Modular Planar Heater Assembly for Grounded Low-Profile Connections
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Solution Overview
Problem
Industry faces challenges in manufacturing and assembling large surface area planar electrical heating apparatuses with integral grounding layers, resulting in non-repairable, bulky, and time-consuming constructions due to exposed connections and non-planar designs.
Innovation Solution
A planar electrical heating apparatus with an outer shell and inner cavity, incorporating a heating element and electric insert, allows for modular assembly with detachable or permanent connections, grounding layers, and thermal insulation, enabling flexible and customizable installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a grounding layer is added to large surface area heating apparatus to mitigate leakage conductance, then electrical safety is improved, but the construction becomes substantially thick and bulky
Solution Approach 1:
The grounding layer is segmented into a discrete grounding strip rather than a continuous layer. This grounding strip is positioned specifically at the perimeter of the heating apparatus where leakage conductance occurs, eliminating the need for a thick continuous grounding layer across the entire surface area.
Solution Approach 2:
The grounding function is extracted from the main heating construction and implemented as a separate, thin grounding strip. This allows the grounding layer to be applied only where needed for electrical safety without adding substantial thickness to the overall apparatus construction.
2Ease of manufacture
If connections are made using round wire routed through the exterior of the shell, then electrical connections are achieved, but the construction becomes non-planar and bulky
Solution Approach 1:
A planar connector is introduced as an intermediary component between the heating element and external wiring. This connector provides a flat, planar interface that eliminates the need for bulky round wire routing through the exterior shell, maintaining the planar construction while enabling electrical connections.
3Productivity
If connections are exposed without a grounding layer to cover them, then assembly is simplified, but electrical safety is compromised
Solution Approach 1:
The grounding strip is merged with the perimeter sealing structure of the heating apparatus. This integration allows the grounding function to be incorporated into the existing assembly process without requiring separate steps for applying grounding protection, thus maintaining assembly speed while ensuring electrical safety.
4Strength
If permanent construction methods are used for heating apparatus assembly, then structural integrity is improved, but repairability and manufacturing flexibility are reduced
Solution Approach 1:
The grounding strip is pre-positioned and integrated into the perimeter structure during manufacturing, but designed to allow for future removal and repositioning. This preliminary integration provides structural integrity during assembly while maintaining flexibility for repairs and manufacturing changes.
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
Facilitates efficient, repairable, and cost-effective assembly of large surface area heating systems with reduced leakage conductance and improved electrical safety, suitable for various industries and applications.
Implementation Method 1
an electrical heating element between the first and the second outer layers, the electrical heating element configured to convert electrical energy to heat energy
Data Source
AI summary
The present invention is directed to an electrical heating device, and in particular, a planar electrical heating device and method for assembling the planar electrical heating apparatus. The planar electrical heating apparatus operable using AC or DC power comprising: an outer shell with an upper shell layer joined to a lower shell layer and defining an internal cavity therebetween; a heating element having at least one heating conductor and a first and a second non-heating conductors positionable with the internal cavity, between the upper shell layer and lower shell layer; a first connector end portion secured to the first and second non-heating conductors for coupling to an electrical power supply; a sealing end portion enclosed the connector end portion for electrical isolation and protection from water ingress.