PTC Heater-ink Polymer Wet-Use Plane Heater
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Solution Overview
Problem
Conventional wet-use plane heaters face issues with leakage current and induced current due to moisture permeability and waterproofing properties of polyethylene terephthalate (PET) films, leading to safety concerns and inefficiencies in heating, especially when used in wet installations.
Innovation Solution
A wet-use plane heater utilizing a positive temperature coefficient (PTC) constant heater-ink polymer combined with multi-walled carbon nanotubes, featuring a laminated structure with polypropylene (PP) films and ester-based nonwoven fabrics to minimize leakage current, and using a double-sided adhesive tape for secure attachment, along with a gravure copper plate and polyurethane for heat treatment to enhance insulation and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PET film is used for electrical insulation and flame retardant in a plane heater, then electrical insulation and flame retardancy are improved, but leakage current increases rapidly due to moisture permeability and waterproofing properties in wet installation
Solution Approach 1:
The patent uses a composite structure combining PET film with polypropylene (PP) film and ester-based nonwoven fabric. The PP film provides enhanced moisture resistance while the nonwoven fabric layer improves adhesion to the cement mortar floor, creating a multi-layer composite that maintains electrical insulation while reducing leakage current in wet installation environments
Solution Approach 2:
The ester-based nonwoven fabric acts as an intermediary layer between the PET/PP film composite and the cement mortar floor. This intermediate layer improves adhesion and creates a barrier that prevents direct contact between moisture from the floor and the insulating film, thereby reducing leakage current while maintaining electrical insulation properties
2Adaptability or versatility
If a wire heater is used for wet installation, then installation flexibility is improved, but thermal efficiency is low due to line heating and power consumption is relatively high
Solution Approach 1:
The patent replaces the traditional wire heater (mechanical heating element) with a plane heater structure that uses a thin-film heating element embedded in a multi-layer composite. This substitution eliminates line heating effects while maintaining installation flexibility, resulting in improved thermal efficiency and reduced energy loss
3Loss of energy
If a carbon-based plane heater is used, then thermal efficiency is improved, but resistance value changes significantly due to repeated use and overheating phenomenon occurs
Solution Approach 1:
The patent changes the material parameters by replacing carbon-based conductive particles with a PTC (positive temperature coefficient) constant heater-ink polymer. This material maintains stable resistance values during repeated use and prevents overheating through self-regulating properties, while preserving the thermal efficiency benefits of plane heater design
4Area of stationary object
If the PET film of the plane heater has a wider installation floor surface, then installation coverage is improved, but moisture or condensation generation increases due to waterproofing properties
Solution Approach 1:
The patent employs a multi-layer composite material structure where the PP film and ester-based nonwoven fabric work together to provide waterproofing properties. This composite structure allows for wider installation floor surface coverage while managing moisture and condensation generation through the synergistic properties of the different material layers
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 effectively reduces the risk of electrical fires and power consumption while ensuring stable and uniform heating, improving flexibility and thermal efficiency, and enabling safe wet installations by minimizing leakage and induced currents.
Implementation Method 1
a constant heater using a positive temperature coefficient (PTC) constant heater-ink polymer
Implementation Method 2
a gravure copper plate and polyurethane for heat treatment to enhance insulation and adhesion
Data Source
AI summary
Provided is a wet-use plane heater using a positive temperature coefficient (PTC) constant heater-ink polymer, wherein the wet-use plane heater has unique characteristics in that it may not only be safe from the damage to the heater and the risk of fire due to self-temperature control characteristics, but a plane heater, which has been mainly installed in dry-use applications due to limitations of leakage current and induced current caused by an increase in contact area with an installation floor, may also be used for wet installation which uses a mortar.