Electrically conductive silicone gel electric heating module

Abstract

This invention belongs to the field of gear life assessment technology. It provides a conductive silicone heating module, belonging to the field of electrothermal equipment technology, comprising an aluminum silicate backplate, a conductive silicone heating film, fiberglass cloth, and a heat-conducting working surface. The aluminum silicate backplate, conductive silicone heating film, fiberglass cloth, and heat-conducting working surface are sequentially stacked and encapsulated to form the heating module. A wired electrode and a surface-mount thermal resistor are provided on the aluminum silicate backplate. The wired electrode and the surface-mount thermal resistor respectively achieve energization and temperature detection when the aluminum silicate backplate contacts the conductive silicone heating film. This invention forms a uniform heating network through continuous conductive silicone heating films and integrates temperature detection functionality, effectively avoiding the problems of low heat transfer efficiency and uneven temperature distribution caused by the discrete distribution of traditional heating wires.

Description

Technical Field

[0001] This invention belongs to the field of electric heating equipment technology, specifically a conductive silicone electric heating module. Background Technology

[0002] In existing technologies, silicone heating modules typically use silicone material as a flexible insulating layer, embedding heating wires as heating elements, and employing an external thermal resistor for temperature monitoring. When powered on, the heating wires generate heat, with the silicone layer handling insulation and some heat conduction. However, because the heating wires are discretely distributed within the silicone matrix, a continuous heating network cannot be formed. Furthermore, the limited thermal conductivity of silicone itself leads to low heat transfer efficiency. This structure results in significantly uneven temperature distribution on the module surface, with some areas overheating while others remain too cold, severely impacting heating uniformity. Simultaneously, the slow thermal response of silicone delays the heating process after power-on, preventing timely attainment of the target temperature and resulting in overall low thermal efficiency. Regarding temperature control, the external thermal resistor can only detect the temperature at specific points, failing to accurately capture the overall temperature change trend of the module, leading to a sluggish temperature control system and insufficient adjustment precision. Summary of the Invention

[0003] The purpose of this application is to provide a conductive silicone heating module that solves the technical problems of low heat transfer efficiency and uneven temperature distribution caused by the discrete distribution of traditional heating wires.

[0004] The technical solution adopted by this invention to solve its technical problem is: a conductive silicone heating module, comprising an aluminum silicate backplate, a conductive silicone heating film, fiberglass cloth, and a heat-conducting working surface; the aluminum silicate backplate, the conductive silicone heating film, the fiberglass cloth, and the heat-conducting working surface are sequentially stacked and encapsulated to form the heating module; the aluminum silicate backplate is provided with a wiring electrode and a surface-mount thermal resistor, which respectively realize energization and temperature detection when the aluminum silicate backplate contacts the conductive silicone heating film.

[0005] Furthermore, the conductive silicone heating film is made of thermally conductive silicone, in which conductive fillers are uniformly dispersed, giving the conductive silicone heating film a predetermined resistance value.

[0006] Furthermore, the wiring electrode is configured as two pieces, both of which are fixedly mounted on the aluminum silicate back plate, and are used to energize the conductive silicone heating film when the aluminum silicate back plate comes into contact with the conductive silicone heating film.

[0007] Furthermore, the conductive silicone heating film is an independent component, not connected to any accessories, and the heat-conducting working surface is detachably encapsulated on top of the fiberglass cloth.

[0008] Furthermore, the thickness of the conductive silicone heating film does not exceed 2.5 mm.

[0009] Furthermore, a high-temperature resistant adhesive is provided on the side of the fiberglass cloth facing the heat-conducting working surface, and the fiberglass cloth is adhered to the heat-conducting working surface by the high-temperature resistant adhesive.

[0010] Furthermore, the raw materials for the conductive silicone heating film, by weight, include: 100 parts silicone rubber compound, 8-25 parts conductive carbon black, 80 parts spherical alumina, 20 parts active magnesium oxide, and 2 parts calcium oxide.

[0011] Furthermore, the conductive silicone heating film is made from the formulated raw materials through mixing, calendering, continuous vulcanization of rolls using a drum vulcanizing machine, and cutting.

[0012] The beneficial effects of this invention are as follows: The aluminum silicate back plate is provided with wiring electrode plates and surface-mount thermal resistors to realize power supply and temperature detection. A uniform heating network is formed by a continuous conductive silicone heating film and the temperature detection function is integrated. This effectively avoids the problems of low heat transfer efficiency and uneven temperature distribution caused by the discrete distribution of traditional heating wires. At the same time, it improves the thermal response speed and temperature control accuracy, and has the advantages of uniform heating, rapid thermal response and precise temperature control. Attached Figure Description

[0013] The invention will now be further described with reference to the accompanying drawings.

