Planar Heater Width Control With Electrothermal Warp Thread Protection
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Solution Overview
Problem
Existing planar heater manufacturing methods risk breaking electrothermal warp threads due to the process of changing the width of the strip-shaped body, which are arranged in a row and generate heat when electricity flows through them.
Innovation Solution
A method that transports a strip-shaped body including electrothermal warp threads and a weft thread, connects an electrode to contact the threads, and cuts the body along a specific direction without altering its width, using a base paper to temporarily hold the threads and facilitating separation, thereby reducing the risk of thread breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the strip-shaped body is cut along the orthogonal direction to change its width to a specific width, then the planar heater can be manufactured with a specific width, but the electrothermal warp threads may break during the cutting process
Solution Approach 1:
A base paper is introduced as an intermediary carrier that temporarily holds the electrothermal warp threads and weft thread during manufacturing. The base paper provides mechanical support and protection to the fragile electrothermal warp threads during handling, transport, and electrode connection processes, preventing thread breakage while enabling precise width control through cutting along the orthogonal direction.
2Manufacturing precision
If the width of the strip-shaped body is changed by cutting along the orthogonal direction, then the planar heater can be manufactured with a specific width, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The electrothermal warp threads and weft thread are pre-assembled on the base paper with the correct spacing and alignment before any cutting operations. This preliminary arrangement on the base paper simplifies subsequent manufacturing steps, as the base paper serves as a pre-prepared template that guides electrode placement and ensures proper thread positioning, reducing overall process complexity despite the cutting step.
3Productivity
If the strip-shaped body is transported in the orthogonal direction, then the planar heater can be manufactured efficiently, but the electrothermal warp threads may shift or misalign during transport
Solution Approach 1:
The base paper acts as a stable intermediary substrate that firmly secures the electrothermal warp threads and weft thread through temporary fixation. This fixation prevents thread shifting or misalignment during transportation in the orthogonal direction, while the base paper itself can be easily transported and positioned, maintaining both manufacturing efficiency and positioning accuracy.
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 method effectively manufactures planar heaters with minimal risk of electrothermal warp thread breakage, maintaining positional relationships and enabling easy assembly of electrodes, resulting in a heating device capable of generating more heat.
Implementation Method 1
plural electrothermal warp threads 36 that generate heat when electricity flows therethrough
Data Source
AI summary
A planar heater manufacturing method, including: transporting a strip-shaped body, the strip-shaped body including plural electrothermal warp threads that generate heat when electricity flows therethrough and that are arranged in a row along one direction, including a single strand of weft thread that together with the electrothermal warp threads configures a cloth, and extending in an orthogonal direction that is orthogonal to the one direction, by transporting the strip-shaped body in the orthogonal direction; and connecting an electrode to the strip-shaped body so as to contact the plural electrothermal warp threads.