Heating module for a heating device
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Solution Overview
Problem
Existing heating modules with rigid ceramic plates and thermal interfaces suffer from reduced mechanical flexibility, leading to gaps and cracks during temperature changes, which impair electric supply and heat transfer efficiency and durability.
Innovation Solution
A laminated structure where a conductive contact sheet is integrated with a soft, insulating thermal interface to form a single flexible component, enhancing mechanical flexibility and preventing gaps, thereby improving electric supply and heat transfer efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If rigid ceramic plates and thermal interfaces are used for insulation and heat transfer, then heat transfer efficiency is improved, but mechanical flexibility is reduced leading to gaps and cracks during temperature changes
Solution Approach 1:
The patent replaces rigid ceramic plates with flexible thermal interface materials that can accommodate thermal expansion and contraction without forming gaps or cracks. The flexible material maintains continuous thermal contact between heating elements and surrounding structures during temperature cycles, ensuring reliable heat transfer while preventing the mechanical failures associated with rigid components.
Solution Approach 2:
The invention uses composite thermal interface materials that combine the thermal conductivity benefits of ceramic-like materials with the mechanical flexibility of polymer or elastomeric matrices. This composite approach allows the material to simultaneously achieve high heat transfer efficiency and the flexibility needed to prevent gaps and cracks during temperature changes.
2Use of energy by moving object
If rigid ceramic plates and thermal interfaces are used for insulation, then electric insulation is provided, but gaps occur between contact sheet and heating element leading to reduced electric supply efficiency
Solution Approach 1:
The flexible thermal interface material maintains continuous, gap-free contact between the contact sheet and heating element throughout thermal cycling. This eliminates air gaps that would otherwise increase electrical resistance and reduce供电 efficiency, while the flexibility ensures sustained intimate contact despite dimensional changes in the heating elements.
3Adaptability or versatility
If multiple separate components (contact sheet, thermal interface, ceramic plate) are used, then functional requirements are met, but assembly complexity is increased
Solution Approach 1:
The patent combines the thermal interface material and ceramic plate functions into a single integrated flexible component. This unified structure eliminates the need for separate assembly steps and reduces the number of interfaces between components, thereby simplifying manufacturing and assembly while maintaining all necessary thermal and electrical insulation functions.
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 laminated structure enhances flexibility, reduces gaps and cracks, and improves both the efficiency and durability of the heating module by ensuring consistent electric supply and heat transfer, while simplifying assembly.
Implementation Method 1
The thermal interface (15, 16) transfers heat and improves the transfer of heat generated in the heating element (3) towards a heating area (19, 20)
Implementation Method 2
A controlled generation and transfer of heat are usually achieved by the use of an electric heating element, which generates heat when it is supplied with electric power
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a heating module (1) with at least one electric heating element (3) and at least one contact sheet (12, 13) for the electric supply of the heating element (3) arranged on the heating element (3), wherein a thermal interface (15, 16) transfers heat of the heating element (3) towards a side of the contact sheet (12, 13) averted from the heating element (3). An improved efficiency as well as an improved durability of the module (1) are achieved by providing an insulating and soft thermal interface (15, 16), on which the contact sheet (12, 13) is laminated. The invention further relates to a heating device (1) with at least one such heating module (1).