Heating element and method of use
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Solution Overview
Problem
Existing heating element designs are limited by their two-dimensional nature and manufacturing challenges, leading to restricted applications and potential for oxidation at joints, which reduces conductivity and creates hot spots.
Innovation Solution
A heating element with a continuous single sheet of material, featuring terminals, segments, and buses with elliptical cutouts in a repeating pattern, allowing for differential heating and three-dimensional configurations, which reduces the need for joints and enhances flexibility and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If heating elements are constructed with multiple segments and joints, then the current path can be extended, but oxidation at joints occurs which reduces conductivity and creates hot spots
Solution Approach 1:
The patent merges multiple heating element segments into a continuous single sheet of material, eliminating joints between segments. This single continuous structure provides an extended current path without the oxidation problems that occur at joints in multi-segment constructions, directly resolving the contradiction between extending current path and preventing joint oxidation.
Solution Approach 2:
The patent incorporates cutouts in the heating element that create segmented heating zones while maintaining a continuous material structure. This allows different regions to provide different levels of heating (differential heating) without requiring physical joints, thus extending functional complexity without compromising reliability.
2Adaptability or versatility
If heating elements use thin gauge foil sheets, then flexibility for different applications is improved, but manufacturing challenges and oxidation susceptibility increase
Solution Approach 1:
The patent transitions from traditional two-dimensional flat heating elements to a three-dimensional configuration by forming the single sheet of material into raised portions and valleys. This adds a vertical dimension that enables complex shapes and differential heating while maintaining the flexibility advantages of thin gauge material, and the continuous structure simplifies manufacturing by eliminating multi-segment assembly.
Solution Approach 2:
The patent creates regions with different properties within the single heating element by forming raised portions with greater mass that provide higher levels of heating. This local differentiation of heating intensity is achieved through geometric variation rather than material changes or additional components, maintaining simplicity while enabling application-specific customization.
3Adaptability or versatility
If heating elements are designed with complex patterns and cutouts, then differential heating capability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent achieves differential heating by varying the mass and geometry of different regions within the single heating element rather than changing material properties or requiring precise multi-material assembly. The raised portions and valleys create natural variations in thermal output that are more tolerant of manufacturing variations, reducing precision requirements while maintaining functional 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
The solution enables improved current flow, reduced oxidation, and increased flexibility in heating element design, allowing for more complex shapes and uniform radiant heating, while minimizing manufacturing complexities and costs.
Implementation Method 1
supplying power to it to generate infrared radiation for space heating
Implementation Method 2
generate infrared radiation for space heating
Data Source
AI summary
A heating element includes first and second terminals and one or more heating element segments extending between the first and second terminals. The one or more heating element segments have a circuit trace that includes at least first and second portions, the at least first and second portions configured so that a surface temperature difference exists between the at least first and second portions when a voltage is applied between the at least first and second terminals. The heating element can also be made with a three dimensional shape, including one that is generated by fastening of the heating element to one or more support plates. The heating element can also have a cylindrical shape and be disposed in an insulating medium in a tubular member to provide varied heating capability along the tubular member length.