Flexible Heating Device with Electroconductive Layer
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Solution Overview
Problem
Conventional electrical surface heating pads are often thick, inflexible, and have limited heating areas, leading to inefficient and uneven heat distribution, which is a challenge in various industries such as textile, automotive, and healthcare.
Innovation Solution
A flexible heating device comprising a flexible substrate layer with an electroconductive heat module that includes a flexible heat generating layer, a conductivity layer, and a lateral heat transfer layer, designed to provide two-dimensional electroconductive heating with a surface resistance range of 2-15 ohms/square, utilizing carbon black particles, carbon nanotubes, and graphene for efficient heat generation and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional resistance heating elements (copper wires, carbon fiber wires) are used, then heating function is provided, but the heating pad becomes thick and inflexible with limited heating area
Solution Approach 1:
The patent replaces conventional mechanical resistance heating elements (copper wires, carbon fiber wires) with a flexible heat generating layer made of electrically conductive material that generates heat through electroconductive heating. This substitution enables two-dimensional heating across the entire surface area while maintaining flexibility and eliminating the thickness issues associated with wire-based heating elements.
Solution Approach 2:
The patent transitions from one-dimensional wire heating to two-dimensional surface heating by using a flexible heat generating layer that spans the entire surface area. This dimensional change allows heat to be generated uniformly across the whole surface rather than along linear wire paths, significantly improving heating coverage and uniformity while maintaining flexibility.
2Area of stationary object
If conventional wire-based heating elements are used, then heating is generated, but the heating area is limited relative to the size of the surface
Solution Approach 1:
The patent implements two-dimensional electroconductive heating across the entire surface area of the flexible heating pad, replacing the one-dimensional wire heating approach. This enables the heating area to cover the full surface rather than being limited to wire paths, significantly improving both heating coverage and efficiency.
Solution Approach 2:
The patent changes the electrical resistance parameter by using a flexible heat generating layer with specific surface resistance (2-15 ohms/square) that is optimized for two-dimensional heating. This resistance parameter allows efficient heat generation across the entire surface area, improving heating efficiency compared to conventional wire-based systems.
3Temperature
If the flexible heat generating layer has perforations to reduce temperature gradient, then heat distribution is improved, but the electrical conductivity may be affected
Solution Approach 1:
The patent applies local quality by having the flexible heat generating layer with perforations in specific regions to manage temperature gradients. The perforations are strategically placed to allow heat transfer while maintaining sufficient electrical conductivity pathways, achieving localized thermal management without compromising overall electrical performance.
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 flexible heating device offers uniform and efficient heating across a larger surface area, improving heat distribution and flexibility, making it suitable for therapeutic patient warming during anesthesia and surgery, while being adaptable to different applications.
Implementation Method 1
The flexible heat generating layer is made of an electrically conductive material having a surface resistance sufficient to generate two-dimensional electroconductive heating when an electric current flows between the first and second electrodes
Implementation Method 2
The lateral heat transfer layer may be interposed between the flexible substrate layer and the flexible heat generating layer for laterally transferring heat from the flexible heat generating layer
Data Source
AI summary
This present disclosure relates to a flexible heating device having a unique layered assembly structure including a flexible heat generating layer. The present disclosure also relates to a method of manufacturing the flexible heating device and method of use of the flexible heating device in various applications.