heating system is used, then space is reduced, but it lifts the floor 5 cm or more and requires additional construction steps
Solution Approach 1:
The heating element uses a thin PTC composition layer (few micrometers to millimeters thick) that can be integrated into the construction material without significantly increasing its thickness. This thin-film approach contrasts with water-based systems that require thick piping layers, enabling integration while maintaining minimal thickness increase.
3Volume of moving object
If printed heater foils are used, then space is reduced, but the system is inflexible and requires pre-configuration of room layout
Solution Approach 1:
The heating system becomes dynamic and adaptable because the PTC composition layer can be integrated into construction materials that are installed in various configurations. The system can adapt to different room layouts, furniture arrangements, and construction preferences, unlike fixed printed foils that require pre-planned layouts.
Solution Approach 2:
The construction material with integrated PTC heating serves as a universal solution that can be applied to floors, walls, and ceilings, and can be configured in different patterns and layouts during the construction process itself, providing both space efficiency and installation flexibility.
4Ease of manufacture
If water pipes or electrical cables are integrated into construction elements, then heating function is provided, but air vents and other construction alterations are required
Solution Approach 1:
The PTC composition layer is extracted from separate heating device components and directly incorporated into the construction material matrix. This extraction eliminates the need for separate air vents, cable conduits, and other auxiliary construction elements that would be required for water pipes or electrical cables.
Solution Approach 2:
The heating function is merged directly into the construction material by integrating the PTC composition layer within the material structure itself. This merging eliminates the need for separate air vents, cable management systems, and other construction alterations that would be required for traditional water-based or cable-based heating systems.
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 provides a space-efficient, flexible, and simplified heating system that reduces energy consumption and offers intrinsic safety against overheating, as the PTC material regulates temperature without the need for additional electronic circuits, and can be seamlessly integrated into construction elements without increasing their thickness.
Implementation Method 1
A thin layer of a resistive (PTC) carbon ink (30) is applied in-between the busbars. The resistive (PTC) carbon ink (30) will heat up when a voltage is applied between the busbar electrodes.
Implementation Method 2
printed heater foils having PTC characteristic
Implementation Method 3
the PTC material regulates temperature without the need for additional electronic circuits
Data Source
Figure 1(a)~3
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Figure 7~9
AI summary
The present invention relates to a heating element, which is integrated into the construction material. Integration of the heating element according to the present invention into the construction material limits space needed for the heating system. In addition, the used heating element provides reduced power consumption compared to conventional technologies. A construction element according to the present invention comprises a construction material, a heating element comprising a foil comprising a PTC composition layer or a PTC composition layer, at least one adhesive layer, a substrate and a connector, wherein said heating element is embedded between said construction material and said substrate, and wherein said PTC layer comprises a semi-crystalline material, at least one binder and an electronically conductive material.