Planar Heating Device Electrode Thermal Damage Prevention

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Planar heating devices face thermal damage issues due to high resistance and heat generation at electrode contacts, leading to operational failures and damage.

Innovation Solution

A planar heating device design with adjustable thickness heating layers and additional heating layers made of carbon nanotubes or conductive oxides, which reduce resistance and act as protective layers for electrodes, preventing thermal damage by distributing heat more evenly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the heating layer thickness is increased to reduce resistance and prevent thermal damage to electrodes, then the reliability of the heating device is improved, but the device complexity increases due to the need for additional heating layers and precise thickness control

Engineering Contradiction:

Improveelectrode thermal damage preventionVSAvoidheating layer structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The heating layer is segmented into multiple distinct layers: a first heating layer with thickness of 10-100 μm, and first and second additional heating layers with thickness of 10-100 μm each. This segmentation allows each layer to serve specific functions in heat distribution and electrode protection, resolving the contradiction by making the complex structure manageable through clear functional division.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The additional heating layers are positioned specifically at the end portions of the heating layer that contact the electrodes, creating local quality enhancement at critical thermal stress points. This localized approach prevents electrode thermal damage without requiring uniform thickness increase throughout the entire heating layer, thus improving reliability while controlling overall device complexity.

Inventive Principle:

Principle #3Local quality

2Reliability

If additional heating layers are added to distribute heat more evenly and protect electrodes, then the operational reliability is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveheat distribution uniformityVSAvoidheating layer thickness control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent specifies parameter ranges for heating layer thickness (10-100 μm) and additional heating layer thickness (10-100 μm), providing manufacturing flexibility within defined boundaries. These parameter changes allow manufacturers to achieve reliable heat distribution without requiring ultra-precise thickness control, as long as the values fall within the specified ranges.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The additional heating layers are designed to be formed in advance during the manufacturing process, with predetermined thickness ranges. This preliminary action ensures that the heat distribution function is built into the structure before operation, reducing the need for post-manufacturing adjustments and simplifying quality control within the specified parameter ranges.

Inventive Principle:

Principle #10Preliminary action

3Duration of action of stationary object

If the heating layer thickness is adjusted to optimize thermal performance, then the operational longevity is improved, but the ease of manufacture decreases due to additional processing steps

Engineering Contradiction:

Improvedevice longevityVSAvoidheating layer formation process

Core Design Contradiction:

Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

The heating device uses composite material structures with different heating layers that can be formed using similar manufacturing techniques. The first heating layer and additional heating layers are both conductive heating materials, allowing them to be deposited or applied using the same or compatible processes, thus improving longevity without significantly complicating manufacturing.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The heating layers are formed with porous structures that facilitate uniform heat distribution and material penetration. This porous material approach allows for simple formation processes such as screen printing, spray coating, or sintering, maintaining ease of manufacture while achieving the thermal performance needed for extended device longevity.

Inventive Principle:

Principle #31Porous materials

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 effectively reduces thermal damage to electrodes by lowering resistance and heat generation at contact points, enhancing the operational reliability and longevity of the heating device.

Implementation Method 1

A typical planar heating element, which generates heat by electricity

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS10638546B2Planar heating device and method of manufacturing the same

Publication Date: 2020.04.28 SAMSUNG ELECTRONICS CO LTD

AI summary

A planar heating device includes a substrate, first and second electrodes disposed on both ends of the substrate, a heating layer disposed on the substrate and configured to contact the first and second electrodes, a first additional heating layer disposed on one end of the heating layer, and a second additional heating layer disposed on the other end of the heating layer.