Plane Heating Element Gap Layout for Dielectric Breakdown Control
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Solution Overview
Problem
Conventional plane heating elements in electric stoves experience dielectric breakdown and local heating due to high potential differences, especially when generating temperatures above 500°C, leading to inefficiencies and damage in high-temperature environments.
Innovation Solution
The design incorporates an inner and outer plane heating element with specific track and bridge configurations, including varying gaps and thicknesses to manage potential differences, ensuring the gap between tracks with the smallest potential difference is shortest and those with larger differences are longer, and electrodes are thicker to reduce resistance and prevent dielectric breakdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the heating element is designed to generate high temperature (above 500°C) with high resistance, then the heating efficiency is improved, but dielectric breakdown and local heating occur due to large potential differences
Solution Approach 1:
The patent applies local quality by varying the gap distances between adjacent tracks at different locations. Specifically, the gap distance is made shorter in regions with smaller potential differences and longer in regions with larger potential differences. This localized adjustment of gap distances optimizes the electrical insulation properties at each specific location, preventing dielectric breakdown while maintaining high heating temperature where needed.
Solution Approach 2:
The patent changes the geometric parameter of the heating element by making the gap distances between tracks non-uniform. Instead of maintaining equal gaps throughout, the gap distances are varied according to the potential difference distribution, with shorter gaps in low-potential regions and longer gaps in high-potential regions. This parameter change resolves the contradiction between high temperature generation and dielectric breakdown prevention.
2Productivity
If the heating element operates in high-temperature environment, then the cooking speed is improved, but the dielectric constant of base material increases causing rapid decrease in capacitive reactance and local heating
Solution Approach 1:
The patent applies preliminary anti-action by pre-configuring the gap distances between tracks to compensate for the anticipated increase in dielectric constant at high temperatures. Before the heating element operates at high temperature, the gap distances are designed to be shorter in low-potential regions and longer in high-potential regions, creating a preventive structure that counteracts the future decrease in capacitive reactance when the dielectric constant increases due to high-temperature operation.
3Ease of manufacture
If uniform gap distance is maintained between all tracks, then the manufacturing is simplified, but dielectric breakdown occurs in regions with large potential differences
Solution Approach 1:
The patent rejects uniform gap distance and instead implements local quality by making the gap distances between adjacent tracks non-uniform. The gap distance is specifically adjusted to be shorter in regions with smaller potential differences and longer in regions with larger potential differences. This localized differentiation maintains manufacturing feasibility while effectively preventing dielectric breakdown in high-potential regions.
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 effectively prevents dielectric breakdown and local heating, allowing for uniform heat generation across the heating area, increasing the maximum heating area while maintaining efficient temperature control within a limited space.
Implementation Method 1
a heating element attached to the surface of the substrate and having a predetermined shape
Implementation Method 2
a substrate including a surface made of an electrically insulating material
Data Source
AI summary
An electric heater includes a substrate and an inner plane heating element formed on one surface of the substrate. The inner plane heating element includes an inner pattern portion connecting a start point with an end point. The inner pattern portion includes a first track, a second track located outside the first track and spaced part from the first track, a first bridge connecting the first track with one end of the second track, a third track located outside the second track and spaced apart from the second track, and a second bridge connecting the other end of the second track with the third track. A first gap G1 between the first and second tracks is shorter than a second gap G2 between the second and third tracks along a virtual line crossing the first, second and third tracks and closer to the first bridge than the second bridge.