[0014] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0015] In the diagram: 1. Conductive silicone heating film; 2. Fiberglass cloth; 3. Thermally conductive working surface; 4. Wiring electrode plate; 5. Surface mount resistance thermometer; 6. Aluminum silicate backplate. Detailed Implementation

[0016] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0017] Please see Figure 1 As shown, this embodiment of the invention provides a conductive silicone heating module, including an aluminum silicate backplate 6, a conductive silicone heating film 1, a fiberglass cloth 2, and a thermally conductive working surface 3. The aluminum silicate backplate 6, the conductive silicone heating film 1, the fiberglass cloth 2, and the thermally conductive working surface 3 are sequentially stacked and encapsulated to form the heating module. The aluminum silicate backplate 6 is provided with a wiring electrode 4 and a surface-mount thermal resistor 5. When the aluminum silicate backplate 6 contacts the conductive silicone heating film 1, the wiring electrode 4 and the surface-mount thermal resistor 5 respectively achieve energization and temperature detection. This module integrates the heating function into the silicone film itself, changing the physical structure of traditional heating wires and achieving surface heating, thereby effectively solving the aforementioned problems.

[0018] Specifically, the module includes an aluminum silicate backplate 6, a conductive silicone heating film 1, a fiberglass cloth 2, and a thermally conductive working surface 3. Alternatively, the backplate can be made of other materials, such as a metal plate or a common plastic plate. The heating element can be a traditional heating wire or a PTC ceramic heating element. The fiberglass cloth can be replaced by other insulating or reinforcing materials, such as mica sheets or common fabrics. The thermally conductive working surface can be made of other thermally conductive materials, such as an aluminum plate or a copper plate.

[0019] Furthermore, the aluminum silicate backplate 6, the conductive silicone heating film 1, the fiberglass cloth 2, and the thermally conductive working surface 3 are sequentially stacked and encapsulated to form the heating module. Alternatively, the components can be assembled in a non-stacked manner, such as by snap-fit, bolt connection, or individual fixing. They can also be non-sequentially stacked, for example, by placing the fiberglass cloth 2 below the conductive silicone heating film 1.

[0020] In addition, the aluminum silicate backplate 6 is provided with a wired electrode plate 4 and a surface-mount thermal resistor 5. As one implementation, the wired electrode plate 4 can be located on the edge or surface of the conductive silicone heating film 1. The surface-mount thermal resistor 5 can be another type of temperature sensor, such as a thermocouple, and can be located on the exterior of the module or on the thermally conductive working surface 3.

[0021] Thus, when the wire electrode 4 and the surface-mount resistor 5 contact the conductive silicone heating film 1 via the aluminum silicate backplate 6, they respectively achieve energization and temperature detection. As one implementation method, energization can be achieved by directly soldering wires to the conductive silicone heating film 1. Temperature detection can be achieved using a non-contact infrared sensor, or by embedding the resistor within the conductive silicone heating film 1.

[0022] The conductive silicone heating module of this embodiment achieves uniform surface heating by using the conductive silicone heating film 1 as the core heating element, effectively solving the problem of uneven heating in traditional heating modules. Simultaneously, its stacked encapsulation structure and direct contact energization and temperature measurement method significantly improve the energization-heating response speed and temperature control accuracy, thereby overcoming the limitations of low thermal efficiency and slow response of traditional modules, and providing a solution for applications requiring precise and uniform heating.

[0023] In some of the embodiments described above in this application, a conductive silicone heating film 1 is proposed to achieve electrothermal conversion. However, in the implementation process, the silicone material itself does not have conductive heating properties. If it cannot be given a specific resistance value, it cannot achieve the function of current passing through and heat generation, causing the heating module to malfunction.

[0024] In this regard, this application further proposes that the conductive silicone heating film 1 is made of thermally conductive silicone, and conductive filler is uniformly dispersed in the thermally conductive silicone, so that the conductive silicone heating film 1 has a predetermined resistance value.

[0025] Specifically, the thermally conductive silicone is a specially formulated silicone material that not only retains the inherent flexibility, weather resistance, and electrical insulation of silicone, but also significantly improves its thermal conductivity by introducing highly thermally conductive components. For example, it can be prepared by filling a silicone matrix with highly thermally conductive but electrically insulating ceramic particles such as alumina, boron nitride, or zinc oxide, or by optimizing the silicone molecular structure to enhance phonon transport efficiency. Its main function is to serve as the matrix material for the conductive silicone heating film 1, providing structural support and flexibility, and ensuring that heat can be efficiently conducted from the inside to the external working surface.

[0026] The conductive filler refers to materials added to thermally conductive silicone to impart electrical conductivity. These fillers themselves have good electrical conductivity and form a continuous conductive network within the silicone matrix. For example, carbon-based materials such as conductive carbon black, graphite, carbon nanotubes, or graphene can be used; metal-based materials such as silver powder, nickel powder, or copper powder can also be used; or metal-coated non-metallic particles such as nickel-plated graphite or silver-plated glass microspheres can be employed.

