Sheet Heater Assembly With Variable Paths for Even Air Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heater assemblies for haircare appliances face issues with uneven heating due to fixed wire diameters and support structures obstructing airflow, leading to overheating and reduced performance.
Innovation Solution
A heater assembly with multiple heater elements having electrical paths of varying widths and thicknesses, formed from sheets with cut-outs, allowing for tailored heating performance and resistance to overheating by positioning elements optimally within the airflow path, and incorporating a temperature sensor for power control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire heater elements with fixed diameter are used, then manufacturing is simple, but all parts experience uniform electrical heating which causes downstream parts to overheat due to reduced cooling
Solution Approach 1:
The patent applies local quality by varying the width of different sections of the heater element. Upstream sections have narrower widths while downstream sections have wider widths, creating non-uniform electrical heating that compensates for the reduced cooling effect downstream. This ensures more uniform temperature distribution along the heater element.
Solution Approach 2:
The patent changes the physical parameter of heater element width along its length. By gradually increasing the width from upstream to downstream sections, the electrical resistance and heating characteristics are modified to account for the cumulative heating effect and reduced air cooling downstream.
2Ease of operation
If mica support structures are used to support the wire, then the wire is supported in the air flow path, but air flow is obstructed leading to uneven heating
Solution Approach 1:
The patent removes the mica support structures from the heater element design. Instead of using separate support structures, the heater element is formed as a continuous flexible circuit board that can be directly mounted, eliminating the air flow obstruction caused by mica supports.
Solution Approach 2:
The patent merges the heater element with its support structure by forming both as a single flexible circuit board component. This integration eliminates the need for separate support structures and allows the heater to be directly mounted in the air flow path without obstruction.
3Ease of manufacture
If uniform width electrical paths are used, then manufacturing is straightforward, but downstream heater elements cannot compensate for reduced cooling and are prone to overheating
Solution Approach 1:
The patent applies local quality by varying the width of electrical paths at different locations. Downstream electrical paths are made wider to increase their heat dissipation capacity and compensate for the reduced cooling effect, while upstream paths remain narrower.
Solution Approach 2:
The patent introduces asymmetry in the electrical path widths, creating a gradient from narrower upstream paths to wider downstream paths. This asymmetric design optimizes temperature control by matching the heating characteristics to the local cooling conditions at each position.
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 solution enables more efficient and even heating, with tailored resilience to overheating and improved airflow, enhancing the performance and reliability of haircare appliance heaters.
Implementation Method 1
An electric current is passed through the wire, causing it to heat up and thus heat up air flowing over it
Data Source
AI summary
A heater assembly for a haircare appliance includes an air duct defining an air flow path extending from an upstream end to a downstream end; a first heater element positioned in the flow path, the first heater element having a first electrical path defined between cut-outs in a first sheet, the air flow path extending through said cut-outs; and a second heater element positioned in the flow path downstream of the first heater element, the second heater element having a second electrical path defined between cut-outs in a second sheet, the air flow path extending through said cut-outs. The first electrical path has a first width and the second electrical path has a corresponding second width which is different to the first width.