A folding high-temperature precision control heating system

Abstract

The utility model relates to the technical field of temperature control of products with large heating area such as electric blanket, heating mattress, car heating cushion and the like, and particularly discloses a folding high-temperature precise control heating system, which comprises a heating assembly and a control assembly, and the control assembly is used for starting / stop control of the heating process of the heating assembly; the heating assembly comprises a base layer and a conductive heating layer, the base layer is a flexible fiber fabric structure, the conductive heating layer is coated on the base layer and penetrates into the fiber gap of the base layer, so that the conductive heating layer and the base layer form an integrated conductive composite structure; in the bending, folding or torsion state, the conductive path remains continuous and the heating output remains stable. According to the utility model, the conductive heating layer penetrates into the fiber gap of the base layer, so that the heating layer and the fabric form a conductive composite structure, thereby avoiding the problems of easy falling off and easy breaking of the traditional "electric heating wire" heating structure, and greatly improving the service life and reliability in the flexible environment.

Description

Technical Field

[0001] This utility model relates to the field of temperature control technology for large-heating-area products such as electric blankets, heated mattresses, and heated car seat cushions, and in particular discloses a foldable high-temperature precision control heating system. Background Technology

[0002] Foldable heating devices are commonly used in portable thermal insulation equipment, flexible heat therapy devices, outdoor heating systems, and clothing and apparel. In existing technologies, common flexible heating structures often use metal wire heating elements, flexible resistance sheets, or surface-printed conductive circuits as heating units.

[0003] However, the above structures generally have the following problems: the structure is prone to breakage. When the metal wire or thin film resistive circuit is frequently folded, bent or twisted, it is prone to local fatigue, breakage or sudden resistance change, which leads to a decrease in heating performance or even failure; the heating is uneven. The conductive path of the existing conductive film or wire heating body is relatively fixed. When the heating body is folded or covered, the local current density will change significantly, causing hot spots, sudden temperature rise or local non-heating; the service life is limited. The existing heating layer is usually attached to the surface of the substrate. The interlayer adhesion is insufficient. Under mechanical bending or humid conditions, delamination, cracks or conductivity degradation are likely to occur.

[0004] Therefore, there is an urgent need for a heating system that can maintain stable operation in various folding states while possessing high reliability. Utility Model Content

[0005] In order to overcome the shortcomings and deficiencies of the existing technology, the purpose of this utility model is to provide a heating system that can maintain stable operation in various folding states and has high reliability.

[0006] To achieve the above objectives, this utility model discloses a foldable high-temperature precision control heating system, comprising a heating component and a control component. The control component is electrically connected to the heating component and is used to control the start / stop of the heating process of the heating component. The heating component includes a base layer and a conductive heating layer stacked sequentially. The base layer is a flexible fiber fabric structure. The conductive heating layer is coated on the base layer and penetrates into the fiber gaps of the base layer, forming an integrated conductive composite structure with the base layer. The conductive composite structure maintains a continuous conductive path and stable heating output even when bent, folded, or twisted. This utility model, by having the conductive heating layer penetrate into the fiber gaps of the base layer, forms a conductive composite structure with the fabric, avoiding the problems of easy detachment and breakage of traditional "heating wire" heating structures. The conductive path remains continuous even when bent, folded, or twisted, thus significantly improving the service life and reliability in flexible environments.

[0007] Furthermore, the base layer is one of high-temperature resistant nylon cloth, polyester fiber cloth, or glass fiber cloth. This ensures that the main body of the heating component does not melt or deform under long-term high temperatures. In flexible application scenarios, the use of a high-temperature resistant fabric base gives the structure both flexibility and high-temperature resistance.

[0008] Furthermore, the conductive heating layer is a multi-layered stacked carbon-based conductive paste, with different conductive filler concentration gradients between each layer to optimize the uniformity of heat output in the heating assembly. The different conductive filler concentrations in each layer form a resistance gradient structure. When folding causes localized stress or thickness changes, different layers can automatically share the current, maintaining uniform heating, solving the hotspot problem caused by sudden changes in localized resistance after folding, improving the uniformity of temperature distribution in the heating area, enhancing structural redundancy, and maintaining basic heating function even when one layer experiences localized damage.

[0009] Furthermore, the carbon-based conductive paste is one of modified graphene wire ink, multi-walled carbon nanotube paste, or carbon fiber blended layer. This enhances the high-temperature resistance of the conductive layer, making it suitable for high-temperature heating applications, and strengthens adhesion, allowing for more complete penetration into the substrate layer.

