Heating Plate With Meltable Conductor for Overheat Cutoff
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Solution Overview
Problem
Existing heating devices for electric vehicles lack a cost-effective and integrated safety mechanism to prevent overheating of resistive elements, relying on external sensors and complex systems that are not inherently safe.
Innovation Solution
A heating plate design with a conductive element made of a meltable material that automatically severs at a predetermined temperature, disconnecting power to the resistive element and preventing further heat generation, without the need for external safety devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature limitation mechanisms using sensors and signal processing means are employed, then safety temperature control is achieved, but device complexity and cost increase
Solution Approach 1:
The heating plate incorporates an intrinsic safety mechanism where the resistive element itself serves as the temperature sensor and safety device. When the substrate temperature exceeds the melting point of the conductive material, the conductive element automatically melts and severs the electrical circuit, eliminating the need for external sensors, signal processing means, and power supply control devices.
Solution Approach 2:
The patent extracts the safety function from external auxiliary devices and integrates it directly into the heating plate structure. The conductive element embedded in the substrate acts as an intrinsic safety mechanism, removing the need for separate temperature sensors, control circuits, and external monitoring systems.
2Reliability
If external sensors and control devices are used for temperature monitoring, then overheating protection is provided, but manufacturing cost increases
Solution Approach 1:
The patent merges the heating function and safety protection function into a single integrated structure. The conductive element serving as both an electrical conductor and a temperature-sensitive safety device is embedded within the substrate, combining multiple functions into one component and eliminating the need for separate safety devices.
Solution Approach 2:
The conductive element is designed as a sacrificial component that melts at a predetermined temperature to sever the circuit. This simple, inexpensive element provides reliable overheating protection through its controlled destruction, replacing complex and expensive external safety systems.
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
Ensures safe operation by automatically preventing overheating, protecting the heating device and its components from damage, while maintaining simplicity and reducing costs.
Implementation Method 1
a resistive element (1.2) arranged on the substrate intended for generating heat in order to heat the thermal fluid... All of the electrical energy supplied by the batteries is transformed into heat.
Implementation Method 2
the conductive element has been melted because it reached the melting temperature or a temperature higher than the melting temperature, giving rise to the severing of the conductive element
Implementation Method 3
a substrate (1.1) with a first face intended for being in contact with a thermal fluid to be heated... the heat generated in this device is transferred to other locations through the thermal fluid
Data Source
Figure 1~2
AI summary
The present invention relates to a heating plate particularly suitable for devices for heating a thermal fluid. The heat generated in this device is conveyed to other locations through the thermal fluid, where the heat is given off, for example, through a heat exchanger configured as a radiator. The heating plate is characterized by an electronics-free safety solution intended to automatically cause the generation of heat to cease when temperatures above a preestablished safety temperature are reached.