Flexible Heating Element Coil Pattern for Thermal Management
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Solution Overview
Problem
Existing heating elements face challenges in being economical, reliable, and lightweight due to material selection and manufacturing methods, which are critical for various industrial applications.
Innovation Solution
A heating element with a flexible substrate and a continuous strand of electrically conductive wire formed into a pattern of coil structures, where each coil has a counterclockwise and clockwise pattern, connected by connector segments, is created using a roll-to-roll web process with inexpensive and environmentally clean methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional heating elements are manufactured using conventional methods, then manufacturing precision and reliability can be maintained, but production cost increases and manufacturing complexity increases
Solution Approach 1:
The patent changes the manufacturing approach from precision machining of individual heating elements to a roll-to-roll web process that forms coil structures from continuous wire on flexible substrate. This parameter change enables high-volume production with consistent precision through automated processes rather than manual or batch manufacturing.
Solution Approach 2:
The patent replaces traditional mechanical manufacturing methods with a web-based process where continuous wire is laid and formed into coil structures on moving substrate. This substitution enables continuous production with automated control, reducing both cost and complexity while maintaining precision.
2Adaptability or versatility
If heating elements are designed with fixed rigid structures, then manufacturing precision is easier to achieve, but adaptability to different applications and thermal expansion/contraction is reduced
Solution Approach 1:
The patent uses flexible substrate and flexible wire structures that can bend and conform to different application geometries. The coil structures are formed from continuous wire that can accommodate thermal expansion and contraction while maintaining electrical connectivity and heating function across various application scenarios.
Solution Approach 2:
The patent creates dynamically adaptable heating elements where the flexible wire coils can expand and contract with thermal cycles. The continuous wire structure allows for dynamic adjustment to different mounting configurations and application requirements while maintaining structural integrity through the flexible substrate support.
3Productivity
If continuous wire is used to form coil structures, then material efficiency and productivity improve, but wire placement precision and structural reliability become more challenging
Solution Approach 1:
The patent replaces manual or batch wire placement with an automated web process where continuous wire is precisely laid and formed into coil structures on moving substrate. Automated control systems ensure consistent wire placement accuracy while enabling continuous high-volume production.
Solution Approach 2:
The patent uses continuous wire fed through the manufacturing process to form coil structures without interruption. This continuous action enables uninterrupted production flow, maximizing productivity while automated guidance systems maintain precise wire placement throughout the continuous forming process.
4Ease of manufacture
If multiple separate heating elements are manufactured, then individual reliability can be optimized, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent combines multiple heating element functions into a single continuous flexible substrate with integrated coil structures. Multiple coils can be formed from continuous wire on the same substrate, creating a unified heating assembly that reduces manufacturing steps, material waste, and assembly complexity while maintaining reliability through consistent factory integration.
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 the production of reliable, economical, and lightweight heating elements with a wide range of sizes and voltage levels, ensuring equal electric potential between coil structures and reducing thermal risks, while maximizing substrate space and accommodating expansion and contraction.
Implementation Method 1
a continuous strand of electrically conductive wire disposed on the adhesive in a pattern of a plurality of coil structures
Data Source
AI summary
A heating element includes a flexible substrate, a layer of adhesive disposed on a surface of the substrate, and a continuous strand of electrically conductive wire disposed on the adhesive in a pattern of coil structures. Each coil structure includes a first coiled part and a second coiled part. The wire in the first coiled part forms a counterclockwise pattern from an outermost turn to an innermost turn of the first coiled part, and the second coiled part has an innermost turn beginning at an end of the innermost turn of the first coiled part. The wire in the second coiled part forms a clockwise pattern from the innermost turn of the second coiled part to an outermost turn. A connector segment of wire connects outermost turns of adjacent ones of the coil structures.