Capacitive Sensor Electrode Integrated in Conductive Ink Heater
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Solution Overview
Problem
Current heater designs incorporating positive temperature coefficient (PTC) conductive ink require cumbersome steps to integrate control circuitry and sensors for automatic switching, making it difficult to efficiently control the heater's on and off functionality.
Innovation Solution
A capacitive sensor electrode is integrated into the same layer of conductive ink used for the open heater circuit pattern, allowing for electrical isolation and control of the PTC conductive ink heater through a capacitive switch, enabling selective control of electrical current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If control circuitry and sensors are integrated into PTC conductive ink heaters using conventional methods, then the heater can be controlled for automatic switching, but the manufacturing process becomes cumbersome and complex
Solution Approach 1:
The patent merges the capacitive sensor electrode with the conductive ink layer used for heater circuit patterns. The sensor electrode is formed as part of the same conductive ink deposition process, eliminating separate integration steps for control circuitry and sensors. This combining approach reduces manufacturing complexity while enabling automatic switching control functionality.
Solution Approach 2:
The conductive ink layer serves multiple functions: it forms both the heater circuit patterns and the capacitive sensor electrode. This multi-functional design allows a single material and process to provide both heating and sensing capabilities, reducing the number of components and manufacturing steps required for automated control.
2Reliability
If separate layers and components are used for control circuitry and sensor electrodes, then electrical isolation can be achieved, but the manufacturing steps increase and efficiency decreases
Solution Approach 1:
The patent combines the sensor electrode and heater circuit into a single conductive ink layer, forming them simultaneously during one deposition process. This eliminates multiple manufacturing steps while maintaining electrical isolation through the peripheral isolation region design, thereby improving productivity without sacrificing reliability.
Solution Approach 2:
The conductive ink layer is segmented into distinct functional regions: the heater circuit pattern, the capacitive sensor electrode, and the peripheral isolation region. This segmentation allows each component to be electrically isolated where needed while being formed as part of a single integrated structure, maintaining reliability with reduced manufacturing complexity.
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
This solution simplifies the integration of control circuitry and sensors, allowing for efficient automatic switching of the heater, reducing complexity and enhancing operational control.
Implementation Method 1
A capacitive sensor electrode spaced from and electrically isolated from the first portion of the layer of conductive ink by a peripheral isolation region surrounding the capacitive sensor electrode
Implementation Method 2
A layer of positive temperature coefficient (PTC) conductive ink on the substrate and the first portion of the layer of conductive ink is in electrical communication therewith to bridge the gaps between the heater conductive paths
Implementation Method 3
depositing conductive ink onto a substrate to form an open heater circuit pattern
Data Source
AI summary
A capacitive sensor electrode for controlling activation and deactivation of a PTC conductive ink heater can be deposited as part of the same layer of conductive ink used to form the open heater circuit pattern for the heater. A layer of conductive ink is deposited on an insulating substrate, with a first portion of the layer forming an open heater circuit pattern and a second portion of the layer forming a capacitive sensor electrode spaced from and electrically isolated from the first portion of the layer. A layer of positive temperature coefficient (PTC) conductive ink is deposited so as to bridge gaps between in the open heater circuit pattern while leaving the capacitive sensor electrode spaced from and electrically isolated from the layer of PTC conductive ink on the first portion of the layer of conductive ink.