Planar Sheet Steel Heating Element for Flexible Seam Bonding

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Solution Overview

Problem

Existing contact heating devices for thermally induced seam bonding of flat flexible material layers suffer from mechanical rigidity, requiring high force for alignment, are costly, and pose safety risks due to high thermal mass, while being inefficient and difficult to handle, especially for less experienced users.

Innovation Solution

A contact heating device using a directly energized, flat, planar sheet steel blank as the heating element, which is flexible and adaptable to uneven surfaces, providing uniform heat distribution and reducing mechanical and thermal stress, with incisions to enhance heating efficiency and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a three-dimensional wedge-shaped heating element is used, then mechanical stability is improved, but handling becomes difficult and high force is required for alignment

Engineering Contradiction:

Improvemechanical stabilityVSAvoidhandling ease

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The heating element is designed as a flat, planar sheet steel blank instead of a three-dimensional wedge shape. This thin, flexible design allows the heating element to be easily handled and inserted between material layers without requiring high alignment force, while still providing sufficient mechanical stability during operation.

Inventive Principle:

Principle #30Flexible shells and thin films

2Stability of the object's composition

If a three-dimensional wedge-shaped heating element is used, then mechanical stability is improved, but alignment precision becomes difficult

Engineering Contradiction:

Improvemechanical stabilityVSAvoidalignment precision

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The flat, planar sheet steel blank design enables precise alignment between material layers. The thin profile allows the heating element to be accurately positioned and inserted between layers without the alignment difficulties associated with bulky three-dimensional wedges, while maintaining sufficient mechanical stability through the inherent rigidity of the sheet steel.

Inventive Principle:

Principle #30Flexible shells and thin films

3Quantity of substance

If a heating element with high thermal mass is used, then heat storage capacity is improved, but operational safety deteriorates due to burn risks

Engineering Contradiction:

Improvethermal massVSAvoidburn risk

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The heating element is designed with optimized thickness and material properties to achieve the desired thermal mass while controlling operating temperature. The flat, planar sheet steel blank provides sufficient heat storage capacity for effective welding, but the reduced cross-section compared to three-dimensional wedges allows for lower operating temperatures, thereby reducing burn risks and improving operational safety.

Inventive Principle:

Principle #35Parameter changes

4Ease of operation

If a flat, planar sheet steel blank is used as heating element, then handling ease is improved, but mechanical stability may worsen

Engineering Contradiction:

Improvehandling easeVSAvoidmechanical stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The flat, planar sheet steel blank provides excellent handling ease due to its thin, flexible profile that can be easily inserted and positioned between material layers. Meanwhile, the sheet steel material itself provides sufficient mechanical stability during welding operations, and the design can be optimized through appropriate thickness selection and structural features to maintain stability while preserving handling advantages.

Inventive Principle:

Principle #30Flexible shells and thin films

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 enhances handling ease, reduces operational costs, improves seam quality, and ensures efficient, safe, and fast welding or gluing operations, even for less experienced users, by compensating for misalignments and uneven surfaces.

Implementation Method 1

a heating element (14) connected between the terminal electrodes (11, 12), wherein the heating element (14) is configured as a directly energized, flat, planar sheet steel blank

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20250346001A1Automatic joining machine and contact heating device for thermally induced, seam bonding of flat, flexible material layers

Publication Date: 2025.11.13 LEISTER TECHNOLOGIES AG

AI summary

A contact heating device for thermally induced (materially cohesive) seam bonding of weldable and/or gluable flat flexible material layers with each other, which are configured as a material web, a material band and/or a material piece and are arranged at least partially overlapping, is provided, the contact heating device comprising: a first terminal electrode and a second terminal electrode; and a heating element connected between the terminal electrodes; wherein the heating element is configured as a directly energized, flat, planar sheet steel blank. The present invention further relates to an automatic welding or joining machine, a hand-held device and a method.