Grid type metal wire heater

Abstract

A grid type metal wire heater comprises a woven mesh and electrode assemblies located at the two opposite ends of the woven mesh. The woven mesh is composed of a plurality of transverse metal wires and a plurality of longitudinal metal wires which are orthogonally woven, the electrode assembly is connected with two opposite ends of the transverse metal wires or the longitudinal metal wires, and the surface of the woven mesh is provided with an insulating heat-conducting layer for protecting the woven mesh and conducting heat; compared with the prior art, the grid structure is formed by weaving the transverse metal wires and the longitudinal metal wires, and current can be uniformly conducted in the woven mesh under the communication action of the woven mesh and the electrode assembly, so that resistance loss is reduced, and electric energy can be converted into heat energy more efficiently; and meanwhile, the woven mesh is protected and supported under the action of the insulating heat-conducting layer, so that the woven mesh can be well adapted to surfaces with various complicated shapes.

Description

Technical Field

[0001] This utility model relates to the field of heating device technology, specifically to a mesh-type metal wire heater. Background Technology

[0002] A metal wire heater is a device that converts electrical energy into heat energy using the resistive properties of a metal conductor. It is widely used in industrial, household appliances, and laboratory equipment.

[0003] Traditional wire heaters typically use rigid materials as the outer shell and support structure, such as stainless steel, aluminum alloy, or copper. When faced with scenarios that require fitting to complex surfaces or where flexibility is required, these heaters are difficult to effectively fit with flexible surfaces due to their own rigidity, thus affecting the heating efficiency of the flexible surfaces.

[0004] In the existing technology, there are different types of flexible heaters.

[0005] The flexible heater is formed by stitching or bonding the metal heating wire to the flexible substrate. The heating wire is formed by spirally winding the metal heating wire around the outer insulating sheath. The heating wire is then stitched or bonded to the flexible substrate to form a heating film. Because the heating element is a conductive wire, only the area where the heating wire is stitched is heated. The surrounding area can only be heated by heat conduction. As a result, the heating film has poor thermal uniformity, high local temperature, high current carrying capacity, and short heating wire life.

[0006] Printed circuit flexible heaters use a printing process to create heating patterns by printing conductive heating paste along specific lines. The conductive ink typically uses precious metal silver paste, while the heating ink is generally composed of metal nanoparticles, carbon-based materials, and organic binders. These heaters are expensive to manufacture, and the conductive heating materials are prone to oxidation over long-term use, affecting their performance.

[0007] Flexible metal film heaters, such as those made of copper foil, stainless steel foil, and nickel foil, are created by using processes like laser etching and chemical etching to form specific patterns, which are then combined with flexible materials. However, the inherent rigidity of metal foil leads to poor flexibility, and the etched nodes are prone to breakage after repeated bending. The etching process also results in material waste and high costs. Furthermore, the precision of etching affects resistance, leading to poor power consistency in the products. Additionally, the etching process involves large amounts of chemical solutions and waste disposal, making it environmentally unfriendly.

[0008] Chinese Publication No. CN118843218A discloses a flexible electric heating mesh fabric, comprising: a heating mesh, a main power supply line, and a coating. The heating mesh includes: positive electrode wires, negative electrode wires, heating wires, warp yarns, and weft yarns; the positive and negative electrode wires are arranged alternately in the warp direction; the heating wires are arranged in the weft direction; the positive electrode wires, negative electrode wires, heating wires, warp yarns, and weft yarns are woven into a mesh to form the heating mesh fabric; there are several heating wires, which are connected in parallel to the positive and negative electrode wires; the positive and negative electrode wires are electrically connected to the main power supply line; the coating is attached to the heating mesh; a single heating wire may break or not heat up.

[0009] The heating mesh fabric disclosed above provides power to the heating wire via positive and negative wires, which are connected to an external power source. In order to ensure a stable connection between the positive and negative wires and the external power source, the deformation strength of the positive and negative wires is inevitably affected, thereby affecting the bonding effect between the heating wire and the flexible surface and the heating efficiency of the flexible surface. Utility Model Content

[0010] The present invention aims to overcome the defects in the prior art and provide a mesh-type metal wire heater with a simple structure, high thermal conductivity, and high radiation.

