Printed heater elements integrated in construction materials
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Solution Overview
Problem
Conventional heating systems for buildings take up significant space and require additional installation steps, are not easily adaptable to walls and ceilings, and lack flexibility in configuration.
Innovation Solution
Integration of a heating element comprising a PTC composition layer, adhesive layer, substrate, and connector within construction materials, allowing for space-efficient, flexible, and simplified installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional heating systems (radiators, stoves, electrical heaters) are used, then heating function is provided, but they take up significant space and are always visible
Solution Approach 1:
The heating element is merged with the construction material (floor, wall, or ceiling) itself, making the construction material serve dual purposes: structural support and heating function. This eliminates the need for separate heating devices that occupy additional space.
Solution Approach 2:
The construction material is given multiple functions: it serves as both the structural building material and the heating element. The heating system becomes an intrinsic part of the construction material rather than an add-on component.
2Volume of moving object
If water based floor heating system is installed, then space is reduced compared to radiators, but the floor is lifted 5 cm or more and additional construction steps are required
Solution Approach 1:
The heating element is combined with the construction material in a single integration step during manufacturing, eliminating the need for separate installation stages and reducing construction complexity.
Solution Approach 2:
The heating element is pre-integrated into the construction material during manufacturing, so that when the construction material is installed, the heating system is already in place, eliminating the need for subsequent installation steps.
3Device complexity
If printed heater foils are used, then space is reduced and installation is simplified, but the configuration must be set before installation and furniture cannot be moved
Solution Approach 1:
The heating system transitions from a static, pre-configured foil to a dynamic system where the construction material with integrated heating can be adapted to different configurations and furniture arrangements after installation.
Solution Approach 2:
The construction material with integrated heating element serves as a universal solution that can be applied in various configurations and locations, providing both structural and heating functions while maintaining flexibility in room arrangement.
4Volume of moving object
If heating element is integrated into construction material, then space is optimized and installation is simplified, but the heating element must be embedded between construction material and substrate
Solution Approach 1:
The heating element, adhesive layer, substrate, and construction material are merged into a single integrated unit during manufacturing, simplifying the overall manufacturing process despite the multi-layer structure.
Solution Approach 2:
The heating system is manufactured as a composite structure combining the construction material, heating element, adhesive layer, and substrate into a single multi-material assembly that functions as one integrated product.
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 integrated heating system occupies no additional space, reduces installation complexity, and provides energy savings with intrinsic overheating protection.
Implementation Method 1
A thin layer of a resistive (FTC) 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
heating elements comprising positive temperature coefficient material (PTC)... The resistive (PTC) carbon ink (30) will heat up when a voltage is applied between the busbar electrodes
Data Source
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.