Modular Layered Heater With Resistive Zones

Solution Overview

Problem

Existing heater technologies require custom design and multiple units for different glass panel sizes, leading to inefficiencies and increased costs due to the need for separate heaters for each size, and lack flexibility in heat distribution across large glass panels.

Innovation Solution

A modular layered heater system comprising multiple resistive zones arranged in parallel circuits with positive temperature coefficient materials, allowing for independent control and power adjustment based on heat sink gradients, enabling flexible sizing and efficient heat distribution across various glass panel sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate unitary heaters are designed for each glass panel size, then heating performance is optimized for each specific size, but device complexity and manufacturing costs increase due to needing multiple custom heaters

Engineering Contradiction:

Improveheating performanceVSAvoidnumber of heaters

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The heater is divided into multiple independently controllable zones or tiles that can be selectively activated. Each zone functions as an independent heating element, allowing the system to accommodate different glass panel sizes by activating only the necessary zones, thereby reducing the need for multiple custom-designed heaters while maintaining optimized heating performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A single heater design with multiple zones serves multiple glass panel sizes, making the heater universal rather than size-specific. The heater can be configured to heat different areas by controlling which zones are active, eliminating the need for separate custom heaters for each glass size.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Area of stationary object

If unitary heaters are used for large glass panels, then heating coverage is sufficient, but adaptability to different glass sizes is reduced

Engineering Contradiction:

Improveheating coverageVSAvoidglass size accommodation

Core Design Contradiction:

Area of stationary objectVSAdaptability or versatility

Solution Approach 1:

The heater is divided into multiple independently controllable zones or tiles that can be selectively activated. Each zone functions as an independent heating element, allowing the system to accommodate different glass panel sizes by activating only the necessary zones, thereby reducing the need for multiple custom-designed heaters while maintaining optimized heating performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heater configuration is made dynamic through independent control of multiple zones. The system can adapt to different glass panel sizes by dynamically adjusting which zones are active, transforming a static size-specific heater into a versatile, adaptable heating system.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If layered heaters with independent zone control are used, then heat distribution is optimized, but device complexity increases due to multiple controlled sections

Engineering Contradiction:

Improveheat distributionVSAvoidcontrol system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The heater is divided into multiple independently controllable zones or tiles that can be selectively activated. Each zone functions as an independent heating element, allowing the system to accommodate different glass panel sizes by activating only the necessary zones, thereby reducing the need for multiple custom-designed heaters while maintaining optimized heating performance.

Inventive Principle:

Principle #1Segmentation

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 modular system reduces manufacturing costs by allowing a single system to accommodate multiple panel sizes, providing efficient and customizable heat distribution while minimizing the need for multiple custom-designed heaters.

Implementation Method 1

The resistive material is applied to the dielectric material in a predetermined pattern and provides a resistive heater circuit

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the resistive traces comprise a positive temperature coefficient material having a relatively high TCR, the resistive traces being responsive to the heating target power gradient

Methodology Applied

Scientific EffectPositive temperature coefficient: Thermistor

Data Source

PatentUS10159116B2Modular layered heater system

Publication Date: 2018.12.18 WATLOW ELECTRIC MANUFACTURING CO

AI summary

A heater system is provided that comprises a plurality of layered heater modules, each module comprising a plurality of resistive zones. The layered heater modules are disposed adjacent one another to form the heater system, which can be adapted for a multitude of different sizes of heating targets. Preferably, the resistive zones comprise a plurality of resistive traces arranged in a parallel circuit and oriented approximately perpendicular to a primary heating direction, wherein the resistive traces comprise a positive temperature coefficient material having a relatively high TCR. The resistive traces are responsive to the heating target power gradient such that the resistive traces output additional power proximate a higher heat sink and less power proximate a lower heat sink along the primary heating direction.