Welded PTC Heater Assemblies for Aircraft Floor Panels
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Solution Overview
Problem
Existing heated floor panel assemblies in aircraft face challenges with multiple layers of film adhesives that hinder heating ability and create insulation and fire resistance issues due to the use of positive temperature coefficient (PTC) heaters.
Innovation Solution
The use of a PTC heater element sandwiched between two thin thermoplastic dielectric layers, which are welded together to secure the heater, eliminating the need for traditional adhesives and allowing for efficient heat transfer while maintaining structural integrity and meeting fire safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple layers of film adhesives are used to secure the PTC heater, then the heater is securely attached to the floor panel, but the heating ability is hindered and fire resistance challenges arise
Solution Approach 1:
The patent removes the adhesive layer entirely from the heater assembly. Instead of using multiple layers of film adhesives to secure the PTC heater, the invention uses a self-adhering PTC heater element with a pressure-sensitive adhesive layer that bonds directly to the dielectric layer, eliminating the separate adhesive layers and their associated insulation and fire resistance problems.
Solution Approach 2:
The patent introduces a dielectric layer as an intermediary between the PTC heater element and the floor panel structure. This dielectric layer serves multiple functions: it provides electrical insulation, thermal management, and structural support, replacing the need for separate adhesive layers while maintaining secure attachment.
2Strength
If multiple layers of film adhesives are used to secure the PTC heater, then the heater is securely attached to the floor panel, but heat transfer efficiency is reduced due to unwanted insulation
Solution Approach 1:
The patent removes the adhesive layer entirely from the heater assembly. Instead of using multiple layers of film adhesives to secure the PTC heater, the invention uses a self-adhering PTC heater element with a pressure-sensitive adhesive layer that bonds directly to the dielectric layer, eliminating the separate adhesive layers and their associated insulation and fire resistance problems.
Solution Approach 2:
The patent changes the thermal properties of the interface between the heater and floor panel by eliminating the adhesive layers. The direct bond between the PTC heater element and dielectric layer creates a thermal pathway with lower resistance, improving heat transfer efficiency while maintaining structural integrity.
3Ease of manufacture
If traditional adhesives are used to attach the heater, then the assembly is simple to manufacture, but fire safety standards are compromised
Solution Approach 1:
The patent removes the adhesive layer entirely from the heater assembly. Instead of using multiple layers of film adhesives to secure the PTC heater, the invention uses a self-adhering PTC heater element with a pressure-sensitive adhesive layer that bonds directly to the dielectric layer, eliminating the separate adhesive layers and their associated insulation and fire resistance problems.
Solution Approach 2:
The patent uses a pressure-sensitive adhesive layer that is integrated into the PTC heater element itself, rather than requiring separate, durable adhesive layers. This integrated adhesive provides sufficient bonding for the application while being simpler and more fire-resistant than traditional multi-layer adhesive systems.
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 configuration enhances heat transfer efficiency, maintains structural integrity, and meets stringent fire, smoke, and toxicity requirements, providing a more reliable and efficient heating solution for aircraft cabin temperature regulation.
Implementation Method 1
a second dielectric layer overlaying and welded to the positive temperature coefficient heater element
Implementation Method 2
positive temperature coefficient heater element on the first dielectric layer
Implementation Method 3
two thin thermoplastic dielectric layers, which are welded together to secure the heater, eliminating the need for traditional adhesives and allowing for efficient heat transfer
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A heated floor panel assembly (30) contains a positive temperature coefficient heater secured in the assembly through a number of welded joints through a thermoplastic dielectric layer. The positive temperature coefficient heater is on a thermoplastic substrate, which is bonded to the thermoplastic dielectric layer. The assembly further includes an impact layer (48), a core layer (38), and structural layers.