Plane Heating Element Layout for Uniform High-Temperature Cooking
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Solution Overview
Problem
Existing electric heaters with plane heating elements face limitations in uniformly heating at high temperatures and maximizing the heating area while achieving high power in a limited area due to inconsistent insulation gaps between bridges, which affect temperature distribution and power delivery.
Innovation Solution
The electric heater incorporates a substrate with a plane heating element featuring a pattern with varying arc-shaped tracks and bridges, where the insulation gaps between bridges are optimized based on potential differences, with narrower gaps at the innermost side and wider gaps at the outermost side, allowing for increased hot wire length and uniform heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If uniform insulation gaps are maintained between all bridges, then electrical insulation is ensured, but the heating area is reduced and uniform high-temperature heating is difficult to achieve
Solution Approach 1:
The patent applies local quality by varying the insulation gap width according to the local electrical potential difference. Bridges at different radial positions have different gap widths: inner bridges (lower potential difference) have narrower gaps, while outer bridges (higher potential difference) have wider gaps. This localized adaptation ensures electrical insulation is sufficient where needed while maximizing heating area where potential difference is lower.
2Productivity
If the heating element is designed to heat a limited area at high temperature, then cooking time is shortened, but the heating area is reduced and power distribution becomes uneven
Solution Approach 1:
The heating element employs local quality by varying the hot wire density and gap width across different radial zones. The pattern portion has higher wire density for concentrated heating where needed, while the surrounding portion provides broader heating coverage. This creates multiple heating zones with different characteristics, enabling both fast cooking in specific areas and overall even heat distribution.
Solution Approach 2:
The heating element is segmented into distinct functional zones: a central pattern portion with higher wire density for concentrated high-temperature heating, and surrounding portions with lower density for broader coverage. This segmentation allows different regions to serve different heating purposes simultaneously, achieving both rapid cooking and even temperature distribution.
3Reliability
If the insulation gap is increased to ensure electrical insulation, then safety is improved, but the achievable power in a limited area is reduced
Solution Approach 1:
The patent applies parameter changes by varying the insulation gap width as a function of radial position and electrical potential difference. Instead of using a fixed gap width, the gap parameter is dynamically adjusted: narrower gaps where potential difference is low, wider gaps where potential difference is high. This optimized parameter distribution maintains electrical insulation safety while maximizing the achievable power density in the limited heating area.
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 enhances the heating area, ensures uniform high-temperature heating, and increases the achievable power in a limited area by optimizing bridge gaps and hot wire length, addressing the limitations of previous designs.
Implementation Method 1
a heating element attached to the surface of the substrate and having a predetermined shape... When current flows along the hot wire of the pattern portion, the magnitude of the voltage measured per the position of the hot wire is different
Data Source
AI summary
An electric heater includes a substrate; and a plane heating element disposed on one surface of the substrate. The plane heating element includes a pattern portion including a start point and an end point, which are located at an outermost side of the pattern portion, the pattern portion including a plurality of tracks having an arc shape, which are spaced apart from each other and are formed to have a length increasing from an innermost side to the outermost side of the pattern portion, and a plurality of bridges connecting the plurality of tracks in series. The plurality of bridges are formed on both sides of the pattern portion with respect to a reference line passing through a center of the pattern portion, and an innermost gap between the pair of bridges located at the innermost side of the pattern portion is narrower than an outermost gap between a pair of bridges located at the outermost side of the pattern portion.