Laser Cutting Flexible Metallic Foils for Heating Elements
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Solution Overview
Problem
The existing production processes for thin, flexible heating elements are costly, environmentally harmful due to the use of acids, and inefficient in handling and recovering waste material, with challenges in cutting and handling the thin, flexible foils.
Innovation Solution
A process using a laser to cut metallic foils fixed on a template with suction or magnetic fixing means, reducing the number of processing steps and eliminating acid use, while facilitating waste recovery and improving foil handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chemical etching process is used to produce flexible heating elements, then the metallic foil can be shaped into complex patterns, but the process requires multiple processing steps, uses harmful acids, increases production costs, and makes waste material recovery difficult
Solution Approach 1:
The invention extracts and eliminates the harmful chemical etching step from the production process. Instead of using acids to remove metal, the patent uses a laser to directly cut and shape the metallic foil according to the desired pattern, completely removing the need for chemical etching while maintaining pattern precision
Solution Approach 2:
The invention replaces the chemical etching system with a laser cutting system. The laser beam acts as a non-contact cutting tool that can precisely shape the metallic foil without requiring chemical baths, multiple processing steps, or harmful acids, thereby simplifying the entire production process
2Ease of manufacture
If thin metallic foils are handled during chemical etching, then the foils can be shaped into flexible heating elements, but the foils tend to roll up during cutting and handling due to their thinness and flexibility
Solution Approach 1:
The invention applies a fixing means to the metallic foil before the cutting operation. This fixing means secures the thin, flexible foil to a support surface, preventing it from rolling up or moving during the laser cutting process. After cutting, the fixing means is removed, allowing the foil to be freely handled as a finished flexible heating element
3Manufacturing precision
If acid-based chemical treatments are used in production, then the metallic foil can be etched into the desired pattern, but the adhesion of insulating layers to the resistance is negatively influenced
Solution Approach 1:
The invention converts the harmful effect of chemical etching on adhesion into a benefit by eliminating the chemical etching process entirely. The laser cutting process does not chemically alter the foil surface in a way that harms adhesion, and in fact, the laser may create a slightly more adhesive surface. This allows insulating layers to be properly applied without the adhesion problems caused by acid treatment
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 reduces production costs, energy consumption, and environmental risks, enhances product quality, and simplifies the production line, allowing for efficient cutting of thin foils with complex patterns and easier recovery of waste materials.
Implementation Method 1
A process using a laser to cut metallic foils fixed on a template
Implementation Method 2
fixing means adapted to fix the foil
Implementation Method 3
fixing means adapted to fix the foil
Data Source
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AI summary
A process for the production of laminar electric resistances by laser cutting a metallic foil fixed to a template provided with a shaped trace and provided with foil fixing means.