[0027] Uniform dispersion refers to the even distribution of conductive fillers within the thermally conductive silicone matrix, avoiding localized aggregation or sparse distribution. This can be achieved through thorough mixing using high-shear mixing equipment (such as internal mixers or two-roll mills) to ensure that the filler particles form uniform conductive pathways throughout the silicone system. Furthermore, surface treatment of the fillers can improve their compatibility with the silicone matrix, thereby enhancing dispersion uniformity.

[0028] The predetermined resistance value refers to the resistance value at which the conductive silicone heating film 1 generates a specific heating power when energized, based on the design requirements of the heating module and by precisely controlling the type and content of the conductive filler and the geometric dimensions (such as thickness) of the conductive silicone heating film 1. For example, the required resistance value can be precisely set by adjusting the amount of conductive carbon black added or by changing the thickness of the film.

[0029] The above technical solution uses thermally conductive silicone as the matrix material and uniformly disperses conductive fillers within it, thereby giving the conductive silicone heating film 1 a specific predetermined resistance value. This design makes the conductive silicone heating film 1 itself a direct heating element, allowing current to flow evenly throughout the film, thus achieving uniform and efficient heating. Compared to traditional heating wire methods, this solution avoids the problems of localized overheating or inaccurate temperature control caused by uneven distribution of heating wires, significantly improving the heating uniformity and thermal efficiency of the heating module. Simultaneously, because the film heats directly, its energization-heating response speed is faster, and its temperature control accuracy is higher, better meeting the needs of applications with high temperature control requirements. Furthermore, this material-level innovation simplifies the module structure and improves overall reliability and flexibility.

[0030] In some of the embodiments described above in this application, a structure is proposed to achieve energization by contacting an aluminum silicate backplate with a conductive silicone heating film. However, in practical applications, how to ensure that a stable, reliable and uniform current input path is formed between the electrode and the film so as to ensure that the heating film can heat up uniformly and maintain a stable working state is a key problem that needs to be solved in the design of this structure.

[0031] In this regard, this application further proposes that the wiring electrode 4 is configured as two pieces, both of which are fixedly mounted on the aluminum silicate back plate 6, and are used to energize the conductive silicone heating film 1 when the aluminum silicate back plate 6 is in contact with the conductive silicone heating film 1.

[0032] Specifically, the connecting electrode 4 refers to a conductive component used to introduce external power current to the conductive silicone heating film 1, and its quantity is limited to two. The connecting electrode 4 can be implemented in various forms. For example, it can be two independent metal sheets, such as copper, aluminum, or stainless steel sheets, firmly attached to the aluminum silicate backing plate 6 by conductive adhesive or mechanical fixing; alternatively, it can be two conductive areas formed on the surface of the aluminum silicate backing plate 6 using conductive coating or printed circuit technology; or it can be two flexible conductive strips, such as conductive fabric or conductive film, fixed by adhesive or pressing. The phrase "fixedly set on the aluminum silicate backing plate 6" refers to the connection method between the connecting electrode 4 and the aluminum silicate backing plate 6, designed to ensure its positional stability. This fixing method can be achieved through adhesives, such as using high-temperature conductive adhesive or structural adhesive to firmly bond the electrode sheet 4 to the predetermined position of the aluminum silicate backplate 6; it can also be achieved through mechanical fixing, such as pre-reserving grooves or holes in the aluminum silicate backplate 6 to embed the electrode sheet 4 or fixing it by riveting, bolts, etc.; in addition, the electrode sheet 4 material can be integrated with the surface of the aluminum silicate backplate 6 through hot pressing or sintering processes. The phrase "used to energize the conductive silicone heating film 1 when the aluminum silicate backplate 6 is in contact with the conductive silicone heating film 1" describes the function of the wiring electrode sheet 4 and its working timing. After the heating module is assembled and the aluminum silicate backplate 6 and the conductive silicone heating film 1 are in contact, the wiring electrode sheet 4, as the current inlet, transmits electrical energy from the external power source to the conductive silicone heating film 1, causing it to generate heat. This can be achieved by making physical contact between the wiring electrode 4 and the surface of the conductive silicone heating film 1 to conduct current; or, in order to optimize the contact effect and current distribution, a thin layer of conductive buffer material can be placed between the wiring electrode 4 and the conductive silicone heating film 1.

[0033] Through the above technical solution, the two electrode plates 4 are fixedly mounted on the aluminum silicate backplate 6, ensuring the positional stability of the electrodes during the assembly and operation of the heating module, effectively avoiding problems such as poor contact or uneven current distribution caused by electrode displacement. The arrangement of the two electrodes provides a basis for the current to flow through the conductive silicone heating film 1, allowing the current to flow evenly across the entire film, thereby promoting uniform heating of the conductive silicone heating film 1. Simultaneously, this design simplifies the assembly process of the heating module, ensuring that the current can be effectively and reliably injected into the conductive silicone heating film 1 through the stability of physical contact, thus improving the reliability of the electrothermal conversion process and ensuring that the heating module can maintain a stable heating state and precise temperature control during operation.

