Planar Resistance Heating Element with Tempered Aluminum Foil
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Solution Overview
Problem
Conventional planar resistance heating elements face issues with heat deformation of insulating substrates leading to non-uniform printing and heat conduction, and improper composition ratios in carbon paste affecting physical properties, including heat-generating capabilities.
Innovation Solution
A manufacturing method involving stepwise tempering of aluminum foil on an insulating substrate to prevent heat deformation, combined with a carbon paste composition optimized for electrically conductive carbon, graphite, resin, solvent, and hardener to ensure uniform conductivity and heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional heating elements use direct current with low resistance, then heat generation is achieved, but temperature control becomes complicated
Solution Approach 1:
The patent changes the electrical parameter by using high voltage alternating current instead of direct current, and uses PTC material whose resistance changes with temperature to automatically regulate power, simplifying temperature control while maintaining heat generation capability
Solution Approach 2:
The PTC resistor element automatically regulates its own temperature through positive temperature coefficient characteristics, where resistance increases with temperature to limit current, enabling self-controlled temperature regulation without complex external control systems
2Ease of manufacture
If electrodes are formed by printing metallic mixture, then electrode formation is achieved, but electric conductivity is poor due to synthetic resin content
Solution Approach 1:
The patent replaces the conventional printed metallic electrode with an aluminum foil electrode that is etched to form the desired pattern. This etched aluminum electrode provides superior and more reliable electric conductivity compared to printed metallic paste containing synthetic resin
Solution Approach 2:
The patent uses a composite structure combining aluminum foil with etch resist pattern, where the aluminum foil provides excellent conductivity and the etch resist defines the electrode pattern, achieving both ease of manufacture and high reliability
3Ease of manufacture
If insulating substrate is heated during manufacturing, then processing is enabled, but heat deformation occurs causing non-uniform printing and heat conduction
Solution Approach 1:
The patent applies a release agent to the insulating substrate before heating and processing. This preliminary action prevents adhesion between the substrate and other components during heating, eliminating heat deformation and ensuring uniform printing and heat conduction in the final product
4Ease of manufacture
If carbon paste composition ratio is improper, then manufacturing is simplified, but physical properties including heat-generating properties deteriorate
Solution Approach 1:
The patent optimizes the composition parameters of carbon paste by specifying precise weight ratios of carbon powder (60-80 parts), resin (10-30 parts), and solvent (10-30 parts). This optimized composition ensures excellent heat-generating properties while maintaining ease of manufacture through proper material selection and mixing
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 method achieves uniform heat conductivity, excellent heat-generation effects, and easy manufacturing with near-zero temperature variation, allowing for the production of planar resistance heating elements with desired resistance properties.
Implementation Method 1
an aluminum foil acting as an electrode layer deposited on an insulating substrate is tempered in multiple steps to prevent heat deformation
Implementation Method 2
a planar resistance heating element wherein an aluminum foil acting as an electrode layer deposited on an insulating substrate is tempered in multiple steps to prevent heat deformation and a resistor element is formed using carbon paste made of a mixture of thermally conductive carbon, graphite, a resin, a solvent and a hardener
Data Source
AI summary
Disclosed herein is a manufacturing method of a planar resistance heating element and a planar resistance heating element made using the method. In the manufacturing method of a planar resistance heating element by etching an aluminum foil deposited on an insulating substrate in a desired pattern, printing carbon paste and connecting current input terminals in parallel, the aluminum foil is adapted to undergo a multiple step tempering process to thereby prevent heat deformation. The carbon paste acting as a resistor element is made of electrically conductive carbon, graphite, a resin, a solvent and a hardener which are mixed so as to optimize physical properties of the carbon paste. As a result, prevention of heat deformation of the insulating substrate, uniform heat conductivity, excellent heat-generation effect and easy manufacture may be achieved. In addition, the use of the carbon paste having optimized physical properties as a resistor element results in good heat-generation and near-zero temperature variation.