[0011] To achieve the above-mentioned utility model objectives, the present utility model adopts the following technical solution: a mesh-type metal wire heater, comprising a braided mesh and electrode assemblies located at opposite ends of the braided mesh; the braided mesh is composed of several transverse metal wires and several longitudinal metal wires orthogonally woven, the electrode assemblies are connected to the opposite ends of the transverse or longitudinal metal wires, and the surface of the braided mesh is provided with an insulating and heat-conducting layer for protecting and conducting heat to the braided mesh.

[0012] As a preferred embodiment of this utility model, a plurality of the transverse metal wires are arranged in rows, and the transverse metal wires have a corrugated structure along the length direction of the transverse metal wires.

[0013] As a preferred embodiment of this utility model, a plurality of the longitudinal metal wires are arranged in rows, and the longitudinal metal wires have a corrugated structure along the length direction of the longitudinal metal wires.

[0014] As a preferred embodiment of this utility model, the several transverse metal wires and longitudinal resistance wires can be interwoven with metal wire materials of different resistivity. Different resistivity materials generate different amounts of heat, so the distribution design can be carried out according to actual heating requirements. The several longitudinal metal wires are interwoven with one or more metal wires selected from stainless steel wire, nickel-chromium wire, and iron-chromium wire.

[0015] As a preferred embodiment of this utility model, the non-heated area can be freely designed within the woven mesh, and the transverse and longitudinal metal wires are arranged to bypass the non-heated area.

[0016] As a preferred embodiment of the present invention, the electrode assembly includes a positive electrode and a negative electrode arranged opposite to each other, and the two ends of the transverse metal wire or the longitudinal metal wire are respectively ultrasonically welded to the positive electrode and the negative electrode or laser welded to each other.

[0017] As a preferred embodiment of this utility model, the surface of the woven mesh is provided with an insulating and heat-conducting layer for protecting and conducting heat to the woven mesh.

[0018] As a preferred embodiment of this utility model, the insulating and thermally conductive layer is coated onto the surfaces of the transverse and longitudinal metal wires.

[0019] In a preferred embodiment of this invention, the insulating and thermally conductive layer is a graphene-containing coating.

[0020] As a preferred embodiment of this utility model, the insulating and heat-conducting layer is further provided with a flexible insulating film compositely disposed on both the inner and outer sides of the woven mesh.

[0021] As a preferred embodiment of this utility model, the diameters of the transverse and longitudinal metal wires are 0.01mm-0.1mm.

[0022] As a preferred embodiment of this utility model, the mesh number of the woven net formed by the plurality of transverse metal wires and the plurality of longitudinal metal wires is 60-500 mesh.

[0023] Compared with the prior art, the beneficial effects of this utility model are: the use of transverse and longitudinal metal wires to weave a mesh structure, and the connection between the transverse metal wires and the electrode assembly, allows the current to be conducted evenly in the transverse metal wires, reducing resistance loss and enabling electrical energy to be converted into heat energy more efficiently. At the same time, the woven mesh is protected and supported by the insulating and heat-conducting layer, which can adapt well to various complex shapes of surfaces.

[0024] Under the action of the woven mesh structure heater, when the heater is subjected to local destructive impact, the woven mesh can buffer the destructive impact and prevent the woven mesh from breaking. During the heating process, even if the woven mesh is partially damaged, the current will spread outwards along the mesh path without affecting the normal operation of the heater. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of this utility model;

[0026] Figure 2 This is a schematic diagram of the structure of a woven mesh;

[0027] Figure 3 This is a diagram illustrating the weaving process of a woven mesh;

[0028] Figure 4This is a schematic diagram showing the connection between the electrode assembly and the braided mesh;

[0029] Figure 5 This is a schematic diagram of the structure of the insulating and heat-conducting layer;

[0030] Figure 6 It is a flat lay diagram of a woven mesh;

[0031] Figure 7 This is a schematic diagram of a combination of flexible insulating films;

[0032] Figure 8 This is a structural schematic diagram of Example 2;

[0033] Figure 9 This is the current flow diagram of the braided mesh in Example 2;

[0034] Figure 10 This is a current flow diagram of the non-heated region in Example 2;

[0035] Reference numerals: 1. Braided mesh; 2. Electrode assembly; 21. Positive electrode; 22. Negative electrode; 3. Transverse metal wire; 4. Longitudinal metal wire; 5. Insulating and heat-conducting layer; 6. Flexible insulating film; 7. Non-heated area. Detailed Implementation

[0036] The embodiments of this utility model will now be described in detail with reference to the accompanying drawings.

