Thermal Blanket Coating and Heating Layer Integration
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Solution Overview
Problem
Existing thermal blankets require a complex manufacturing process and are material-intensive due to their multi-layer design, while still needing an impermeable outer layer for functionality, which cannot be dispensed with.
Innovation Solution
Incorporating conductive threads into the intermediate layer to generate heat through current flow, eliminating the need for a separate hot air source and using a polyurethane coating directly applied to the intermediate layer to replace the outer layer, creating a more efficient and simplified structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-layer design with separate inner layer, intermediate layer, and outer layer is used, then the thermal blanket achieves air permeability, pressure relief, and moisture impermeability, but the manufacturing process becomes complex and material-intensive
Solution Approach 1:
The patent combines the intermediate layer and outer layer into a single integrated layer. This integrated layer contains conductive threads for heat generation, spacer structures for air circulation and pressure relief, and a polyurethane coating for moisture impermeability, thereby eliminating the need for a separate outer layer while maintaining all necessary functions
Solution Approach 2:
The integrated layer serves multiple functions simultaneously: it provides structural support and pressure relief through spacer structures, generates heat through conductive threads, enables air circulation for convective heating, and prevents moisture penetration through the polyurethane coating. This multi-functional design reduces overall system complexity
2Reliability
If a separate outer layer with polyurethane coating is used, then moisture impermeability and air tightness are ensured, but material consumption increases and production becomes more intensive
Solution Approach 1:
The polyurethane coating is applied directly to the integrated layer, merging the moisture protection function with the structural layer. This eliminates the need for a separate outer layer, reducing material consumption while ensuring moisture impermeability and air tightness through the coating
Solution Approach 2:
The polyurethane coating forms a thin film on the integrated layer that provides effective moisture and air barrier properties. This thin film approach achieves the required protection with minimal material addition
3Device complexity
If conductive threads are integrated into the intermediate layer for heat generation, then a separate hot air source is eliminated, but the structure becomes more complex
Solution Approach 1:
The conductive threads integrated into the intermediate layer enable the blanket to generate its own heat through electrical current, making the system self-sufficient. This eliminates the need for external hot air sources and associated infrastructure, achieving energy independence despite the added complexity of electrical integration
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 solution reduces material intensity, simplifies production, and maintains pressure-relieving and heat-conductive properties, ensuring effective temperature control without the need for a separate outer layer, while providing a self-sustaining heat source and improved insulation.
Implementation Method 1
The intermediate layer or intermediate layer is provided with conductive threads. The advantage of providing the intermediate layer or intermediate layer with conductive threads is that there is no need for a hot air source. Rather, the heat is generated by the current flowing through the conductive threads.
Implementation Method 2
an air- and moisture-impermeable coating is applied to the intermediate layer, the intermediate layer being arranged between the coating and the inner layer
Implementation Method 3
at least one inner layer which faces the body to be warmed by means of the warming blanket and is designed to be permeable to warm air; The thermal underlay is placed on and under the body with its inner layer facing the body and not only insulates it, but warms it convectively, i.e. with warm air flowing out.
Implementation Method 4
as an intermediate layer, at least one spacer/supporting fabric or knitted fabric, in particular at least one fabric made of chemical fibers or a polyester fabric or knitted fabric, for letting through, for conducting, for flowing through and/or for transporting the warm air
Data Source
Figure 1
Figure 2a~2b
AI summary
The present invention relates to a thermal counterpane (100), in particular a thermal sheet, having at least one inner layer (14) which faces the body to be warmed by means of the thermal counterpane (100) and is designed to be permeable to the warm air; and at least one intermediate layer (16) through which the warm air passes, is conducted, flows and/or is transported. In order, in the case of thermal counterpanes, to replace an outer layer which is composed of polyester and polyurethane, the invention proposes applying a coating to the intermediate layer (16).