Radiant Heating Element With Folded Conductor Strips
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Solution Overview
Problem
Current radiant heating devices for hobs are limited to a maximum heating power of approximately 3600W due to the electrical resistance of the heating conductor strip, making it difficult to achieve higher heat outputs.
Innovation Solution
A heating device with a flat carrier made of heat-insulating and electrically insulating material, featuring a heating element composed of at least two heating conductor strips that are folded together or placed on top of each other, with their lateral sides touching partially but not completely, and connected via spot welds, allowing for increased current and heating power while maintaining manufacturability and reducing thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single thick heating conductor strip is used to increase current capacity, then heating power increases, but manufacturing difficulty increases and thermal stress resistance decreases
Solution Approach 1:
The heating element is divided into multiple thin heating conductor strips (at least two) that are folded together or placed on top of each other. This segmentation allows each strip to remain thin and easy to manufacture while the combined structure achieves the required current capacity and heating power, resolving the contradiction between power output and manufacturing ease.
Solution Approach 2:
Instead of increasing the thickness (one dimension) of a single conductor strip, the invention uses multiple strips folded together in a multi-layer configuration. This dimensional approach maintains the thinness and manufacturability of individual strips while achieving the electrical capacity equivalent to a much thicker single strip.
2Power
If a single thick heating conductor strip is used to increase current capacity, then heating power increases, but resistance to thermal expansion damage decreases
Solution Approach 1:
By segmenting the heating element into multiple thin strips rather than using a single thick strip, the invention reduces thermal stress and improves resistance to thermal expansion damage. Each thin strip can better accommodate thermal cycling without cracking, while the folded-together configuration maintains the required current capacity for high heating power.
Solution Approach 2:
The heating element creates a composite structure by folding multiple conductor strips together with their lateral sides touching partially. This composite configuration combines the thermal resilience of thin strips with the electrical capacity of a thicker equivalent, achieving both high power and reliability.
3Stability of the object's composition
If heating conductor strips are completely overlapped, then structural stability increases, but heating surface area decreases
Solution Approach 1:
The invention applies different overlapping characteristics to different parts of the heating conductor strips. The lateral sides touch partially to provide local stability, while the upper surfaces remain exposed to maximize heating area. This local differentiation resolves the contradiction between structural stability and heating surface area.
Solution Approach 2:
Instead of complete overlapping of the heating conductor strips, the invention uses partial contact through lateral side touching. This partial action provides sufficient structural stability to prevent excessive movement while leaving the majority of the strip surfaces exposed for optimal heating area.
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 a higher heating output while simplifying manufacturing and reducing the risk of damage from thermal expansions, as the heating element can be designed with a corrugated structure and integrated holding members that enhance stability and durability.
Implementation Method 1
Due to the electrical resistance of the heating element or conductor strip, the maximum heating output for such a radiant heating device in household use is currently limited to approximately 3600W or 3700W
Implementation Method 2
The two lateral sides of the heating conductor strip radiate heat during operation at slightly over 1000°C, which then radiates upwards
Data Source
Figure 1~5
Figure 6~9
AI summary
A heating device, designed as a radiant heating element for a cooktop, comprises a flat support with a carrier surface. This carrier surface has at least one heating element on its upper surface, which is highly corrugated and arranged in strips in a specific pattern. The heating element has at least two heating conductor strips, each with lateral edges, a top edge, and a bottom edge. These at least two heating conductor strips are laid together or on top of each other with their lateral edges facing each other and are in at least partial contact. The at least two heating conductor strips are firmly and permanently bonded together, preferably before the corrugation.