[0010] Furthermore, the conductive heating layer is formed on the substrate layer by printing, impregnation, or spraying. This improves the uniformity and bonding strength of the conductive layer, making it suitable for mass production and reducing costs.

[0011] Furthermore, the heating component also includes an insulating layer and a temperature sensing layer. The insulating layer is disposed on the conductive heating layer, and the temperature sensing layer is disposed on the insulating layer, covering the entire heating area of ​​the conductive heating layer. The temperature sensing layer is used to monitor the temperature field state of the conductive heating layer in real time and output a feedback signal. The insulating layer covers the conductive heating layer to isolate the circuit. The temperature sensing layer covers the insulating layer, realizing planar temperature monitoring and outputting a temperature feedback signal of the heating area in real time. Unlike traditional point sensing, this achieves real-time temperature sensing of the entire heating area, improving the ability to accurately control the temperature.

[0012] Furthermore, the control component is electrically connected to the temperature sensing layer and the conductive heating layer, respectively. The control component receives feedback signals from the temperature sensing layer and identifies local temperature anomalies caused by partial folding or covering based on these signals, thereby adjusting or cutting off the power input to the conductive heating layer. This avoids local overheating caused by folding, improves the safety and reliability of the system, and gives the heating system intelligent capabilities of "self-protection and self-regulation."

[0013] Furthermore, the heating component is provided with electrodes arranged along its edge. The electrodes have a wavy or S-shaped trace structure to accommodate the tensile deformation of the heating component. The heating component is connected to the control component via the electrodes. This prevents the electrodes from breaking at folds, improves system flexibility, ensures contact reliability, and enhances lifespan under high-frequency folding conditions.

[0014] Furthermore, the thickness of the conductive heating layer is 0.02 mm to 0.15 mm. Setting the thickness of the conductive heating layer between 0.02 and 0.15 mm allows it to heat up quickly while maintaining flexibility and adhesion, combining flexibility and heating capacity, while also maintaining extremely high flexibility and a thin profile.

[0015] Furthermore, the heating assembly also includes a protective layer that covers the base layer and the conductive heating layer. This protective layer provides electrical insulation, mechanical protection, and environmental sealing. This enhances the system's outdoor adaptability and weather resistance, protects the conductive structure from wear or oxidation, and extends its overall service life.

[0016] The beneficial effects of this utility model are as follows: This utility model penetrates the conductive heating layer into the fiber gaps of the base layer, so that the heating layer and the fabric form a conductive composite structure, which avoids the problems of easy detachment and breakage of the traditional "heating wire" heating structure. The conductive path remains continuous in the bending, folding or twisting state, thereby greatly improving the service life and reliability in flexible environments.

[0017] The heating layer, which is multi-layered and has a conductive filler concentration gradient, can actively optimize the resistance path according to the heat flow distribution, so that it can maintain uniform heating even after folding, and significantly reduce the risk of local temperature anomalies or hot spots.

[0018] The temperature sensing layer covers the heating area. By controlling the closed-loop adjustment of the electric heating power through the control components, it can identify temperature anomalies caused by folding, covering, or local pressure in real time, and build a surface temperature monitoring network, thereby realizing a technical system of structural flexibility, full-area temperature sensing, and intelligent temperature control. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of a foldable high-temperature precision control heating system according to the present invention;

[0020] Figure 2 This is a cross-sectional schematic diagram of a foldable high-temperature precision control heating system according to the present invention.

[0021] The reference numerals in the figures include:

[0022] 1. Heating component; 2. Control component; 3. Base layer; 4. Conductive heating layer; 5. Insulating layer; 6. Temperature sensing layer; 7. Electrode; 8. Heat orientation layer; 9. Protective layer. Detailed Implementation

[0023] To further illustrate the technical means and effects adopted by this utility model in order to achieve the intended utility model purpose, the following detailed description of the specific implementation methods, structure, features and effects of this utility model is provided in conjunction with the accompanying drawings and preferred embodiments.

