Dual-Zone Plane Heating Element Design to Eliminate Dead Zones
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Solution Overview
Problem
Conventional electric heaters with plane heating elements suffer from asymmetrical heating, leading to dead zones with lower temperature distributions, which reduce heating efficiency and create aesthetically undesirable appearances due to the formation of hot and dead zones.
Innovation Solution
The electric heater design includes a substrate with a first plane heating element and a second plane heating element, where the second pattern portion is formed outside the first, with connectors and electrodes strategically placed to maximize high-temperature areas and ensure symmetrical heating, eliminating dead zones by configuring the heating elements in a dual or triple pattern type to uniformly distribute heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a second pattern portion is formed outside a first pattern portion to expand heating area, then the heating area is increased, but asymmetrical heating occurs and dead zones are generated
Solution Approach 1:
The patent applies asymmetry principle by intentionally designing the second pattern portion with asymmetric connector placement relative to the first pattern portion. The connectors are positioned at specific asymmetric locations to compensate for the inherent asymmetry of the second pattern portion, ensuring symmetrical heat distribution across the entire heating area and eliminating dead zones.
Solution Approach 2:
The patent implements local quality by varying the connector placement strategy for different zones. The first pattern portion uses one connector configuration while the second pattern portion uses a different connector configuration, with each locally optimized to achieve uniform heat distribution in its respective zone while contributing to overall symmetry.
2Temperature
If high resistance is designed to generate heat above 500°C, then heating temperature is improved, but excessive local heating occurs and hot wire is destroyed
Solution Approach 1:
The patent applies local quality by designing different resistance characteristics for different pattern portions. The first pattern portion has higher resistance to generate intense heat for rapid cooking, while the second pattern portion has lower resistance to provide supplementary heating and prevent excessive temperature concentration, thereby distributing thermal stress and improving hot wire durability.
Solution Approach 2:
The patent converts the potential harm of excessive local heating into a benefit by strategically placing the second pattern portion with lower resistance in areas prone to excessive heating. This converts the harmful concentration of heat into a beneficial distributed heating pattern that protects the hot wire while maintaining overall heating effectiveness.
3Reliability
If connectors are placed to connect pattern portions with electrodes, then electrical connection is established, but asymmetrical placement causes uneven heat distribution
Solution Approach 1:
The patent applies asymmetry principle by intentionally designing the connector placement to be asymmetric relative to the pattern portions they connect. The connectors are positioned at specific asymmetric locations that compensate for the asymmetric geometry of the second pattern portion, ensuring that the resulting heat distribution is symmetrical across the entire heating area.
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 configuration enhances heating efficiency by maximizing the high-temperature area, ensuring uniform heat distribution, and improving the aesthetic appearance by eliminating dead zones, thus shortening cooking time and preventing electrode damage from excessive heating.
Implementation Method 1
a heating element attached to the surface of the substrate, current flowing through the heating element generates heat
Data Source
AI summary
An electric heater includes a substrate (an insulating material capable of forming a conductor pattern on a surface of an insulating substrate), a first plane heating element formed on one surface of the substrate, and a second plane heating element formed on one surface of the substrate to be located outside the first plane heating element. The first plane heating element includes a first pattern portion connecting a start point with an end point located in a first zone, a pair of first electrodes located outside the first zone, and a pair of first connectors connecting the first pattern portion with the first electrodes. The second plane heating element includes a second pattern portion located in a second zone surrounding the first zone and connecting a start point with an end point, and at least some of the first connectors are located in the second zone.