Portable Heater Ceramic Substrate Design to Reduce Ignition Risk

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Solution Overview

Problem

Portable electric space heaters lack safety features and pose a risk of igniting nearby objects due to intense heat output and silent operation, making them hazardous, especially for children and adolescents.

Innovation Solution

A portable heater design featuring a ceramic substrate with a heating element and a concave reflective surface, where the ceramic substrate is mounted on a grill cover with a predetermined profile, allowing for unobstructed radiation and minimizing direct contact risks, combined with safety features like a tip-over switch and thermal fuse to prevent overheating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a resistive heating element is used to produce intense heat output, then heating efficiency is improved, but the risk of igniting nearby objects increases

Engineering Contradiction:

Improveheating efficiencyVSAvoidignition risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

A ceramic substrate is introduced as an intermediary between the resistive heating element and the surrounding environment. The ceramic material conducts heat efficiently to maintain heating performance while its inherent fire-resistant properties prevent direct flame contact and reduce ignition risk of nearby objects.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The intense heat that could potentially cause ignition is redirected through a reflective surface that channels the thermal energy in controlled directions away from flammable materials, converting the harmful intense heat into beneficial directed heating while minimizing fire risk.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Ease of operation

If a resistive heating element operates silently, then operational quietness is improved, but safety monitoring becomes more difficult

Engineering Contradiction:

Improveoperational quietnessVSAvoidsafety monitoring

Core Design Contradiction:

Ease of operationVSDifficulty of detecting and measuring

Solution Approach 1:

The ceramic substrate exhibits visible color changes or glow patterns at different temperature levels, providing visual feedback that allows users to monitor the heater's operational state and detect potential safety issues without relying on audible signals, thus maintaining operational quietness while enabling safety monitoring.

Inventive Principle:

Principle #32Color changes

3Productivity

If the heating element is exposed for direct heating, then heating effectiveness is improved, but contact safety risk increases

Engineering Contradiction:

Improveheating effectivenessVSAvoidcontact safety risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The heating system is segmented into distinct functional layers: the resistive heating element generates heat, the ceramic substrate conducts and distributes it, and the reflective surface directs the thermal energy. This segmentation allows the heating element to remain effective while being physically separated from direct contact zones by the ceramic and reflective components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating function is transitioned from direct contact heating to radiant heating through the reflective surface. By changing the dimension of heat transfer from conductive (direct contact) to radiant (electromagnetic waves), the system maintains heating effectiveness while eliminating the need for direct contact between the heating element and objects or users.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 design efficiently redirects radiant heat away from the heater, minimizing the risk of contact and ignition, while safety features ensure operational safety, providing effective and safe task-specific heating.

Implementation Method 1

an electric space heater has a resistive heating element which releases radiant energy

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Implementation Method 2

a heat reflector with a concave reflective surface configured to define a field of reflective radiation

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 3

a ceramic substrate with a heating element configured to define a field of direct radiation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11371748B2Portable heater with ceramic substrate

Publication Date: 2022.06.28 THE MERCHANT OF TENNIS INC

AI summary

A portable heater that includes a ceramic substrate with a heating element configured to define a field of direct radiation, a heat reflector with a concave reflective surface configured to define a field of reflective radiation, a grill cover mounted on the heat reflector, where the ceramic substrate is mounted on an interior side of the grill cover with the heating element facing the concave reflective surface such that the field of direct radiation onto the concave reflective surface is unobstructed.