Dual-Surface Heater with Offset Heating Elements
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Solution Overview
Problem
Existing heaters with multiple heating elements on a long substrate face challenges in reducing size and preventing substrate damage due to thermal stress when switching heating ranges for objects of different sizes.
Innovation Solution
A heater design featuring a metal substrate with insulating and protection parts on both surfaces, where heating elements of different lengths are strategically placed to allow for adjustable heating ranges without increasing substrate width, using metal materials to enhance rigidity and reduce thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple heating elements are provided side by side in the lateral direction of the long substrate, then the heating range can be switched according to the size of the object to be heated, but the dimension of the substrate in the lateral direction becomes large, making it difficult to reduce the size of the heater
Solution Approach 1:
The patent transitions from arranging heating elements in the lateral direction to arranging them in the longitudinal direction of the substrate. By extending heating elements along the length of the substrate rather than placing them side by side across the width, the heater achieves versatile heating ranges for different object sizes while maintaining a compact lateral dimension.
2Adaptability or versatility
If multiple heating elements are provided on one surface of a long substrate, then the heating range can be switched according to the size of the object to be heated, but the temperature difference in the longitudinal direction of the long substrate may become large, causing the substrate to crack due to generated thermal stress
Solution Approach 1:
The patent divides the heating function into multiple heating elements of different lengths positioned at different locations along the longitudinal direction of the substrate. This segmentation allows selective activation of heating elements based on object size, enabling heating range switching while distributing thermal stress across multiple segments rather than concentrating it in one large heating zone.
Solution Approach 2:
The patent implements local quality by providing heating elements with different lengths at different positions along the substrate. Each heating element is optimized for specific heating ranges, and the substrate structure is designed to handle thermal stress locally at each heating zone, preventing cracks by matching the heating pattern to the substrate's thermal stress distribution.
3Ease of manufacture
If a substrate made of ceramics is used, then the heater can be manufactured with traditional materials, but when the heating range is switched according to the size of the object to be heated, the temperature difference in the longitudinal direction of the long substrate may become large, and the substrate may be cracked due to the generated thermal stress
Solution Approach 1:
The patent changes the material parameter from ceramics to metal for the substrate. This material substitution maintains ease of manufacture while fundamentally improving thermal stress resistance. The metal substrate's higher ductility and thermal conductivity allow it to accommodate temperature differences and thermal stress without cracking, enabling reliable heating range switching for different object sizes.
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
Enables versatile heating for objects of varying sizes while minimizing substrate damage and size, by offsetting thermal stress through balanced heating element placement and material selection.
Implementation Method 1
a heating element provided on one surface of the substrate and extending in the longitudinal direction of the substrate
Data Source
AI summary
A heater includes: a substrate including metal and having a shape extending in one direction; a first insulating part provided on a first surface of the substrate; a first heating element provided on the first insulating part and extending along a longitudinal direction of the substrate; a first protection part provided on the first insulating part and covering the first heating element; a second insulating part provided on a second surface of the substrate facing the first surface; a second heating element provided on the second insulating part and extending along the longitudinal direction of the substrate; and a second protection part provided on the second insulating part and covering the second heating element. A length of the second heating element is different from a length of the first heating element in the longitudinal direction of the substrate.