Thermal-Sprayed Heating Tracks With Post-Processed Resistance Tuning
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Solution Overview
Problem
Existing methods for producing electric heating elements face challenges in maintaining precise electrical resistance tolerances due to variations in the coating thickness of conductive tracks, leading to increased scrap rates as small deviations in thickness affect electrical resistance, especially in high-power applications.
Innovation Solution
A post-processing method is employed to adjust the electrical resistance of heating tracks by removing conductive material from designated sections using techniques like laser ablation, ion sputtering, or micro milling, ensuring the resistance falls within narrow tolerance ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal spray is used to deposit conductive material onto insulating surface to form heating tracks, then heating elements can be produced efficiently for household goods and electric cars, but the coating thickness cannot be controlled precisely enough to meet narrow electrical resistance tolerances
Solution Approach 1:
The patent applies preliminary action by designing an adjustment section with intentionally increased width (0.5 to 1.0 mm wider) during the initial thermal spray deposition. This extra width is prepared in advance to accommodate subsequent material removal through laser ablation or other post-processing methods, allowing the final dimensions to be precisely controlled after the coating is deposited.
Solution Approach 2:
The patent replaces mechanical measurement and adjustment methods with laser ablation technology. Instead of using traditional mechanical machining or manual adjustment to control coating thickness and electrical resistance, the invention uses laser energy to precisely remove material from the adjustment section, achieving superior dimensional control and electrical resistance tolerance.
2Manufacturing precision
If tight tolerances are assumed on coating thickness to meet electrical resistance specifications, then electrical resistance can be controlled within +/â10%, but small deviations in coating thickness still lead to rejected parts
Solution Approach 1:
The patent applies parameter changes by modifying the width parameter of the adjustment section rather than attempting to control the coating thickness parameter during thermal spray deposition. By changing the width parameter after deposition through laser ablation, the invention achieves precise electrical resistance control while accepting the natural variations in coating thickness, thereby reducing scrap rate.
Solution Approach 2:
The patent applies the extraction principle by removing excess conductive material from the adjustment section through laser ablation or other post-processing methods. This selective removal of material allows precise control of the final track dimensions and electrical resistance, converting parts that would have been rejected into acceptable products.
3Manufacturing precision
If the adjustment section is made wider than the remaining portion of the heating track, then material can be removed to adjust electrical resistance, but the adjustment section requires additional post-processing time
Solution Approach 1:
The patent applies partial action by providing adjustment capability only in specific sections of the heating track rather than controlling the entire track dimensions. The adjustment section is localized and designed with extra width only where needed, allowing selective post-processing that minimizes overall processing time while achieving the required electrical resistance tolerance.
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 approach significantly reduces scrap rates by ensuring nearly all parts meet the specified electrical resistance criteria, minimizing waste and improving production efficiency.
Implementation Method 1
post-processing adjustment is performed by removing material from the adjustment section, e.g., via laser ablation
Implementation Method 2
post-processing adjustment is performed by removing material from the adjustment section, e.g., via laser ablation, ion sputtering
Implementation Method 3
thermal spray is a widely industrialized technology used in household goods and electric cars
Data Source
AI summary
Post-processing of electrically conductive tracks formed from a metal coating deposited by thermal spraying on an insulating surface. In order to compensate deviations in the resulting electrical resistance caused by variations in coating thickness or coating structure, the track width is adjusted after producing the track. The adjustment of the track width can be done on an adjustment section provided along a length of the conductive track or on the full track length.