Planar Heating Element With Undulating Contact For Uniform Current
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Solution Overview
Problem
Existing heating elements with flat, heat-generating layers face challenges in ensuring uniform current distribution, leading to potential 'hotspots' due to uneven electrical heating current supply, especially when the current is conducted both on the surface and within the volume of the layer.
Innovation Solution
The use of two electrical contacts with a first contact element extending curvedly into the heat-generating layer and a second contact element extending parallel to the first, with multiple common contact points, ensures even current distribution across the entire surface and volume of the heat-generating layer, preventing hotspot formation through a stable and flexible connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single contact element is used to supply electrical current to the heat-generating layer, then the device complexity is reduced, but uneven current distribution occurs leading to hotspot formation
Solution Approach 1:
The single contact element is divided into multiple contact elements (first contact element and second contact element) that are arranged parallel to each other. Each contact element supplies current to different regions of the heat-generating layer, ensuring uniform current distribution across the entire layer and preventing hotspot formation.
Solution Approach 2:
The contact elements are extended in the direction perpendicular to the surface of the heat-generating layer, creating a three-dimensional current supply path. This vertical arrangement allows multiple contact points to be established across the layer thickness, improving current distribution uniformity without increasing lateral complexity.
2Manufacturing precision
If the first contact element extends curvedly into the heat-generating layer to improve current distribution, then current distribution uniformity is improved, but the contact element length increases
Solution Approach 1:
Instead of extending the contact element laterally in a curved path within the plane of the layer, the contact element is extended vertically in the direction perpendicular to the layer surface. This three-dimensional approach achieves improved current distribution by contacting multiple regions of the layer at different depths, while minimizing the overall length required compared to lateral curvature.
3Adaptability or versatility
If the heat-generating layer is made stretchable to accommodate movement, then adaptability is improved, but maintaining electrical connection stability becomes more difficult
Solution Approach 1:
The contact elements are designed to be movable relative to the heat-generating layer, allowing them to follow the layer's stretching and deformation. The contact elements can slide or flex within their mounting structures, maintaining continuous electrical connection even when the layer changes shape or size during use.
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
This configuration ensures homogeneous heating of the heat-generating layer by utilizing the entire current-conducting cross-section, maintaining low electrical transition resistances, and accommodating movement and stretching, thus preventing localized temperature increases.
Implementation Method 1
the first contact element and the second contact element have a multiplicity of common contact points. The electrical contacts serve as electrodes here in order to provide an interface for the electrical current to be fed in and the heat-generating layer
Implementation Method 2
since the first contact element extends curvedly in the heat-generating layer, this requires a first contact element with a large length. In particular if the first contact element has a higher electrical resistance, the simultaneous use of the second contact element parallel to the direction of extension of the first contact element
Data Source
AI summary
The invention relates to heating element, comprising a planar, heat-generating layer (100) and two electrical contacts (101; 103) for providing an electric heating current, wherein the electrical contacts (101; 103) are arranged on the heat-generating layer (100) on opposite sides of the layer (100), wherein at least one of the contacts comprises a first contact element (102) and a second contact element (104; 200), wherein the first contact element (102) extends in the heat-generating layer (100) in an undulating manner as viewed in a first plane (112) perpendicular to the extent of the layer (100), wherein the second contact element (104; 200) extends parallel to the extension direction (106) of the first contact element, wherein the first contact element (102) and the second contact element (104; 200) have a plurality of common contact points as viewed in the extension direction (106).