[0034] In some of the solutions mentioned above in this application, a conductive silicone heating film, fiberglass cloth, and a thermally conductive working surface are stacked and packaged to form an electric heating module. However, in actual production and maintenance, if the heating film is fixedly connected to external accessories or the thermally conductive working surface, the overall structure of the module will become rigid. Once a local failure occurs or the thermally conductive working surface needs to be replaced, the entire packaged structure must be disassembled, which not only increases maintenance costs but also easily damages the core heating film, limiting the flexibility and maintainability of the module in different application scenarios.

[0035] In this regard, this application further proposes that the conductive silicone heating film 1 is an independent component, not connected to any accessories, and the heat-conducting working surface 3 is detachably encapsulated on top of the fiberglass cloth 2.

[0036] Specifically, the conductive silicone heating film 1, as an independent component, exists as a self-contained, fully functional heating unit within the entire heating module, without any permanent or irreversible physical or electrical connections to other structural or functional components. For example, during manufacturing, the conductive silicone heating film 1 can be molded separately, without being integrally molded or bonded to the aluminum silicate backing plate 6, fiberglass cloth 2, or thermally conductive working surface 3; or, the conductive silicone heating film 1 can be combined with other components through reversible mechanical fixing methods, such as clamping, pressing, or simple stacking contact, rather than through permanent methods such as adhesives or welding. This design ensures that the conductive silicone heating film 1 can be easily removed or replaced during module assembly, maintenance, or replacement without damaging other components.

[0037] Meanwhile, the conductive silicone heating film 1 is not connected to any accessories. Here, "accessories" refers to additional components, besides the core stacked components such as the aluminum silicate backing plate 6, fiberglass cloth 2, thermally conductive working surface 3, wiring electrode plate 4, and surface-mount thermal resistor 5, that may be used for fixing, support, decoration, or auxiliary functions. For example, the conductive silicone heating film 1 itself does not have any pre-set holes, protrusions, or inserts for connecting external frames, supports, or cables; or, the conductive silicone heating film 1 is positioned solely by its own flexibility or contact force with other layers, without relying on additional connectors (such as screws, clips, rivets, etc.) for direct fixation. This further emphasizes the independence of the conductive silicone heating film 1, reduces the external stress it experiences during manufacturing and use, simplifies its structure, and reduces the risk of failure.

[0038] Furthermore, the thermally conductive working surface 3 is detachably encapsulated above the fiberglass cloth 2, indicating that the connection between the thermally conductive working surface 3 and the fiberglass cloth 2 is non-permanent. This allows the thermally conductive working surface 3 to be separated from or reinstalled from the module without damaging the fiberglass cloth 2 or the conductive silicone heating film 1. For example, the thermally conductive working surface 3 can be connected to the fiberglass cloth 2 via mechanical clips, magnetic adsorption, or reusable adhesives (such as Velcro or low-tack tape); or, the thermally conductive working surface 3 can be placed above the fiberglass cloth 2 by pressure or gravity and fixed as a whole by an external frame or shell, rather than being permanently bonded directly to the fiberglass cloth 2.

[0039] Through the above technical solution, the conductive silicone heating film 1 is designed as an independent component without any attachments, achieving physical isolation between the core heating unit and external structural components. This ensures that the heating film 1 is in a relatively independent state within the module, avoiding interference with the film's heating performance caused by mechanical stress or connection methods of external attachments. Simultaneously, the heat-conducting working surface 3 is detachably encapsulated on top of the fiberglass cloth 2, allowing it to be replaced or maintained according to actual usage needs without damaging the overall structure between the heating film 1 and the fiberglass cloth 2. This modular and detachable design not only enhances the adaptability of the heating module to different installation environments but also significantly reduces the risk of overall scrapping due to localized wear or replacement requirements. It demonstrates the flexibility of the structural design and the convenience of maintenance, effectively solving the problems of rigid overall module structure, high maintenance costs, easy damage to core components, and limited flexibility and maintainability.

[0040] In some of the embodiments described above in this application, conductive silicone heating films are proposed to achieve planar heating. However, in practical applications, if the film thickness is not properly designed, it will directly affect the heat conduction efficiency, the adaptability of flexible installation, and the compactness of the overall structure, resulting in stress concentration or thermal response hysteresis when installed on complex curved surfaces.

[0041] In this regard, this application further proposes that the thickness of the conductive silicone heating film 1 shall not exceed 2.5 mm.

[0042] Specifically, the thickness of the conductive silicone heating film 1 is limited to within 2.5 mm, for example, it can be precisely controlled between 0.5 mm and 2.5 mm. This thickness can be achieved through a precise calendering process or molding technology to ensure that the film reaches the required thinness during production. Furthermore, by selecting a silicone material with highly conductive filler dispersion uniformity, the conductive silicone heating film 1 can maintain a stable resistance value and uniform heating performance even at a thinner thickness. For example, the film thickness can be further optimized to 1.0 mm or 1.5 mm to meet the higher requirements for flexibility and thermal response speed in different application scenarios.

