Heating Element With Dielectric Layers For Overheating Protection
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Solution Overview
Problem
Existing heating elements with dielectric enamel layers face challenges in efficient temperature detection and overheating protection, particularly due to labor-intensive production processes and vulnerability to gas bubbles leading to electric short-circuits, especially when earthed.
Innovation Solution
Positioning heating and sensor tracks between two dielectric layers simplifies production, maintains a safe distance to reduce breakdown risks, and incorporates a sintered glass layer for additional protection, allowing for efficient leakage current measurement and rapid overheating detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single dielectric layer is used with heating and sensor tracks arranged successively, then the production process is simplified, but the tracks are vulnerable to gas bubbles causing electric short-circuits
Solution Approach 1:
The single dielectric layer is segmented into a first dielectric layer and a second dielectric layer arranged one on top of the other. The heating track and sensor track are positioned between these two layers, creating separate dielectric barriers above and below each track. This segmentation prevents gas bubbles in one layer from causing short-circuits between adjacent tracks, as the second dielectric layer provides an additional insulating barrier.
2Measurement precision
If heating and sensor tracks are positioned close together to improve sensitivity, then detection precision improves, but the risk of breakdown due to gas bubbles increases
Solution Approach 1:
Instead of increasing the horizontal distance between tracks to avoid breakdown, the solution moves the protection into the vertical dimension by introducing a second dielectric layer above the tracks. This allows the tracks to remain close together horizontally for sensitive detection while the vertical stacking of dielectric layers prevents breakdown caused by gas bubbles.
3Ease of manufacture
If the heating track is left uncovered to simplify production, then manufacturing is easier, but the heating track is vulnerable to damage
Solution Approach 1:
The second dielectric layer serves multiple functions simultaneously: it provides electrical insulation between the heating and sensor tracks, protects the heating track from mechanical damage and environmental factors, and maintains the structural integrity of the heating element. This multi-functionality eliminates the need for separate protective layers while simplifying the overall structure.
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 enhances the lifespan of the heating element by reducing breakdown risks, enabling sensitive and reliable temperature measurement and protection against overheating, even when the heating element is earthed, with improved durability and safety features.
Implementation Method 1
The dielectric enamel layer is herein arranged on a generally metal substrate for heating, after which metal heating tracks are arranged on the dielectric enamel layer
Implementation Method 2
heat is generated by conducting electric current through the at least one heating track
Implementation Method 3
The intermediate layer with dielectric properties not only provides for a good transmission of the generated heat to the substrate for heating
Implementation Method 4
the leakage current through the dielectric depends partly on the electrical resistance of the dielectric. Because the electrical resistance of the dielectric, at least in a determined temperature range, in turn depends on the temperature
Data Source
Figure 1~2
Figure 3~4
AI summary
The use of enamel as dielectric intermediate layer in the manufacture of heating elements is known. The dielectric enamel layer is herein arranged on a generally metal substrate for heating, after which metal heating tracks are arranged on the dielectric enamel layer by means of silkscreen techniques. The invention relates to an improved heating element. The invention also relates to a liquid container provided with such a heating element.