[0037] like Figures 1-7 As shown, a mesh-type wire heater includes a braided mesh 1 and electrode assemblies 2 located at opposite ends of the braided mesh 1; the braided mesh 1 is composed of several transverse metal wires 3 and several longitudinal metal wires 4 orthogonally woven, and the electrode assemblies 2 are connected to the opposite ends of the transverse metal wires 3; the surface of the braided mesh 1 is provided with an insulating and heat-conducting layer 5 for protecting and conducting heat to the braided mesh 1.

[0038] The transverse metal wires 3 and longitudinal metal wires 4 are woven as the warp and weft of the woven mesh 1. The electrode assembly 2 is used to energize the transverse metal wires 3 and longitudinal metal wires 4. Under the action of energization, the transverse metal wires 3 and longitudinal metal wires 4 are heated, thereby achieving the heating effect of the entire woven mesh 1. The transverse metal wires 3 and longitudinal metal wires 4 are in an energized state during the heating process. The insulating and heat-conducting layer 5 is used to insulate the transverse metal wires 3 and longitudinal metal wires 4 from the contact object in the energized state. At the same time, the insulating and heat-conducting layer 5 is used to transfer the heat generated by the transverse metal wires 3 and longitudinal metal wires 4.

[0039] Several transverse metal wires 3 are arranged in rows, and the transverse metal wires 3 have a corrugated structure along the length direction of the transverse metal wires 3. The transverse metal wires 3 and the longitudinal metal wires 4 can be made of metal materials such as iron-chromium alloy, nickel-chromium alloy, stainless steel, and copper. The transverse metal wires 3 and the longitudinal metal wires 4 have good electrical and thermal conductivity. The several longitudinal metal wires 4 are interwoven from one or more metal wires of stainless steel wire, nickel-chromium wire, and iron-chromium wire.

[0040] The electrode assembly 2 includes a positive electrode 21 and a negative electrode 22 located at both ends of the transverse metal wire 3 and the longitudinal metal wire 4, respectively. When the motor assembly 2 is energized with the transverse metal wire 3 through the positive electrode 21 and the negative electrode 22, the longitudinal metal wire 4 is energized with the transverse metal wire 3 through contact. Similarly, when the motor assembly 2 is energized with the longitudinal metal wire 4 through the positive electrode 21 and the negative electrode 22, the transverse metal wire 3 is energized with the longitudinal metal wire 4 through contact.

[0041] The two ends of the transverse metal wire 3 or the longitudinal metal wire 4 are fixedly connected to the positive electrode 21 and the negative electrode 22, respectively. The positive electrode 21 and the negative electrode 22 can be metal foil or metal wire, such as copper foil, aluminum foil, or stainless steel foil. The ends of the transverse metal wire 3 or the longitudinal metal wire 4 are connected to the positive electrode 21 or the negative electrode 22 by welding, pressing, or riveting. Welding can be done by ultrasonic welding, laser welding, brazing, etc., and the welding method can be selected according to actual needs.

[0042] The longitudinal metal wires 4 and transverse metal wires 3, both with a corrugated structure, ensure that the woven mesh 1 has a certain degree of deformation redundancy, thereby better fitting with the flexible heated object and ensuring the heating effect of the woven mesh 1.

[0043] The insulating and heat-conducting layer 5 is coated on the surface of the transverse metal wire 3 and the longitudinal metal wire 4. The insulating and heat-conducting layer 5 is a graphene-containing composite material. The graphene composite material has high thermal conductivity and high emissivity, which enables the heat of the heating wire to be quickly and maximally conducted and radiated outward, thereby improving thermal efficiency.

[0044] Outside the insulating and heat-conducting layer 5, there is also a composite flexible insulating film 6 set on both the inner and outer sides of the woven mesh 1. The transverse metal wires 3 and the longitudinal metal wires 4 are sandwiched between the two flexible insulating films 6 for composite. The flexible insulating film 6 can be made of materials such as polyimide, polyethylene terephthalate, and thermoplastic polyurethane, which have good flexibility, insulation and high temperature resistance, and can effectively protect the transverse metal wires 3 and the longitudinal metal wires 4, while ensuring the safe use of the woven mesh 1 in various environments.

[0045] Example 2: Figures 8-10As shown, the specific structure and size of the woven mesh 1 are set according to actual needs. The woven mesh 1 can be formed into an eye mask structure or other structures required by actual needs. The woven mesh 1 can also form a non-heated area 7 without horizontal metal wires 3 and vertical metal wires 4 to meet the needs of different situations and different environments.