[0043] By limiting the thickness of the conductive silicone heating film 1 to no more than 2.5 mm through the above technical solution, the thermal resistance of the heating module is significantly reduced. This allows the heat generated inside the conductive silicone heating film 1 to be transferred to the heat-conducting working surface 3 more quickly and efficiently, thereby greatly improving the overall thermal response speed and heat conduction efficiency of the heating module. At the same time, the thinner thickness gives the conductive silicone heating film 1 better flexibility and bending performance, enabling it to better conform to the target surface when facing complex installation environments such as flat surfaces, arcs, multi-curved surfaces, and torsional surfaces, effectively reducing stress concentration that may occur during installation and ensuring uniform heating. Given that the conductive silicone heating film 1 itself is a direct heating unit, its thin design further amplifies the advantages of planar heating, resulting in a faster power-on-heat-generating response and higher temperature control accuracy. In addition, this thickness limitation also helps to achieve a lightweight and compact design of the heating module, providing a wider range of adaptability for applications with limited space or high flexibility requirements. Combined with the surface-mount thermal resistor 5 set on the aluminum silicate backplate 6, the faster thermal response speed makes the temperature detection more real-time and accurate, thus ensuring the precise temperature control capability of the entire electric heating module.

[0044] In some of the solutions described above in this application, an electric heating module is formed by stacking and packaging. However, in practical applications, the connection stability between the electric heating module and the heat-conducting working surface is often difficult to guarantee. If the connection is not firm, it will lead to a decrease in heat conduction efficiency, or even detachment or poor contact when installed on complex curved surfaces, thereby affecting the overall heating performance and service life.

[0045] In this regard, this application further proposes that the fiberglass cloth 2 is provided with a high-temperature resistant adhesive on the side facing the heat-conducting working surface 3, and the fiberglass cloth 2 is adhered to the heat-conducting working surface 3 by the high-temperature resistant adhesive.

[0046] Specifically, the fiberglass cloth 2, or glass fiber cloth, is a material woven from glass fibers, possessing excellent high-temperature resistance, insulation, and mechanical strength properties. In this application, it serves as an intermediate layer between the conductive silicone heating film 1 and the heat-conducting working surface 3, providing structural support and a certain degree of insulation. A high-temperature resistant adhesive is applied to the side facing the heat-conducting working surface 3 to provide an adhesive interface for subsequent bonding operations. The high-temperature resistant adhesive refers to an adhesive that maintains good adhesion performance even at high temperatures; its main function is to provide reliable adhesion, ensuring a tight bond between the heating module and the heat-conducting working surface 3. One implementation method is to uniformly coat the high-temperature resistant adhesive onto a specific surface of the fiberglass cloth 2 during its production process through coating, impregnation, or spraying. Another implementation method is to use a pre-formed high-temperature resistant adhesive film, which is then laminated with the fiberglass cloth 2 during assembly to form a fiberglass cloth 2 with adhesive backing.

[0047] Based on this, the fiberglass cloth 2 is adhered to the heat-conducting working surface 3 using high-temperature resistant adhesive. This means that the adhesive properties of the high-temperature resistant adhesive are used to firmly connect the fiberglass cloth 2 to the heat-conducting working surface 3. This adhesion method is a key step in achieving stable heat conduction and structural fixation between the heating module and the heat-conducting working surface 3. The heat-conducting working surface 3 is the target surface to which the heating module ultimately transfers heat. Its material and shape may vary, such as a metal plate, ceramic substrate, or composite material surface. Adhesion eliminates air gaps between the two, improves heat conduction efficiency, and ensures that the heating module maintains a stable position and contact under various working conditions and installation postures. One implementation method is to directly press the fiberglass cloth 2 with high-temperature resistant adhesive onto the heat-conducting working surface 3 during the assembly of the heating module, and cure it through appropriate pressure and / or heat to allow the adhesive to fully exert its bonding effect. Another implementation method is to first apply the high-temperature resistant adhesive to the heat-conducting working surface 3, then adhere the fiberglass cloth 2, and then perform a curing process.

[0048] By applying a high-temperature resistant adhesive to the side of the fiberglass cloth 2 facing the heat-conducting working surface 3, and using this adhesive to bond the fiberglass cloth 2 to the heat-conducting working surface 3, this application effectively solves the problems of poor connection stability and low heat conduction efficiency between the heating module and the heat-conducting working surface 3. In the above-mentioned stacked encapsulation structure of the conductive silicone heating module, the heat generated by the conductive silicone heating film 1 needs to be efficiently transferred to the heat-conducting working surface 3. If there is a gap between the two or the connection is not firm, it will lead to heat loss and uneven temperature. The introduction of the high-temperature resistant adhesive allows the fiberglass cloth 2 to be tightly and evenly adhered to the heat-conducting working surface 3, eliminating any possible air gaps, thereby ensuring the lossless and efficient transfer of heat from the conductive silicone heating film 1 to the heat-conducting working surface 3 through the fiberglass cloth 2. In addition, due to the high temperature resistance of the adhesive, it can maintain stable bonding strength even when the heating module is operating at high temperature for a long time, preventing the module from falling off or shifting due to thermal expansion and contraction or external vibration. This greatly enhances the structural stability and heat conduction reliability of the heating module in complex installation scenarios such as planes, arcs, and multi-curved surfaces, thereby improving the overall heating performance and service life.

