Planar Heating Element With Dual-Material Wire Mesh
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional planar heating elements using single thickness and material wires suffer from uneven heat distribution and reliability issues, as they can be overloaded or burned out due to high resistance, especially when parts are cut off or have varying flexibility.
Innovation Solution
A planar heating element with a mesh structure comprising two wire parts of different thicknesses and materials, where the first wire part is made of stainless steel with higher resistance and the second wire part is made of conductive materials like copper or nickel, allowing for even current distribution and heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thin wires are used for weaving the planar heating element, then flexibility is improved, but resistance increases causing burnout
Solution Approach 1:
The heating element is divided into multiple thin wire strands that are woven together. Each strand carries a portion of the total current, distributing the electrical load and reducing the resistance and heat concentration in any single wire, thereby preventing burnout while maintaining flexibility.
Solution Approach 2:
The heating element uses composite construction by weaving multiple thin wire strands together to form a mesh structure. This composite approach combines the flexibility of thin wires with improved current distribution, creating a reliable heating element that resists burnout.
2Ease of manufacture
If single material wires are used, then manufacturing is simplified, but heat distribution becomes uneven
Solution Approach 1:
Different regions of the heating element use wires with different properties. The weaving pattern and wire selection are optimized for specific areas to achieve uniform heat distribution across the entire element, with higher current density in regions requiring more heat and lower density in regions requiring less.
Solution Approach 2:
The electrical current dynamically distributes itself across the woven wire structure based on resistance variations. The interlacing pattern creates multiple current paths with varying resistance, allowing the system to self-regulate and achieve uniform heat distribution without complex manufacturing controls.
3Power
If high resistance wires are used, then heat generation is improved, but reliability decreases due to burnout
Solution Approach 1:
The high resistance heating function is segmented across multiple parallel wire paths. Each individual wire operates at lower current and resistance, but collectively they provide the required heating power while maintaining reliability and preventing burnout through current distribution.
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 even heat distribution across the entire plane, preventing overheating and burnout, while providing excellent flexibility, weight reduction, corrosion resistance, and durability through fine control of electric current.
Implementation Method 1
a first wire part which generates heat when power is supplied
Data Source
AI summary
The present invention relates to a planar heating element and, more particularly, to planar heating using a multiple electrode system configured to uniformly generate heat by weaving using wires having different thicknesses and materials. In order to achieve the aforementioned objective, a planar heating element of the present invention comprises: a first wire part which is heated to generate heat when power is supplied and which is formed of a mesh structure having a regular size; a second wire part which generates heat when power is supplied and which is formed at a mesh size relatively larger than the mesh size of the first wire portion; and a module part for supplying power to the first wire part and the second wire part.