Plane Electric Heater Bridge Layout for Uniform Heating

Solution Overview

Problem

Existing electric heaters with plane heating elements face challenges in achieving uniform heating while minimizing dielectric breakdown and local heating, particularly at bridge connections between tracks.

Innovation Solution

The design incorporates a substrate with a first plane heating element featuring tracks connected by bridges with specific protrusions and curved portions, and a second plane heating element with inner tracks and bridges, optimizing track widths and bridge sizes to maintain uniform heating and reduce insulation breakdown.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the bridge connects adjacent tracks directly without protrusions or curved portions, then the structure is simple, but local heating occurs at the bridge and dielectric breakdown risk increases

Engineering Contradiction:

Improvebridge structureVSAvoidlocal heating and dielectric breakdown

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The bridge includes a curved portion that protrudes toward an adjacent track, creating a non-linear geometric configuration. This curvature increases the clearance distance between the bridge and the track, reducing heat concentration and preventing dielectric breakdown while maintaining structural integrity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The bridge structure incorporates localized protrusions and curved portions at specific critical locations where heat concentration occurs. These localized geometric modifications target the problematic areas without requiring changes to the entire bridge structure, optimizing heat distribution and electrical insulation at critical points.

Inventive Principle:

Principle #3Local quality

2Productivity

If the track width is increased to reduce resistance and improve heating uniformity, then heating performance improves, but the clearance between track and bridge decreases, increasing dielectric breakdown risk

Engineering Contradiction:

Improveheating uniformityVSAvoidinsulation breakdown resistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The bridge includes a curved portion that protrudes toward an adjacent track, creating a non-linear geometric configuration. This curvature increases the clearance distance between the bridge and the track, reducing heat concentration and preventing dielectric breakdown while maintaining structural integrity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The bridge structure incorporates localized protrusions and curved portions at specific critical locations where heat concentration occurs. These localized geometric modifications target the problematic areas without requiring changes to the entire bridge structure, optimizing heat distribution and electrical insulation at critical points.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If the bridge size is reduced to minimize local heating, then local heating decreases, but the structural strength and electrical insulation capability are compromised

Engineering Contradiction:

Improvelocal heating at bridgeVSAvoidbridge structural and insulation strength

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The bridge includes a curved portion that protrudes toward an adjacent track, creating a non-linear geometric configuration. This curvature increases the clearance distance between the bridge and the track, reducing heat concentration and preventing dielectric breakdown while maintaining structural integrity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The bridge structure incorporates localized protrusions and curved portions at specific critical locations where heat concentration occurs. These localized geometric modifications target the problematic areas without requiring changes to the entire bridge structure, optimizing heat distribution and electrical insulation at critical points.

Inventive Principle:

Principle #3Local quality

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 even heating of objects, minimizes local heating at bridges, and maintains consistent width of the first plane heating element, thereby preventing insulation breakdown and reducing hotspots.

Implementation Method 1

an electric heater using a Joule heat generated by flowing current through a resistance wire or the like

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11435088B2Electric heater and cooking appliance having same

Publication Date: 2022.09.06 LG ELECTRONICS INC

AI summary

An electric heater includes a substrate; and a first plane heating element disposed on one surface of the substrate, in which the first plane heating element includes a first track; a second track spaced apart from the first track; and a third track spaced apart from the second track. At least a portion of the second track is located between the first track and the third track, and the first track and the second track are connected by a first bridge, where the first bridge includes a first outer protrusion protruding toward the third track. The third track is formed with a curved portion which protrudes in an outward direction, and the first outer protrusion faces an inside of the curved portion in the outward direction and is spaced apart from the curved portion.