[0046] The diameter of the transverse metal wire 3 and the longitudinal metal wire 4 is 0.01mm-0.1mm. The mesh number of the woven mesh 1 formed by the transverse metal wire 3 and the longitudinal metal wire 4 is 60-500 mesh. The diameter of the transverse metal wire 3 and the longitudinal metal wire 4 and the mesh number of the woven mesh 1 can be adjusted and set according to actual needs. The entire woven mesh 1 can be designed and cut into any shape, such as rectangle, circle, triangle, etc., to suit different heating scenarios.

[0047] In practical use, the resistance requirements of different products vary, and metal wires with different resistivities can be selected according to needs. The resistance can be adjusted by adjusting the spacing of the longitudinal metal wires. The design does not have to follow the standard wire diameter and aperture width. For example, a 60-mesh mesh is 25.4*1000 / 60=423μm, which means 1 wire diameter + 1 aperture width = 423μm. Generally, the wire diameter is 140μm and the aperture width is 283μm. It can be designed as a combination of 30μm wire diameter + 393μm aperture width, or a combination of 50μm wire diameter + 373μm aperture width, with fine wire diameter + large mesh or free combination, thereby adjusting the product resistance.

[0048] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention; therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0049] Although this document frequently uses reference numerals such as woven mesh 1, electrode assembly 2, positive electrode 21, negative electrode 22, transverse metal wire 3, longitudinal metal wire 4, insulating and thermally conductive layer 5, flexible insulating film 6, and non-heated area 7, the possibility of using other terms is not excluded. These terms are used merely for the convenience of describing and explaining the essence of this invention; interpreting them as any additional limitation would contradict the spirit of this invention.

Claims

1. A mesh wire heater comprising a woven mesh (1) and electrode assemblies (2) located at opposite ends of the woven mesh (1); characterised in that, The woven mesh (1) is composed of several transverse metal wires (3) and several longitudinal metal wires (4) woven orthogonally, and the electrode assembly (2) is connected to the opposite ends of the transverse metal wires (3) or the longitudinal metal wires (4).

2. A mesh wire heater according to claim 1, characterized in that, The transverse metal wires (3) are arranged in rows, and the transverse metal wires (3) have a corrugated structure along the length direction of the transverse metal wires (3). The transverse metal wires (3) are interwoven with one or more of stainless steel wires, nickel-chromium wires, and iron-chromium wires.

3. A mesh wire heater according to claim 1, characterized in that, The longitudinal metal wires (4) are arranged in rows, and the longitudinal metal wires (4) have a corrugated structure along the length of the longitudinal metal wires (4). The longitudinal metal wires (4) are woven together by interlacing one or more of stainless steel wires, nickel-chromium wires, and iron-chromium wires.

4. A mesh wire heater according to claim 1, characterized in that, The electrode assembly (2) includes a positive electrode (21) and a negative electrode (22) arranged opposite to each other, and the two ends of the transverse metal wire (3) or the longitudinal metal wire (4) are ultrasonically welded to the positive electrode (21) and the negative electrode (22) respectively.

5. A mesh wire heater according to claim 1, characterized in that, The woven mesh (1) has a non-heated area (7) formed inside, and the transverse metal wires (3) and longitudinal metal wires (4) are arranged around the non-heated area (7).

6. A mesh wire heater according to claim 1, characterized in that, The surface of the woven mesh (1) is provided with an insulating and heat-conducting layer (5) for protecting and conducting heat to the woven mesh (1). The insulating and heat-conducting layer (5) is coated on the surface of the transverse metal wire (3) and the longitudinal metal wire (4).

7. A mesh wire heater according to claim 6, characterized in that, The insulating and thermally conductive layer (5) is a graphene-containing coating.

8. A mesh wire heater according to claim 7, characterized in that, The insulating and heat-conducting layer (5) is further provided with a flexible insulating film (6) that is compositely disposed on both the inner and outer sides of the woven mesh (1).

9. A mesh wire heater according to claim 1, characterized in that, The diameters of the transverse metal wire (3) and the longitudinal metal wire (4) are 0.01 mm to 0.1 mm.

10. A mesh wire heater according to claim 1, characterized in that, The mesh (1) formed by the woven wires (3) and the longitudinal wires (4) has a mesh count of 60-500.

Images