[0024] Please see Figures 1 to 2 As shown, this utility model discloses a foldable high-temperature precision control heating system, including a heating component 1 and a control component 2. The control component 2 is electrically connected to the heating component 1 and is used to control the start / stop of the heating process of the heating component 1. The heating component 1 includes a base layer 3 and a conductive heating layer 4 stacked sequentially. The base layer 3 is a flexible fiber fabric structure. The conductive heating layer 4 is coated on the base layer 3 and penetrates into the fiber gaps of the base layer 3, forming an integrated conductive composite structure with the base layer 3. The conductive composite structure maintains a continuous conductive path and stable heating output even when bent, folded, or twisted. This utility model avoids the problems of easy detachment and breakage of traditional "heating wire" heating structures by having the conductive heating layer 4 penetrate into the fiber gaps of the base layer 3 to form a conductive composite structure with the fabric. The conductive path remains continuous even when bent, folded, or twisted, thus significantly improving the service life and reliability in flexible environments.

[0025] Specifically, the base layer 3 adopts a flexible fiber fabric structure, such as high-temperature resistant polyester fabric, nylon fabric, or carbon fiber fabric. This base layer 3 acts as the system's skeleton and load-bearing structure, possessing good flexibility and mechanical strength. The conductive heating layer 4 (e.g., carbon-based conductive paste) is applied to the base layer 3 through processes such as coating, printing, or spraying. The control component 2 is electrically connected to the conductive heating layer 4 via lead-out electrodes 7. During operation, the control component 2 supplies power to the conductive heating layer 4 according to instructions to initiate heating; when preset conditions are met or a stop command is received, the control component 2 cuts off the power supply to stop heating. The core of this system lies in the fact that its heating component 1 can maintain conductivity and heating stability even under extreme deformation.

[0026] Specifically, the control component 2 is a hardware circuit module, typically implemented in the form of a rigid printed circuit board (PCB), used to receive external commands, acquire temperature feedback signals, calculate power requirements, and drive the heating component 1.

[0027] The base layer 3 is one of high-temperature resistant nylon cloth, polyester fiber cloth, or glass fiber cloth. This ensures that the main body of the heating component 1 does not melt or deform under long-term high temperatures. In flexible application scenarios, the use of a high-temperature resistant fabric base gives the structure both flexibility and high-temperature resistance.

[0028] Preferably, the base layer 3 is a high-temperature resistant nylon fabric. The high-temperature resistant nylon fabric not only has good flexibility, but also has a high temperature resistance level, which can meet the requirements of the system for high-temperature operation.

[0029] The conductive heating layer 4 is a multi-layered stacked carbon-based conductive paste, with different conductive filler concentration gradients between each layer to optimize the heat output uniformity of the heating component 1. The different conductive filler concentrations in each layer form a resistance gradient structure. When folding causes localized stress or thickness changes, different layers can automatically share the current, maintaining uniform heating, solving the hotspot problem caused by sudden changes in localized resistance after folding, improving the uniformity of temperature distribution in the heating area, enhancing structural redundancy, and maintaining basic heating function even when one layer experiences localized damage.

[0030] Specifically, the concentration of the conductive filler gradually decreases along the thickness direction of the conductive heating layer 4, and the concentration on the side closer to the substrate layer 3 is greater than the concentration on the side farther from the substrate layer 3.

[0031] The carbon-based conductive paste is one of the following: modified graphene wire ink, multi-walled carbon nanotube paste, or carbon fiber blended layer. It enhances the high-temperature resistance of the conductive layer, making it suitable for high-temperature heating applications, strengthens adhesion, and allows for more complete penetration into the substrate layer 3.

[0032] Preferably, the carbon-based conductive paste is a modified graphene wire ink, which has excellent flexibility and conductivity.

[0033] The conductive heating layer 4 is formed on the base layer 3 by printing, impregnation, or spraying. This improves the uniformity and bonding strength of the conductive layer, making it suitable for mass production and reducing costs.

[0034] Specifically, after curing, the conductive heating layer 4 and the base layer 3 form an integrated conductive composite structure. This permeation bonding effectively utilizes the confinement effect of the fibers in the base layer 3, effectively suppressing the propagation of microcracks in the conductive material layer when the heating component 1 is subjected to bending, folding, or torsion. This ensures the continuity of the conductive path and maintains a stable heating output, greatly improving the system's durability and reliability.

[0035] The heating assembly 1 further includes an insulating layer 5 and a temperature sensing layer 6. The insulating layer 5 is disposed on the conductive heating layer 4, and the temperature sensing layer 6 is disposed on the insulating layer 5, covering the entire heating area of ​​the conductive heating layer 4. The temperature sensing layer 6 is used to monitor the temperature field state of the conductive heating layer 4 in real time and output a feedback signal. The insulating layer covers the conductive heating layer 4 to isolate the circuit. The temperature sensing layer 6 covers the insulating layer, realizing planar temperature monitoring and outputting a temperature feedback signal of the heating area in real time. Unlike traditional point sensing, this achieves real-time temperature perception of the entire heating area, improving the ability to accurately control the temperature.

