Heating panel and method therefor
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Solution Overview
Problem
The existing methods for manufacturing and installing heating panels in building constructions are costly, labor-intensive, and prone to issues such as high temperatures causing gypsum degradation, warping of structural timber, and difficult termination of electrical circuits.
Innovation Solution
A method involving the continuous deposition of heating elements and electrical conductor members along the sides of a wallboard feed, with transverse conductor members for easy termination, and the use of settable gypsum slurry with porous sheet materials to facilitate even heating and reduce installation complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heating panels are installed behind ceiling wallboards, then heating effect is achieved, but high temperatures cause gypsum to lose integrity and degenerate
Solution Approach 1:
The heating panel is segmented into multiple heating zones with independent temperature control, allowing different regions to operate at different temperatures. This prevents any single zone from reaching temperatures that would degrade gypsum while maintaining overall heating effectiveness.
Solution Approach 2:
The patent implements local quality control by providing temperature regulation specific to different regions of the heating panel. This ensures that temperatures remain within safe ranges for gypsum materials while achieving effective heating in occupied spaces.
2Ease of manufacture
If moulded heating panels are manufactured manually, then heating elements are integrated into wallboards, but production is expensive and difficult to automate
Solution Approach 1:
Heating elements are pre-assembled and tested before being integrated into the wallboard manufacturing process. This preliminary preparation enables automated integration into the continuous production line, improving both ease of manufacture and production rate.
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated placement and integration systems. This substitution enables continuous production while maintaining precise integration of heating elements into wallboards.
3Reliability
If electrically heated panels with embedded circuits are used, then heating is achieved, but short circuit breaks are difficult to establish and locate
Solution Approach 1:
The heating panel incorporates monitoring systems that provide feedback on the status of heating elements and electrical circuits. This enables real-time detection of faults and provides information for locating issues without requiring complex diagnostic procedures.
Solution Approach 2:
The patent incorporates visual indicators that change color or provide visual signals to indicate the status of heating zones and detect faults. This makes fault detection straightforward through visual inspection rather than complex electrical testing.
4Temperature
If structural timber is exposed to high heat above ceiling wallboards, then heating effect is achieved, but timber dries out and shrinks causing warping
Solution Approach 1:
The patent introduces thermal insulation materials as intermediaries between the heating panel and the structural timber. This intermediary layer allows heat to be distributed effectively for heating purposes while preventing excessive temperatures from reaching the timber, thereby maintaining timber stability and preventing warping.
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 approach reduces production costs, minimizes gypsum degradation, prevents structural damage, and simplifies the installation process by allowing for efficient heat distribution and easy electrical connections.
Implementation Method 1
heating panels that operate on electrical resistivity
Implementation Method 2
a first outer layer of porous sheet material and a second outer layer of porous sheet material
Data Source
Figure 1
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AI summary
A radiant heating panel, for typical use as cover for interior walls and ceilings, is provided, that is manufactured in a continuous process involving at least one sheet material, a settable material and a heating element. A method of installing such a heating panel is also provided, along with an apparatus and method required to terminate the heating panel.