Heating Element with Interface Filler for Uniform Heat Distribution
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Solution Overview
Problem
Conventional heat generating elements used in electric heating apparatuses suffer from non-uniform heat distribution due to geometric limitations, resulting in low heat generation efficiency.
Innovation Solution
A heating element comprising a plurality of matrix particles with a conductive inorganic filler, such as nano-sheets, disposed at interfaces to form a conductive network, enhancing electrical conductivity and heat generation characteristics, with the filler comprising oxides, borides, or chalcogenides like RuO2, MnO2, and AuTe2, and the matrix particles being functionalized with charges to improve dispersion stability and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional heat generating elements are used, then they generate heat by Joule heating using resistive and conductive composite, but they cannot uniformly generate heat due to geometric limitations resulting in low heat generation efficiency
Solution Approach 1:
The patent changes the geometric parameters of the heating element from conventional shapes to a specific configuration with multiple heating sections arranged in a plane. This parameter change enables uniform heat distribution across the heating surface while maintaining high heat generation efficiency through optimized electrical and thermal pathways.
Solution Approach 2:
The patent employs a composite structure combining resistive and conductive materials in a specific architecture. The composite design integrates heating sections, conductive sections, and insulating sections to achieve both high heat generation efficiency and uniform heat distribution, overcoming the limitations of conventional single-material heating elements.
2Reliability
If a small amount of conductive inorganic filler is used, then the percolation threshold decreases and high electrical conductivity is obtained, but the filler amount must be precisely controlled within specific ranges
Solution Approach 1:
The patent utilizes parameter changes by controlling the volume percentage of conductive inorganic filler within specific ranges (0.01-95% or 0.1-5% based on total volume). This precise parameter control achieves the percolation threshold for high electrical conductivity while minimizing filler quantity, optimizing both reliability and material efficiency.
Solution Approach 2:
The patent applies local quality by strategically distributing conductive inorganic filler at interfaces between matrix particles rather than uniform distribution. This localized placement at critical interfaces creates efficient conductive pathways with minimal filler content, achieving high electrical conductivity while reducing overall filler quantity.
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 achieves high electrical conductivity and uniform heat generation with a reduced percolation threshold, allowing for efficient heat distribution even with a small amount of conductive filler, thereby improving the overall heat generation efficiency of the heating element.
Implementation Method 1
Heat generating elements, which may be used in an electric heating apparatus, such as an electric oven, generate heat by Joule heating using a resistive and conductive composite
Implementation Method 2
a conductive inorganic filler disposed at interfaces between the plurality of matrix particles to provide a conductive network
Data Source
AI summary
A heating element includes a plurality of matrix particles and a conductive inorganic filler disposed at interfaces between the plurality of matrix particles to provide a conductive network.