Flexible Heating Device with Segmented PTC Foil for Uniform Heat
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Solution Overview
Problem
Existing electric heating devices for personal hygiene products, such as lady pants and napkin cases, face issues with uneven heating, oxidation in moist environments, rigidity, and complex temperature control, leading to potential short circuits and reduced usability.
Innovation Solution
A rechargeable electrical heating device featuring a flexible heat generator with a PTC carbon foil and silver conductive lines, encapsulated in TPU, allowing for self-temperature control and flexibility, and powered by a rechargeable or disposable battery, ensuring consistent heating without complex structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electric heating wires are used for heating, then heating function is achieved, but uneven heating and local overheating occur
Solution Approach 1:
The heating element is divided into multiple discrete heating sections (first heating section, second heating section, etc.) distributed across different flexible substrates. Each heating section contains multiple heating wires arranged in parallel, creating a segmented heating structure that distributes heat more uniformly across the heating area and prevents local overheating.
Solution Approach 2:
Different regions of the heating device have different heating sections configured to provide localized heating control. The heating wires in each section can be independently controlled, allowing different temperature zones to be created according to specific heating requirements, achieving both uniform overall heating and localized temperature control.
2Adaptability or versatility
If electric heating wires are sewed in the product, then heating function is integrated, but the product becomes hard to bend
Solution Approach 1:
The heating wires are mounted on flexible substrates (such as flexible circuit boards or flexible printed circuits) rather than being sewn directly into the product. These flexible substrates can bend and deform without damaging the heating wires, maintaining both the heating function and the flexibility of the final product. The substrates act as flexible carriers that protect the rigid heating wires while allowing bending motion.
Solution Approach 2:
The heating structure transitions from a two-dimensional sewn configuration to a multi-layered three-dimensional structure where heating wires are mounted on flexible substrates that can bend in multiple directions. This dimensional change allows the heating element to maintain its electrical connections while accommodating bending movements in various planes.
3Reliability
If electric heating wires are used in moist environment, then heating function is provided, but oxidation and short circuit occur
Solution Approach 1:
Flexible substrates and protective enclosures act as intermediary barriers between the heating wires and the moist environment. These substrates provide physical protection and electrical insulation, preventing moisture from directly contacting the heating wires and causing oxidation or short circuits, while still allowing the heating function to operate effectively.
Solution Approach 2:
The invention replaces traditional mechanical sewing connections with electrical connections on flexible substrates. This substitution eliminates the need for penetrations or openings that would expose heating wires to moisture, providing inherent protection against oxidation and short circuits while maintaining the heating function.
4Reliability
If temperature control and fuse are added, then safety and control are improved, but structure becomes complex
Solution Approach 1:
The heating device incorporates self-regulating heating sections that automatically control their own temperature based on local conditions. Each heating section can independently regulate its temperature without requiring external control systems, providing both temperature control and safety functions while keeping the overall structure simple and avoiding complex control circuits.
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 device provides uniform and reliable heating, is resistant to moisture, flexible, and self-regulates temperature, extending its usage period and simplifying control, thus overcoming the limitations of existing technologies.
Implementation Method 1
a first heat generating line arranged on the first flexible substrate layer and covering a portion of the first conductive line
Implementation Method 2
PTC carbon foil
Implementation Method 3
the second flexible substrate layer is bonded to the first flexible substrate layer by means of a hot-pressing process
Data Source
AI summary
The present disclosure discloses a rechargeable electrical heating device (1), comprising a flexible heat generator (1a) and a power source (1b) connected to the flexible heat generator (1a), wherein the flexible heat generator (1a) comprises: a first flexible substrate layer (11), a conductive line (12) comprising a positive line (121) and a negative line (122), a first heat generating line (13), a second flexible substrate layer (14), and a first connector (15), wherein the positive line (121) and the negative line (122) are not directly connected to each other, and wherein the positive line (121) is electrically connected to the negative line (122) by means of the first heat generating line (13).