[0049] In some of the solutions mentioned above in this application, conductive silicone heating films are proposed to achieve uniform heating and flexible installation. However, in this process, how to accurately control the resistivity, thermal conductivity and physical stability of the conductive silicone through specific formulation components to ensure the heating uniformity, heat conduction efficiency and structural reliability of the heating module under long-term operation is still a technical challenge that needs to be solved.

[0050] In this regard, this application further proposes that the raw materials of the conductive silicone heating film 1 include, by weight, 100 parts of silicone compound, 8-25 parts of conductive carbon black, 80 parts of spherical alumina, 20 parts of active magnesium oxide, and 2 parts of calcium oxide.

[0051] The silicone compound, used as the matrix material for the conductive silicone heating film 1, is formulated at a weight ratio of 100 parts, providing the film with the necessary flexibility, insulation properties, and basic mechanical strength. This matrix material ensures that the conductive silicone heating film 1 can adapt to various installation requirements, including flat surfaces, arcs, curved surfaces, and even torsional surfaces, while providing a stable carrier for the subsequent dispersion of conductive and thermally conductive fillers. Specifically, the silicone compound can be made of vinyl silicone rubber, methyl vinyl silicone rubber, or phenyl vinyl silicone rubber, which have excellent high-temperature resistance, to meet the requirements of different operating temperatures and mechanical properties.

[0052] Conductive carbon black, as a conductive filler, is crucial for achieving the predetermined resistance value of the conductive silicone heating film 1, with its weight proportion controlled within the range of 8 to 25 parts. By precisely controlling the amount of conductive carbon black added, a uniform and stable conductive network can be formed in the silicone matrix, ensuring that current can flow through the entire film, thereby achieving uniform heating of the film itself. For example, conductive carbon blacks with different particle sizes, structures, and surface chemical properties, such as acetylene black, furnace black, or channel black, can be selected according to the required resistivity to optimize conductivity and processing flowability.

[0053] Spherical alumina is added at a weight ratio of 80 parts as a highly efficient thermally conductive filler. Its unique spherical structure helps to form continuous and efficient thermally conductive channels in the silicone matrix, significantly improving the overall thermal conductivity of the conductive silicone heating film 1. This structure not only facilitates the uniform and rapid transfer of heat from the inside of the film to the thermally conductive working surface 3, but also maintains good fluidity during the mixing process, avoiding processing difficulties caused by irregular filler shapes. For example, spherical alumina with different particle size distributions can be selected to further optimize the thermal conductivity and the material's filling density.

[0054] Activated magnesium oxide is added at a weight ratio of 20 parts, primarily serving a reinforcing and stabilizing role. Activated magnesium oxide interacts with the silicone matrix, effectively enhancing the mechanical strength, tear resistance, and heat aging resistance of the conductive silicone heating film 1. This is crucial for ensuring that the material structure does not degrade or its performance deteriorates during long-term, repeated heating and cooling cycles, thereby maintaining the long-term temperature control accuracy and operational stability of the heating module.

[0055] Calcium oxide, added at a weight ratio of 2 parts, works synergistically with active magnesium oxide to further enhance the overall performance of the conductive silicone heating film 1. Calcium oxide can act as an auxiliary reinforcing agent, improving the material's hardness and wear resistance. In some cases, it can also act as a hygroscopic agent, helping to improve the material's stability in humid environments. Its addition ensures that the conductive silicone heating film 1 maintains excellent physical properties and chemical stability even under harsh operating conditions.

[0056] Through the above technical solutions, the specific formulation of the conductive silicone heating film 1 proposed in this application can precisely control its resistivity, thermal conductivity, and physical stability. Specifically, the silicone compound serves as the matrix, providing flexibility and insulation; the precise proportion of conductive carbon black (8-25 parts) ensures that the conductive silicone heating film 1 has a predetermined uniform resistance value, allowing current to flow evenly throughout the film, thereby achieving uniform heating and rapid response, effectively avoiding the problems of uneven heating and poor temperature control accuracy in traditional heating modules. The introduction of spherical alumina (80 parts) significantly improves the thermal conductivity of the conductive silicone heating film 1, ensuring that heat can be quickly and efficiently transferred from the inside of the film to the heat-conducting working surface 3, thereby improving the overall thermal efficiency. In addition, the synergistic effect of active magnesium oxide (20 parts) and calcium oxide (2 parts) greatly enhances the mechanical strength, anti-aging properties, and long-term stability of the conductive silicone heating film 1, ensuring that the structure and performance of the heating module do not significantly degrade under long-term operation and repeated thermal cycling, thus maintaining excellent temperature control accuracy and reliability. Overall, this formulation enables the conductive silicone heating film 1 to not only function as an independent heating element, but also optimizes its thermal conductivity, mechanical strength, and long-term stability, providing a high-performance and highly reliable core heating component for the conductive silicone heating module.

