Grooved Heater Unit With Block Body to Prevent Heat Pools

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Solution Overview

Problem

In heater units, the formation of heat pools between the heater and the plate can lead to disconnection of the heater and poor temperature uniformity and controllability.

Innovation Solution

The inclusion of a block body between the heater and the second plate, which is in contact with the second plate, helps to suppress the formation of heat pools by improving thermal conduction and ensuring the heater is pressed firmly in place.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the heater is directly placed on the plate, then the structure is simple, but heat pools form between the heater and plate causing disconnection and poor temperature uniformity

Engineering Contradiction:
Improveheater connection reliabilityVSAvoidheater unit structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

A support structure is introduced as an intermediary component between the heater and the plate. This support structure includes multiple support portions that contact the plate and support the heater, preventing direct contact between the heater and plate while eliminating heat pool formation. The intermediary structure resolves the contradiction by improving heater connection reliability through mechanical support and heat distribution, at the cost of increased structural complexity.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Temperature

If the heater is pressed firmly to improve thermal conduction, then temperature uniformity improves, but the heater may disconnect due to heat pool formation

Engineering Contradiction:
Improvetemperature uniformityVSAvoidheater connection stability
Core Design Contradiction:
TemperatureVSReliability

Solution Approach 1:

The support structure acts as a mediator that distributes the heater's weight and thermal load across multiple contact points with the plate. This prevents localized heat accumulation (heat pools) that would cause disconnection, while still maintaining sufficient thermal conduction through the support portions. The intermediary structure enables temperature uniformity improvement without compromising heater connection stability.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The support structure is divided into multiple discrete support portions rather than a single continuous contact point. This segmentation distributes the thermal and mechanical load across multiple locations, preventing heat pool formation at any single point while maintaining overall thermal conduction. The segmented structure resolves the contradiction between temperature uniformity and connection stability.

Inventive Principle:
Principle #1Segmentation

3Temperature

If thermal conduction is improved by direct contact, then temperature controllability improves, but heat pools form causing heater disconnection

Engineering Contradiction:
Improvetemperature controllabilityVSAvoidheat pool formation
Core Design Contradiction:
TemperatureVSObject-affected harmful factors

Solution Approach 1:

The support structure serves as an intermediary thermal conduction path between the heater and plate. It provides controlled thermal conduction through its material properties and geometry, improving temperature controllability while its distributed contact geometry prevents heat pool formation. The intermediary structure enables beneficial thermal conduction while eliminating the harmful heat accumulation effect.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The support structure has different local properties: it provides good thermal conduction in the vertical direction (through its thickness) while providing limited thermal conduction in the horizontal direction (at the contact points with the plate). This local quality differentiation enables improved temperature controllability through vertical heat transfer while preventing horizontal heat pool formation at the interface.

Inventive Principle:
Principle #3Local quality

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

This configuration effectively suppresses heater disconnection, enhances temperature uniformity, and improves temperature controllability by ensuring efficient heat transfer from the heater to the plate.

Implementation Method 1

since thermal conduction from the heater to the plate is improved

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The block body may press the heater

Methodology Applied
Scientific EffectMechanical pressure: Mechanical Force

Data Source

PatentUS20250168934A1Heater unit
Publication Date: 2025.05.22 NHK SPRING CO LTD
  • US20250168934A1 patent drawing
  • US20250168934A1 patent drawing
  • US20250168934A1 patent drawing

AI summary

A heater unit includes a heater, a first plate including a groove portion in which the heater is disposed, a second plate overlapping the first plate so as to cover the groove portion, and a block body disposed between the heater and the second plate. The block body is in contact with the second plate. The groove portion includes a first region having a first depth and a second region having a second depth greater than the first depth. The block body is disposed in the second region.