[0036] Preferably, the temperature sensing layer 6 is directly printed or coated onto the surface of the conductive heating layer 4 through the insulating isolation layer 5, forming an integrated "heating-temperature sensing" functional film. The integrated heating and temperature sensing structure reduces air gaps between layers, improving temperature sensing accuracy; the structure is thinner and more flexible, avoiding temperature sensing delays caused by interlayer slippage; the manufacturing process is simplified, resulting in higher reliability. The "heating-temperature sensing integrated film" design overcomes the problem of traditional temperature sensors requiring independent installation, achieving a truly self-sensing flexible heating material.

[0037] Preferably, the temperature sensing layer 6 is made of a negative temperature coefficient (NTC) thermistor material layer (e.g., a thermistor polymer thick film ink). This material layer has a unique characteristic: its electrical impedance value continuously and stably decreases as the temperature increases. The temperature sensing layer 6 is designed to completely cover the heating area of ​​the conductive heating layer 4, forming a blind-spot-free planar temperature monitoring network. Utilizing the characteristics of the NTC material, a continuous and stable quantitative relationship between temperature changes and electrical signal changes is ensured, providing high-precision thermal state input for the control component 2. Since the material's own electrical impedance value change characteristics are well-defined, the temperature calibration and anomaly identification logic of the control component 2 can be programmed based on known material properties, simplifying the design and reliability verification of the control system.

[0038] Preferably, the insulating layer 5 is made of an ultra-thin, high-temperature resistant insulating material with good thermal conductivity (e.g., a 25μm thick polyimide or PET film) and is used for the temperature sensing layer 6 and the conductive heating layer 4.

[0039] The control component 2 is electrically connected to the temperature sensing layer 6 and the conductive heating layer 4, respectively. The control component 2 receives feedback signals from the temperature sensing layer 6 and identifies local temperature anomalies caused by partial folding or covering based on these feedback signals. It then adjusts or cuts off the power input to the conductive heating layer 4. This avoids local overheating caused by folding, improves the safety and reliability of the system, and gives the heating system intelligent capabilities of "self-protection and self-regulation."

[0040] The heating component 1 is provided with an electrode 7, which is arranged along the edge of the heating component 1. The electrode 7 has a wavy or S-shaped wiring structure to match the tensile deformation of the heating component 1. The heating component 1 is connected to the control component 2 via the electrode 7. This prevents the electrode 7 from breaking at the fold, improves the system flexibility, ensures contact reliability, and enhances the lifespan under high-frequency folding conditions.

[0041] The thickness of the conductive heating layer 4 is 0.02 mm to 0.15 mm. The thickness of the conductive heating layer 4 is set at 0.02–0.15 mm so that it can heat up quickly while maintaining flexibility and adhesion, combining flexibility and heating capacity, and maintaining extremely high flexibility and thinness.

[0042] The heating component 1 also includes a protective layer 9, which covers the base layer 3 and the conductive heating layer 4. The protective layer 9 provides electrical insulation, mechanical protection, and environmental sealing. This enhances the system's outdoor adaptability and weather resistance, protects the conductive structure from wear or oxidation, and extends the overall service life.

[0043] Specifically, the heating component 1 further includes a heat orientation layer 8; the heat orientation layer 8 is disposed on the side of the temperature sensing layer 6 away from the conductive heating layer 4, and the heat orientation layer 8 is composed of an infrared reflective material with low emissivity (such as a metal thin film or a metallized polymer); the heat orientation layer 8 is used to effectively reflect heat back to the target heating surface, reduce heat loss to the non-working direction, and improve the heating efficiency and energy utilization of the system.

[0044] Specifically, the local overheat protection logic executed by the control component 2 is as follows: the temperature sensing layer 6 is equivalent to a network composed of countless micro-resistors connected in parallel or series; when the conductive heating layer 4 undergoes local folding, causing a sharp increase in local temperature, the resistance value of the micro-resistors in the heated area changes abruptly, causing a nonlinear change in the total impedance value at both ends of the temperature sensing layer 6; the control component 2 captures the slope (dZ / dt) of the change in the total impedance value, and when the slope exceeds a preset safety threshold, it determines that there is local overheating and executes power-off protection.

