Heating Element Composition for Antifungal Heat Generation

Solution Overview

Problem

Existing heating elements with exothermic compositions face challenges in preventing fungi and mold growth due to the addition of water and oxidizable metals, requiring complex process control and lacking antisepsis and antifungal properties.

Innovation Solution

Incorporating tri-alkali metal phosphate within a specific mass range into the exothermic composition, along with oxidizable metals and water, to provide antisepsis and antifungal abilities while maintaining favorable exothermic characteristics, including a layered structure with a carbon component and electrolyte for enhanced heat generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If water is added to the exothermic composition containing oxidizable metal and carbon component, then favorable exothermic characteristics are achieved, but fungi and mold growth occur requiring complex process control

Engineering Contradiction:

Improveexothermic temperatureVSAvoidfungi and mold growth

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of water (which promotes fungal growth) into a beneficial factor by using it as a hydrogen source for the exothermic reaction. The water reacts with the oxidizable metal to produce hydrogen gas and heat, transforming the problematic moisture into a useful reactant that drives the heating function while consuming the water that would otherwise support microbial growth.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces an aeration layer as an intermediary structure that controls air flow to the exothermic composition. This layer regulates oxygen supply to maintain favorable exothermic characteristics while limiting conditions that would promote fungal and mold growth, effectively mediating between the need for heat generation and the need to prevent biological contamination.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If tri-alkali metal phosphate is added to provide antisepsis and antifungal properties, then fungi and mold growth are prevented, but the composition complexity increases

Engineering Contradiction:

Improvefungi and mold growthVSAvoidcomposition complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The tri-alkali metal phosphate serves multiple functions simultaneously: it acts as an antiseptic and antifungal agent to prevent microbial growth, while also functioning as a pH adjuster to maintain favorable conditions for the exothermic reaction. This multi-functionality reduces the need for separate additives, thereby limiting composition complexity despite the protective properties provided.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent specifies precise parameter ranges for tri-alkali metal phosphate content (0.5-1.1 parts by mass per 100 parts by mass of oxidizable metal) and water content (50-90 parts by mass per 100 parts by mass of oxidizable metal). By controlling these parameters within defined ranges, the patent achieves effective antisepsis and antifungal protection while maintaining favorable exothermic characteristics, balancing protection needs with compositional simplicity.

Inventive Principle:

Principle #35Parameter changes

3Power

If water content is increased to maintain exothermic reaction, then heat generation is improved, but the risk of fungi and mold growth increases

Engineering Contradiction:

Improveheat generationVSAvoidfungi and mold growth

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful effect of water (which promotes fungal growth) into a beneficial factor by using it as a hydrogen source for the exothermic reaction. The water reacts with the oxidizable metal to produce hydrogen gas and heat, transforming the problematic moisture into a useful reactant that drives the heating function while consuming the water that would otherwise support microbial growth.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces an aeration layer as an intermediary structure that controls air flow to the exothermic composition. This layer regulates oxygen supply to maintain favorable exothermic characteristics while limiting conditions that would promote fungal and mold growth, effectively mediating between the need for heat generation and the need to prevent biological contamination.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 heating element achieves effective antisepsis and antifungal properties, maintaining exothermic temperatures between 40°C and 70°C, with improved heat generation and uniformity, reducing the risk of fungi and mold growth.

Implementation Method 1

capable of producing heat by an oxidation reaction of an oxidizable metal

Methodology Applied

Scientific EffectOxidation reaction: Oxidation

Implementation Method 2

Incorporating tri-alkali metal phosphate within a specific mass range into the exothermic composition, along with oxidizable metals and water, to provide antisepsis and antifungal abilities

Methodology Applied

Scientific EffectAntisepsis and antifungal action: Preservative

Implementation Method 3

maintaining exothermic temperatures between 40°C and 70°C, with improved heat generation and uniformity

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Data Source

PatentUS9915443B2Heating element and heating implement containing the same

Publication Date: 2018.03.13 KAO CORP

AI summary

The present invention relates to a heating element (1) having an exothermic composition containing an oxidizable metal, a carbon component and water. Tri-alkali metal phosphate is contained in the heating element (1), and the content of water in the heating element (1) is equal to or larger than 50 parts by mass and equal to or smaller than 90 parts by mass for 100 parts by mass of the oxidizable metal, and the content of tri-alkali metal phosphate as a phosphate group is equal to or larger than 0.5 parts by mass and equal to or smaller than 1.1 parts by mass for 100 parts by mass of the oxidizable metal.