Wet Planar Heating Element Air Pockets Leakage Current
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Solution Overview
Problem
Conventional planar heating elements used in wet construction face issues with high power consumption, risk of electrical fires due to local overheating, and increased leakage current, which complicates maintenance and safety.
Innovation Solution
A wet planar heating element is designed with a structure comprising an upper and lower waterproof film layer, a planar heating layer, and non-woven fabric layers with multiple pores and surface irregularities, forming air pockets to minimize leakage current and enhance flexibility, allowing for effective wet construction and reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If a wire heater is used for wet construction, then heating function is provided, but power consumption is high due to low thermal efficiency
Solution Approach 1:
The patent uses a non-woven fabric layer with porous structure as a substrate for the heating element. The porous structure provides thermal insulation while maintaining flexibility and conformability to floor surfaces, thereby improving thermal efficiency and reducing power consumption compared to conventional wire heaters
Solution Approach 2:
The heating element is constructed as a composite structure combining non-woven fabric substrate, heating wire, waterproof film, and air pockets. This composite design optimizes both thermal efficiency and electrical insulation properties, addressing the energy consumption issue while maintaining heating functionality
2Reliability
If a wire heater with serial circuit configuration is used, then heating is provided, but when one circuit is opened the entire heating element stops working and maintenance is difficult
Solution Approach 1:
The heating element is divided into multiple independent heating zones or modules that can function independently. If one section fails, others continue to operate, improving reliability and facilitating easier maintenance by allowing replacement of only the defective segment
3Ease of operation
If a planar heating element with PET film is used for wet construction, then heating function is provided, but leakage current increases suddenly causing earth leakage circuit breaker to operate
Solution Approach 1:
A non-woven fabric layer is introduced as an intermediary between the heating element and the waterproof film. This fabric layer acts as an electrical insulation barrier that reduces leakage current while still allowing thermal conduction and maintaining flexibility for wet construction applications
Solution Approach 2:
Air pockets are incorporated into the structure of the heating element, creating an inert electrical environment. The air layers provide additional electrical insulation, reducing leakage current and preventing earth leakage circuit breaker operation while maintaining heating functionality
4Adaptability or versatility
If conventional planar heating element structure is used, then heating is provided, but flexibility is limited
Solution Approach 1:
The heating element uses a non-woven fabric substrate and thin film structures instead of rigid materials. This enables the heating element to be flexible and conformable to various floor surfaces and shapes, improving adaptability for different construction applications while maintaining structural integrity
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 solution effectively reduces leakage current, lowers the risk of electrical fires, and improves the flexibility of the heating element, enabling safer and more efficient wet construction applications.
Implementation Method 1
non-woven fabric layers with multiple pores and surface irregularities, forming air pockets to minimize leakage current
Implementation Method 2
a planar heating layer interposed between the upper waterproof film layer and the lower waterproof film layer
Data Source
AI summary
The present invention relates to a wet planar heating element and a method manufacturing the same. The element including: a planar heating unit including an upper waterproof film layer, a lower waterproof film layer, a planar heating layer, and an electrode layer; an external waterproof film layer; and a non-woven fabric layer. According to the present invention, it is possible to minimize leakage current due to pores of a non-woven fabric substrate and a low dielectric constant of air in air pockets, thereby solving problems that an earth leakage circuit breaker operates. Accordingly, wet construction can be performed, power consumption can be reduced, and an electrical fire risk can be remarkably lowered. In addition, it is possible to improve flexibility of the planar heating element, whereby the use of the planar heating element can be expanded and the efficiency of the construction work can be increased.