Sol-Gel Heating Element Layer for Domestic Appliances
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sol-gel based layers for heating elements in domestic appliances face challenges in achieving accurate thickness control and minimizing shrinkage during the drying and curing process, which affects the thermal stability and insulation efficiency, especially at high power densities.
Innovation Solution
The use of concentrated prepolymerized sol-gel precursors, combined with screen-printing and specific particle fillers, allows for the creation of dense, non-porous insulating layers with controlled thickness and high thermal stability, suitable for high power density applications, and the incorporation of conductive particles for resistive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spray coating is used to apply sol-gel layers, then the application process is simple and common, but the thickness control accuracy is insufficient
Solution Approach 1:
The patent changes the physical parameters of the sol-gel precursor by prepolymerizing it to increase viscosity and reduce shrinkage. This parameter modification enables the material to be successfully applied via screen-printing while achieving accurate thickness control and minimal shrinkage during curing.
Solution Approach 2:
The patent replaces the spray coating mechanical system with a screen-printing system. This substitution allows for precise thickness control through the screen mesh while maintaining ease of manufacture through direct patterning and reduced material waste.
2Ease of operation
If non-concentrated non-prepolymerized sol-gel precursor is used, then the composition is easier to apply, but the shrinkage amount during drying and curing is excessive
Solution Approach 1:
The patent applies preliminary action by prepolymerizing the sol-gel precursor before final application. This pre-treatment partially polymerizes the material, reducing the subsequent shrinkage that occurs during drying and curing, while still maintaining adequate flow properties for screen-printing application.
Solution Approach 2:
The patent modifies the concentration and polymerization state parameters of the sol-gel precursor. By prepolymerizing and concentrating the solution, the material achieves a balance between applicability (足够的流动性 for screen-printing) and shrinkage control (reduced volume change during curing).
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 results in heating elements with reduced shrinkage, enhanced thermal stability, and increased dielectric strength, enabling efficient insulation and high power density operation without cracking, suitable for applications like laundry irons and other domestic appliances.
Implementation Method 1
The layer according to the present invention is obtained from a concentrated prepolymerized sol-gel precursor
Implementation Method 2
the amount of shrinking of the sol-gel precursor composition is reduced considerably compared to the use on a non-concentrated non-prepolymerized sol-gel precursor
Implementation Method 3
Heat is generated by passing an electric current through the resistive layer
Implementation Method 4
The function of the insulating layer is to isolate the heat-generating resistive element from the substrate
Implementation Method 5
allows for the creation of dense, non-porous insulating layers with controlled thickness and high thermal stability
Data Source
AI summary
Disclosed is a layer for use in a domestic appliance, based on a sol-gel precursor. This layer can be obtained by screen-printing and comprises an organosilane compound. The layer is obtained from a concentrated pre-polymerized sol-gel precursor. The layer can be used as an insulating layer or as a conductive layer in a heating element. Furthermore, the layer can be used for decorative purposes.