[0057] In some of the solutions mentioned above in this application, conductive silicone heating films are proposed to achieve uniform heating and flexible installation. However, in the actual production process, how to ensure that the conductive filler is highly uniformly distributed in the silicone matrix through standardized industrial processing procedures, and to achieve precise control of the film thickness and resistance value, so as to ensure the performance consistency and stability of the heating module in mass production, is a challenge faced by the prior art.

[0058] In this regard, this application further proposes that the aforementioned conductive silicone heating film 1 is made from the raw materials of the formula through mixing, calendering, continuous vulcanization of rolls in a drum vulcanizing machine, and cutting.

[0059] Specifically, mixing refers to the process of thoroughly and uniformly mixing the formulation raw materials, such as the silicone matrix, conductive fillers, and other additives. This process aims to ensure that the conductive fillers are highly uniformly dispersed in the silicone material, thereby laying the foundation for the subsequent formation of a conductive silicone electrothermal film 1 with a stable resistance value, and effectively avoiding local resistance differences and uneven heating caused by uneven filler distribution. For example, mixing can be carried out using equipment such as an internal mixer or a two-roll mill, where mechanical shearing and extrusion actions ensure that the components are fully integrated.

[0060] Calendering refers to the process of extruding and stretching a compounded rubber material through a series of rotating rollers to form a continuous sheet with a predetermined thickness and width. This process is crucial for precisely controlling the thickness of the conductive silicone heating film 1, ensuring the consistency of the film's resistance value in different areas, and thus guaranteeing the overall heating uniformity and performance stability of the heating module. Calendering is typically achieved using a multi-roll calender, such as a two-roll, three-roll, or four-roll calender, and the film thickness is precisely controlled by adjusting the roller gap and rotation speed.

[0061] Continuous vulcanization of rolls using a drum vulcanizing machine refers to the process of continuously heating and vulcanizing calendered conductive silicone sheets through a drum vulcanizing machine, transforming them from a plastic state to an elastic state, and outputting them in roll form. This continuous vulcanization method ensures that the conductive silicone heating film 1 achieves a uniform degree of vulcanization along its entire length, avoiding performance fluctuations that may occur with traditional segmented vulcanization, and significantly improving production efficiency and product consistency. For example, the vulcanization process can be precisely controlled by adjusting the temperature, speed, and pressure parameters of the drum vulcanizing machine.

[0062] Cutting refers to the process of cutting the continuously vulcanized conductive silicone heating film roll into individual components of specific sizes and shapes according to actual application requirements. This step is the final stage of the production process and aims to process large-size rolls into final forms that meet product specifications, such as through die-cutting, laser cutting, or punching, to achieve efficient and precise forming.

[0063] Through the above technical solutions, this application provides a clear and controllable process path for the industrial production of conductive silicone heating film 1. The mixing process ensures the uniform dispersion of conductive filler in the silicone matrix, guaranteeing the resistance uniformity of the conductive silicone heating film 1 from the source and effectively avoiding problems such as local overheating or uneven heating. The calendering process enables precise control of the film thickness, further ensuring the resistance consistency of the heating module in different areas, thereby improving the uniformity of heating and temperature control accuracy. The introduction of continuous vulcanization of the roll material using a drum vulcanizing machine not only significantly improves production efficiency, but more importantly, through a continuous heat treatment process, ensures the uniformity of vulcanization degree of the film along its length, effectively solving the performance fluctuation problem that may be caused by traditional segmented vulcanization, and significantly improving the batch consistency and reliability of the product. The final cutting process enables customized molding of the product. The organic combination of this series of process steps enables the conductive silicone heating film 1 to be mass-produced with stable performance and high efficiency. It effectively solves the challenge of ensuring uniform distribution of conductive filler and precise control of film thickness and resistance value in large-scale production, thereby ensuring that the conductive silicone heating module has excellent electrothermal conversion performance, heating uniformity, temperature control accuracy and service life in practical applications.

[0064] The following example will provide a more detailed explanation of the above technical solution: In an industrial production scenario, a user needs to heat a material requiring high temperature uniformity and response speed at a specific location. Traditional heating modules, due to uneven heating, low thermal efficiency, slow energization-heating response, and poor temperature control accuracy, cannot meet these process requirements. Therefore, a conductive silicone heating module is used to solve these problems.

[0065] The structure of this conductive silicone heating module includes an aluminum silicate backplate 6, a conductive silicone heating film 1, a fiberglass cloth 2, and a thermally conductive working surface 3. These components are stacked and packaged in sequence to form a complete heating module.