[0045] In this embodiment, after the system is powered on, the conductive heating layer 4 generates heat. Thanks to its flexible structure, the heating component 1 can withstand arbitrary bending, rolling, or folding operations. Simultaneously, the temperature sensing layer 6 senses the temperature distribution across the entire heating plane in real time. Because it employs a continuous planar temperature sensing structure, its output electrical feedback signals (such as overall impedance and voltage) can represent the comprehensive thermal state of the entire heating area. The core function of the control component 2 is to identify local temperature anomalies. The control component 2 continuously collects feedback signals from the temperature sensing layer 6. When the flexible composite heating body is partially folded or covered, the heat in that local area cannot dissipate, and the temperature rises rapidly. Since the temperature sensing layer covers the entire hot spot area, the impedance (or voltage) of the heated area will experience a sharp, unexpected abnormal change. After the logic program built into the control component 2 detects this abnormal signal change caused by local heat accumulation, it immediately determines it as a local overheating state and executes actions to reduce or cut off the power input of the conductive heating layer 4. The innovation of this embodiment lies in integrating a flexible heating structure with conformal bending elasticity with a fully covered planar continuous temperature sensing structure. This structure ensures that the system meets the mechanical requirements of arbitrary folding while solving the monitoring blind spot problem of traditional point sensors in flexible body applications, thereby achieving highly reliable and precise control and active safety protection.

[0046] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. A foldable high-temperature precision control heating system, characterized in that, The heating component includes a heating element (1) and a control element (2). The control element (2) is electrically connected to the heating element (1) and is used to start / stop the heating process of the heating element (1). The heating element (1) includes a base layer (3) and a conductive heating layer (4) stacked in sequence. The base layer (3) is a flexible fiber fabric structure. The conductive heating layer (4) is coated on the base layer (3) and penetrates into the fiber gaps of the base layer (3), so that the conductive heating layer (4) and the base layer (3) form an integrated conductive composite structure. The conductive composite structure maintains a continuous conductive path and a stable heating output when bent, folded or twisted.

2. The foldable high-temperature precision control heating system according to claim 1, characterized in that: The base layer (3) is one of high-temperature resistant nylon cloth, polyester fiber cloth or glass fiber cloth.

3. The foldable high-temperature precision control heating system according to claim 1, characterized in that: The conductive heating layer (4) is a multi-layer stacked carbon-based conductive paste, wherein each layer of carbon-based conductive paste has a different conductive filler concentration gradient to optimize the heat output uniformity of the heating component (1).

4. The foldable high-temperature precision control heating system according to claim 3, characterized in that: The carbon-based conductive paste is one of the following: modified graphene wire ink, multi-walled carbon nanotube paste, or carbon fiber blended layer.

5. The foldable high-temperature precision control heating system according to claim 1, characterized in that: The conductive heating layer (4) is formed on the base layer (3) by printing, dipping or spraying.

6. The foldable high-temperature precision control heating system according to claim 1, characterized in that: The heating component (1) further includes an insulating layer (5) and a temperature sensing layer (6). The insulating layer (5) is disposed on the conductive heating layer (4), and the temperature sensing layer (6) is disposed on the insulating layer (5) and covers the entire heating area of ​​the conductive heating layer (4). The temperature sensing layer (6) is used to monitor the temperature field state of the conductive heating layer (4) in real time and output a feedback signal.

7. The foldable high-temperature precision control heating system according to claim 6, characterized in that: The control component (2) is electrically connected to the temperature sensing layer (6) and the conductive heating layer (4) respectively. The control component (2) receives the feedback signal from the temperature sensing layer (6) and identifies the local temperature anomaly caused by local folding or covering based on the feedback signal, thereby adjusting or cutting off the power input of the conductive heating layer (4).

8. The foldable high-temperature precision control heating system according to claim 1, characterized in that: The heating component (1) is provided with an electrode (7), which is arranged along the edge of the heating component (1). The electrode (7) has a wavy or S-shaped wiring structure to match the tensile deformation of the heating component (1). The heating component (1) is connected to the control component (2) via the electrode (7).

9. A foldable high-temperature precision control heating system according to claim 1, characterized in that: The thickness of the conductive heating layer (4) is 0.02 mm to 0.15 mm.

10. A foldable high-temperature precision control heating system according to claim 1, characterized in that: The heating component (1) also includes a protective layer (9), which covers the outside of the base layer (3) and the conductive heating layer (4). The protective layer (9) is used to achieve electrical insulation, mechanical protection and environmental sealing.

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