Waterproof Heating Pad Polymer Encapsulation Method
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Solution Overview
Problem
The existing methods for manufacturing waterproof heating mats, which involve gluing heating films to pre-existing mats, limit size and shape variability, lead to heating inefficiencies, and potential failure modes due to inconsistent glue application and performance degradation over time.
Innovation Solution
A method involving dispensing liquid polymer onto a conveyor belt, partially curing it, placing a heating film, and encapsulating it with a second layer of polymer to form a waterproof heating mat, allowing for uniform shape creation and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heating films are glued to pre-existing waterproof mats, then the manufacturing process is simple, but the size and shape variability is limited
Solution Approach 1:
The patent combines the heating film and waterproof mat into a single integrated structure where the heating film is embedded within the waterproof mat material itself, rather than gluing separate components. This merging allows for unlimited size and shape variations since the heating elements are incorporated during the mat formation process, eliminating the constraints of matching pre-existing mat dimensions.
Solution Approach 2:
The heating film is positioned and secured within the waterproof mat before the mat is fully formed and cured. This preliminary action allows the heating elements to be embedded at the optimal location during the forming process, enabling custom sizes and shapes to be created without the limitations of post-manufacturing gluing methods.
2Ease of manufacture
If heating films are glued to waterproof mats, then assembly is straightforward, but heating efficiency is reduced
Solution Approach 1:
By merging the heating film with the waterproof mat into a single integrated structure, the patent eliminates gaps and interfaces between separate components. This integration ensures maximum thermal contact between the heating elements and the mat material, significantly improving heating efficiency while the combined structure is formed as one unit during manufacturing.
3Ease of manufacture
If glue is applied to secure heating films, then the heating film is attached to the mat, but potential failure modes increase
Solution Approach 1:
The patent extracts and eliminates the glue layer from the construction entirely. Instead of using adhesive to attach the heating film to the waterproof mat, the heating film is embedded within the mat material itself during the forming process. This removal of the glue component eliminates all associated failure modes such as inconsistent application, leakage, and degradation over time.
Solution Approach 2:
The patent replaces the temporary and degradable glue layer with a permanent integrated structure where the heating film becomes an intrinsic part of the waterproof mat. This eliminates the need for a separate attachment layer that would otherwise degrade over time under heat and moisture conditions.
4Ease of manufacture
If glue is used to attach heating films, then the heating film is secured, but performance degradation occurs over time
Solution Approach 1:
The patent removes the glue layer that causes performance degradation over time. By embedding the heating film within the waterproof mat material during formation, the heating elements remain permanently secured without any adhesive that could deteriorate under repeated heating and moisture exposure, ensuring long-term performance durability.
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 method enables the production of waterproof heating mats with enhanced size and shape flexibility, reduced risk of failure, and improved heating efficiency by encapsulating the heating elements within polymer layers, ensuring consistent performance.
Implementation Method 1
partially curing the first amount of liquid polymer to form a first layer; curing the second amount of liquid polymer to form a second layer
Implementation Method 2
These heating films often include heating elements such as rows of carbon ink positioned between bus bars extending longitudinally across the film
Data Source
AI summary
A method of manufacturing a waterproof heating mat includes pouring a first amount of a liquid polymer onto a surface of a conveyer belt; partially curing the first amount of liquid polymer to form a first layer; placing a heating film on the first layer such that at least one side of the heating film is covered by the first layer; pouring a second amount of the liquid polymer onto the heating element and the first layer; and curing the second amount of liquid polymer to form a second layer, the second layer contacting the first layer to at least partially encapsulate the heating element between the first layer and the second layer.