Plane Electric Heater Layout for Uniform Heating Without Dead Zones
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Solution Overview
Problem
Conventional electric heaters with plane heating elements suffer from asymmetrical heating, leading to dead zones with lower temperature distributions, which reduce heating efficiency and create aesthetically undesirable appearances due to the formation of hot and dead zones when a second pattern portion is outside a first pattern portion.
Innovation Solution
The electric heater incorporates a substrate with a first plane heating element and a second plane heating element, where the second pattern portion surrounds the first, with connectors located in the opening region of the second pattern portion to enhance heat distribution and symmetry, thereby eliminating dead zones and increasing the high-temperature area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a second pattern portion is provided outside a first pattern portion to expand heating area, then the heating area is increased, but dead zones are generated in the zone where the second pattern portion is formed
Solution Approach 1:
The patent applies asymmetry by strategically placing connectors in the opening region of the second pattern portion, which is asymmetric relative to the overall heating element. This asymmetric connector placement ensures that the connectors are positioned within the heating zone where they can generate heat to eliminate dead zones, while the electrodes remain outside the hot zone to avoid overheating. This resolves the contradiction by creating an asymmetric design that optimizes both heating area expansion and temperature distribution uniformity.
2Temperature
If high resistance is designed in the heating portion to generate heat at temperature higher than 500°C, then heating temperature is increased, but local over-heating occurs and the hot wire is destroyed
Solution Approach 1:
The patent applies local quality by differentiating the resistance characteristics of different components. The pattern portions (hot wires) are designed with appropriate resistance to generate heat without excessive local overheating, while the connectors are designed with higher resistance to generate additional heat in the opening region. The electrodes are positioned outside the hot zone to avoid overheating. This localized differentiation of resistance properties allows the system to achieve high heating temperatures while preventing hot wire destruction through controlled heat distribution.
3Shape
If connectors are placed outside the second pattern portion to avoid interference, then the second pattern portion can be formed completely, but dead zones remain in the opening region
Solution Approach 1:
The patent applies dimensionality change by utilizing the opening region (a spatial dimension within the second pattern portion) to place connectors. Instead of placing connectors only outside the second pattern portion, the design incorporates connectors within the opening region of the second pattern portion, effectively using the available space in a different dimensional arrangement. This allows the connectors to be positioned where they can generate heat to eliminate dead zones while the electrodes remain outside the hot zone to avoid overheating, thus maintaining both pattern completeness and heating efficiency.
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 uniform, symmetrical heating across the entire zone, increasing the high-temperature area, improving heating efficiency, and preventing user misinterpretation of the heater's functionality due to aesthetically improved design.
Implementation Method 1
a heating element attached to the surface of the substrate and having a predetermined shape... As current is supplied through the electrodes, radiant heat is generated in the heater track
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~5
AI summary
An electric heater includes a substrate (an insulating material capable of forming a conductor pattern on a surface of an insulating substrate), a first plane heating element formed on one surface of the substrate, and a second plane heating element formed on one surface of the substrate to be located outside the first plane heating element. The first plane heating element includes a first pattern portion connecting a start point with an end point located in a first zone, a pair of first electrodes located outside the first zone, and a pair of first connectors connecting the first pattern portion with the first electrodes. The second plane heating element includes a second pattern portion located in a second zone surrounding the first zone and connecting a start point with an end point, and at least some of the first connectors are located in the second zone.