Printed Heating Element Nanometal Paths Power Density
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Solution Overview
Problem
Conventional heating elements face limitations in achieving high power density and flexibility, particularly in accommodating complex surface contours, and often rely on polymer binders or particles that can restrict performance and manufacturing versatility.
Innovation Solution
The development of printed heating elements with particle-free metal or nanometal paths, using conductive inks and substrates, allows for the creation of high-power density heating elements that can be printed on various substrates, including those with complex shapes, using techniques like inkjet or aerosol printing, without the need for polymer binders, enabling flexible and efficient heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional conductive paths (wires, etched foils, screen-printed tracks) are used, then structural integrity is maintained, but power density and flexibility are limited
Solution Approach 1:
The patent changes the physical state of conductive materials from bulk (wires, foils) to nanoscale particles and molecular compounds. This parameter change enables the conductive path to be printed in flexible configurations on complex surfaces while achieving high power density through optimized nanometal networks without polymer binders.
Solution Approach 2:
The patent replaces conventional mechanical conductive paths (wires, etched foils) with printed nanometal tracks formed from conductive inks. This substitution allows for greater design flexibility and adaptability to complex surfaces while maintaining electrical conductivity through carefully controlled nanometal particle arrangements.
2Stability of the object's composition
If polymer binders are used in conductive paths, then structural stability is improved, but performance and manufacturing versatility are restricted
Solution Approach 1:
The patent extracts and removes polymer binders from the conductive path composition, using only nanometal particles and molecular conductive compounds. This extraction eliminates the performance restrictions and manufacturing versatility limitations imposed by polymer binders while maintaining structural stability through optimized nanometal network design.
Solution Approach 2:
The patent uses composite materials consisting of nanometal particles (silver, copper, aluminum) combined with molecular conductive compounds rather than conventional polymer binder composites. This composite approach provides both structural stability and enhanced manufacturing versatility, allowing the conductive ink to be printed on diverse substrates including flexible and complex surfaces.
3Reliability
If particle-based conductive materials are used, then conductivity is achieved, but heat transfer efficiency is reduced
Solution Approach 1:
The patent changes the particle size parameter to the nanoscale and transitions from discrete particles to molecular-level conductive compounds. This parameter change reduces inter-particle resistance and improves thermal contact, thereby enhancing heat transfer efficiency while maintaining electrical conductivity through the optimized nanometal network structure.
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 approach enables the production of heating elements with power densities exceeding 400 watts per square meter, accommodating complex surfaces, and allows for direct integration into components, enhancing manufacturing flexibility and performance by eliminating polymer binders and utilizing nanometal paths for efficient heat transfer.
Implementation Method 1
A heating element converts electricity into heat through the process of ohmic heating wherein the passage of an electric current through a conductive path releases heat.
Data Source
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AI summary
A heating element 10 is provided with a conductive path pattern 12 which can be printed in a mask-free manner (e,g., drop-on-demand) with existing printing technology. The printing step can be performed, for example, with a thermal inkjet printer, a piezoelectric inkjet printer, an aerosol jet printer, or an ultrasound printer. The ink solution can formulated so that it establishes an electrically conductive path which is free of polymer binders.