Dual-Zone Plane Heating Element Layout 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 aesthetics, and limit uniform heat generation across the entire heating area.
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 eliminate dead zones, ensuring symmetrical heating.
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 dead zones with low temperature distribution are generated causing asymmetrical heating
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 strategically positioned at specific locations (e.g., at 45-degree angles or at dead zone positions) to compensate for the asymmetric heating distribution, thereby eliminating dead zones and achieving uniform temperature distribution across the expanded heating area.
Solution Approach 2:
The patent applies local quality principle by placing connectors at specific strategic locations within the second pattern portion, particularly at positions corresponding to dead zones or areas requiring additional heat distribution. This localized placement ensures that heat is uniformly distributed across different regions of the heating element, addressing temperature non-uniformity in specific areas rather than uniformly across the entire structure.
2Temperature
If high resistance is designed in the heating portion to generate heat at temperature higher than 500° C., then high temperature heating is achieved, but excessive local heating occurs and the hot wire is destroyed
Solution Approach 1:
The patent applies segmentation principle by dividing the heating element into multiple pattern portions (first and second pattern portions) with multiple connectors distributed across different locations. This segmentation distributes the electrical load and heat generation across multiple zones, preventing excessive current concentration in any single area, thereby avoiding localized overheating and hot wire destruction while maintaining high temperature heating capability.
3Ease of manufacture
If connectors are placed to connect the first pattern portion with electrodes, then electrical connection is established, but dead zones are generated in the second pattern portion where connectors are not placed
Solution Approach 1:
The patent applies local quality principle by strategically placing connectors at specific locations within the second pattern portion, particularly at positions corresponding to dead zones or areas requiring additional heat distribution. This localized placement ensures that heat is uniformly distributed across different regions of the heating element, addressing temperature non-uniformity in specific areas rather than uniformly across the entire 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
This configuration effectively increases the high-temperature area, eliminates dead zones, and enhances heating efficiency and aesthetics by uniformly generating heat across the entire heating zone.
Implementation Method 1
a heating element attached to the surface of the substrate and having a predetermined shape
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.