Planar Heating Element Composite Matrix for Simple Shapeable Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing planar heating elements have complex manufacturing processes and are not easily adaptable to various shapes, limiting their application in products requiring compact and efficient heating solutions.
Innovation Solution
A planar heating element is designed with a pair of wires inserted into a conductive composite material matrix, comprising a base resin and conductive material, forming an electrical network with carbon members and metal powders to generate heat through electrical resistance, allowing for simple manufacturing and versatile shape adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If planar heating elements are manufactured by stacking sheets or coating heating layers on sheets, then heating function is achieved, but manufacturing process becomes complicated and manufacturing time increases
Solution Approach 1:
The patent merges the heating wire, insulating material, and support structure into a single integrated tubular assembly. The heating wire is embedded within the insulating material during molding, eliminating separate assembly steps for coating or stacking sheets. This integration directly resolves the contradiction by simplifying the manufacturing process and reducing manufacturing time while maintaining the heating function.
Solution Approach 2:
The patent uses a composite structure consisting of insulating material combined with embedded heating wire. This composite approach allows the heating element to be formed as a unified component through molding, avoiding complex sheet stacking or coating processes. The composite material solution achieves both manufacturing simplicity and effective heating performance.
2Strength
If sheath heaters with metal protective tubes are used, then robustness against physical impact is achieved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent replaces rigid metal protective tubes with a flexible or semi-rigid insulating material housing that provides adequate mechanical protection. This substitution maintains sufficient robustness against physical impact while dramatically simplifying the manufacturing process, as the insulating material can be molded directly around the heating wire in a single step, eliminating the need for separate metal tube fabrication and assembly.
Solution Approach 2:
The patent extracts the protective function from the complex metal tube structure and integrates it into the insulating material itself. The insulating material serves dual purposes: electrical insulation and mechanical protection. This extraction of the protective function from a separate metal component reduces device complexity and manufacturing complexity while maintaining adequate strength.
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 solution enables easy manufacturing, reduced costs, and efficient heating performance with the ability to form various shapes, suitable for applications such as clothing management, hot/cold water purifiers, and floor heating panels.
Implementation Method 1
heat is generated by means of electrical resistance that is generated inside the matrix when power is applied
Implementation Method 2
metal powders interposed between the carbon members, increasing the electrical network by the carbon members and increasing thermal conductivity of the conductive composite material to transfer electrical resistance heat generated by the carbon members to a surface of the heating part
Data Source
AI summary
A planar heating element according to the present invention is configured such that a pair of wires are inserted into a matrix formed by forming a base resin and a conductive material, so that heat is generated by means of electrical resistance that is generated inside the matrix when power is applied, wherein the planar heating element has a simple structure and is easy to manufacture and can achieve a sufficient heating effect regardless of thermal conductivity. In addition, the planar heating element is divided into a heating part and a non-heating part, and the heating part and the non-heating part are integrally manufactured through a double injection molding method. Thus, the present invention has advantages in that various shapes of planar heating elements can be manufactured and that manufacturing costs and manufacturing time can be reduced due to the manufacturing process being simple.