[0066] Specifically, the aluminum silicate backplate 6 serves as the support structure for the module, and it is equipped with two wired electrode plates 4 and a surface-mount thermal resistor 5. The two wired electrode plates 4 are fixed to the aluminum silicate backplate 6, and when the aluminum silicate backplate 6 comes into contact with the conductive silicone heating film 1, they are responsible for supplying electricity to the conductive silicone heating film 1. The surface-mount thermal resistor 5 is also mounted on the aluminum silicate backplate 6 and enables real-time temperature detection of the film when it comes into contact with the conductive silicone heating film 1.

[0067] The conductive silicone heating film 1 is the core heating component of this module; it is a standalone component and is not connected to any accessories. Film 1 is made of thermally conductive silicone, in which conductive fillers are uniformly dispersed, for example, by weight, comprising 100 parts silicone compound, 8-25 parts conductive carbon black, 80 parts spherical alumina, 20 parts activated magnesium oxide, and 2 parts calcium oxide. This formulation gives the conductive silicone heating film 1 a predetermined resistance value. The thickness of the conductive silicone heating film 1 is controlled to not exceed 2.5 mm to ensure rapid heat conduction. Film 1 is manufactured through processes such as mixing, calendering, continuous vulcanization of the roll material using a drum vulcanizing machine, and cutting.

[0068] Fiberglass cloth 2 is located between the conductive silicone heating film 1 and the heat-conducting working surface 3. A high-temperature resistant adhesive is provided on the side of the fiberglass cloth 2 facing the heat-conducting working surface 3, allowing the fiberglass cloth 2 to be firmly adhered to the heat-conducting working surface 3. The heat-conducting working surface 3 is designed to be detachably encapsulated above the fiberglass cloth 2 for easy maintenance or replacement.

[0069] In practical applications, when current is applied to the conductive silicone heating film 1 through the electrode plate 4, the current flows through the entire film 1 due to the uniform distribution of the conductive filler, resulting in uniform heating. This direct and uniform heating method avoids the uneven temperature problem caused by localized heating of traditional heating wires. Heat is directly and efficiently transferred from the conductive silicone heating film 1 to the fiberglass cloth 2, and then through the high-temperature resistant adhesive to the heat-conducting working surface 3, ultimately acting on the material to be heated. Simultaneously, the surface-mount resistance thermometer 5 continuously monitors the temperature of the conductive silicone heating film 1 and feeds the data back to the control system, achieving precise temperature control of the module.

[0070] Compared to traditional methods that embed heating wires within silicone insulation, this module's conductive silicone heating film 1 directly serves as the heating element, ensuring uniform current distribution and eliminating the uneven heating caused by the spaced distribution of heating wires. Since heat is generated and conducted directly within the film 1, rather than indirectly through the insulation layer, the energization-heating response speed is improved, resulting in higher thermal efficiency. Furthermore, the surface-mount resistance temperature detector (RTD) 5 directly contacts the heating film 1, providing more accurate temperature feedback and thus improving temperature control precision. Eliminating the need for heating wires reduces manufacturing costs, and the flexibility of the conductive silicone heating film 1 allows it to adapt to various installation requirements, including flat surfaces, arcs, and curved surfaces, enhancing the product's applicability.

[0071] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A conductive silicone heating module, characterized in that: The device includes an aluminum silicate backplate (6), a conductive silicone heating film (1), a fiberglass cloth (2), and a thermally conductive working surface (3). The aluminum silicate backplate (6), the conductive silicone heating film (1), the fiberglass cloth (2), and the thermally conductive working surface (3) are stacked and packaged in sequence to form a heating module. The aluminum silicate backplate (6) is provided with a wiring electrode plate (4) and a surface-mount thermal resistor (5). When the wiring electrode plate (4) and the surface-mount thermal resistor (5) contact the conductive silicone heating film (1), they respectively achieve power supply and temperature detection.

2. The conductive silicone heating module according to claim 1, characterized in that: The conductive silicone heating film (1) is made of thermally conductive silicone, and conductive fillers are uniformly dispersed in the thermally conductive silicone, so that the conductive silicone heating film (1) has a predetermined resistance value.

3. The conductive silicone heating module according to claim 1, characterized in that: The wiring electrode piece (4) is configured as two pieces, and both wiring electrode pieces (4) are fixedly disposed on the aluminum silicate back plate (6) for energizing the conductive silicone heating film (1) when the aluminum silicate back plate (6) contacts the conductive silicone heating film (1).

4. The conductive silicone heating module according to claim 1, characterized in that: The conductive silicone heating film (1) is an independent component and is not connected to any accessories. The heat-conducting working surface (3) is detachably encapsulated above the fiberglass cloth (2).

5. A conductive silicone heating module according to claim 1, characterized in that: The thickness of the conductive silicone heating film (1) does not exceed 2.5 mm.

6. The conductive silicone heating module according to claim 1, characterized in that: The fiberglass cloth (2) is provided with a high-temperature resistant adhesive on the side facing the heat-conducting working surface (3), and the fiberglass cloth (2) is adhered to the heat-conducting working surface (3) by the high-temperature resistant adhesive.

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