Flexible Polymer Heating Element With Low-Resistance PTC Layer
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Solution Overview
Problem
Conventional polymer heating elements require high electrical resistance, leading to increased costs due to the need for comb-shaped electrodes and expensive conductive pastes, and lack flexibility and reliability, especially when using extrusion molding methods.
Innovation Solution
A polymer heating element with a low-resistance polymer resistor formed on a thin film, using an electrically insulating base substrate with thin metal wire electrodes and a conductive layer containing a resin component, conductor, and additive, which improves bending resistance, bonding, and provides barrier effects against smoking and ignition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional polymer resistor with high electrical resistance (1000 Ω·cm or more) is used, then a comb-shaped electrode configuration is required to supply electricity in close proximity, but this increases the consumption quantity of expensive conductive paste and results in higher cost
Solution Approach 1:
The patent fundamentally changes the electrical resistance parameter of the polymer resistor from conventional high resistance (1000 Ω·cm or more) to low resistance (10^-2 to 10^2 Ω·cm). This parameter change enables the use of simple electrode configurations instead of complex comb-shaped electrodes, significantly reducing conductive paste consumption and manufacturing cost while maintaining heating reliability
Solution Approach 2:
The patent extracts and eliminates the need for complex comb-shaped electrode structures by reducing the polymer resistor's electrical resistance. This extraction simplifies the overall heating element design, removing the requirement for closely spaced comb electrodes and reducing dependence on expensive conductive paste materials
2Manufacturing precision
If an electrically insulating base substrate is used to coat an ink-like polymer resistor, then a heating portion can be formed in a thin film form, but the base substrate must be smooth, free from impregnation and resilient, which results in loss of flexibility
Solution Approach 1:
The patent changes the surface property parameters of the base substrate, specifically making it rough and permeable rather than smooth and non-impregnating. This allows the polymer resistor to be formed as a thin film while maintaining flexibility, as the rough and permeable surface enables better adhesion and material integration without requiring a smooth, rigid substrate
Solution Approach 2:
The patent creates a composite structure where the polymer resistor is integrated with the rough and permeable base substrate. This composite approach allows the heating element to achieve both thin film characteristics and flexibility, as the rough permeable substrate provides mechanical compliance while the polymer resistor layer provides the heating function
3Power
If a comb-shaped electrode is formed by printing and drying silver paste, then electricity can be supplied to the polymer resistor, but the consumption quantity of conductive paste increases resulting in higher price
Solution Approach 1:
The patent changes the electrical resistance parameter of the polymer resistor to low resistance values, which fundamentally alters the electricity supply requirements. This enables the use of simple electrode configurations that require minimal conductive paste, reducing material consumption from the extensive amounts needed for comb-shaped electrodes while maintaining full power supply capability
Solution Approach 2:
The patent replaces expensive silver paste-based comb-shaped electrodes with simpler electrode structures that use minimal conductive paste. This substitution uses cheaper, lower-quantity materials to achieve the same electrical supply function, significantly reducing the quantity of expensive conductive paste required
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 results in a cost-effective, flexible, and reliable planar heating element with enhanced usability and durability, capable of maintaining function over prolonged use without the need for complex configurations or expensive materials.
Implementation Method 1
a conductive layer which is in contact with both the electrodes and the polymer resistor
Implementation Method 2
a polymer heating element which utilizes Joule heat of a polymer resistor
Data Source
AI summary
A polymer heating element includes an electrically insulating base substrate, at least a pair of electrodes made of a plurality of thin metal wires formed on the electrically insulating base substrate, a polymer resistor which is not in direct contact with the pair of electrodes and which has PTC characteristics, and conductive layers which are in contact with both the electrodes and the polymer resistor. The conductive layers include at least a resin component, a conductor component and an additive component.