AC Vacuum Sealer Heating Element With Shock-Protected Insulation
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Solution Overview
Problem
Conventional household vacuum sealers using low-voltage direct currents face safety hazards due to inadequate insulation and lack of anti-shock features, preventing the use of AC power which could enhance heating efficiency.
Innovation Solution
A household vacuum sealer design that uses AC power with a laminated heating layer, insulated composite layer, and protective cap to ensure safety and efficiency, featuring a laminated heating layer with polyimide and metal resistance tapes, and a protective cap to prevent electric shock, along with a NTC thermistor and thermal fuse for temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If AC power is used to power the heating wire, then heating efficiency and working efficiency are improved, but safety hazards increase due to inadequate insulation and lack of anti-shock features
Solution Approach 1:
The patent applies composite materials by combining multiple insulating tape layers (Teflon tape, polyimide tape, and other insulating materials) to form a multi-layer insulated composite structure around the heating wire. This composite insulation structure provides both high-temperature resistance and electrical insulation, enabling safe AC power operation while maintaining heating efficiency.
Solution Approach 2:
The patent implements beforehand cushioning by pre-installing a protective cap with insulating properties over the heating wire assembly before AC power is applied. This protective cap serves as a preliminary safety barrier that prevents direct exposure to high voltage and provides shock protection, allowing the system to operate safely at AC voltages without risking electric shock to users.
2Ease of manufacture
If only 1-3 layers of insulating tape are used to cover the heating wire, then fabrication cost is reduced, but insulation reliability deteriorates due to inability to pass high voltage test and easy breaking
Solution Approach 1:
The patent uses composite materials by combining multiple types of insulating tapes (Teflon tape, polyimide tape, and other insulating materials) in a multi-layer structure. This composite approach provides superior insulation reliability and high-voltage testing performance compared to single-layer tape, while the modular layer structure remains cost-effective to manufacture.
Solution Approach 2:
The patent employs flexible shells and thin films by using multiple thin insulating tape layers that are staked and adhered together to form a flexible yet robust insulation structure. These thin film layers provide adequate insulation for AC power operation while maintaining flexibility and resistance to breaking, balancing cost and reliability.
3Device complexity
If the exposed insulating tape is broken easily, then device complexity is reduced, but safety hazards increase due to electric shock risk
Solution Approach 1:
The patent applies beforehand cushioning by installing a protective cap over the heating wire assembly before any exposure to users or environment occurs. This protective cap serves as a preliminary safety barrier that prevents direct access to the heating wire and insulating tape, eliminating electric shock risk while adding minimal structural complexity.
Solution Approach 2:
The patent uses flexible shells and thin films by employing a protective cap made of insulating material that encloses the heating wire and insulating tape. This protective shell provides continuous protection against electric shock while maintaining flexibility and adding minimal complexity to the overall device structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design allows for quick heat conduction and efficient sealing while reducing fabrication costs and safety risks, achieving a 50-70% reduction in heating time and improved safety through the use of AC power.
Implementation Method 1
The laminated heating layer includes a high-temperature resistance tapes made of polyimide and a metal resistance tape adhered on the high-temperature resistance tapes
Implementation Method 2
The hot-melt sealing element includes a negative temperature coefficient (NTC) thermistor configured to control a temperature of the laminated heating layer
Implementation Method 3
the hot-melt sealing element includes a thermal fuse configured to avoid the temperature of the laminated heating layer exceeding a set safety value
Implementation Method 4
the insulated composite layer includes multiple insulated tape layers which are staked and adhered to form the insulated composite layer
Data Source
AI summary
A household vacuum sealer contains: a base, a lid, and a hot-melt sealing element. The base includes a receiving chamber for accommodating a control circuit and a vacuum pump. The base also includes a vacuuming chamber and an accommodation chamber. The hot-melt sealing element includes a holder, a mica slice, a laminated heating layer, the insulated composite layer, and a protective cap. The insulated composite layer includes multiple insulated tape layers. The laminated heating layer includes a high-temperature resistance tapes made of polyimide, a metal resistance tape, two electrical connection films, and two alternating current (AC) electrodes. The mica slice is parallelly fixed on a top of the holder. The laminated heating layer includes the two electrical connections. Furthermore, the protective cap is covered on the insulated composite layer and includes a hollowly elongated zone.