Thick Film Element Double-Sided Heat Conductivity
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Solution Overview
Problem
Conventional thick film heating elements lack double-sided high heat conductivity, leading to inefficient and uneven heating, structural bulkiness, environmental concerns, and short service life, particularly in household and industrial applications.
Innovation Solution
A three-layered thick film element with a carrier, a thick film coating, and a covering layer, where the heat transfer rates of each layer are optimized to ensure uniform heating on both sides, with the thick film coating being the heating material, and the carrier and covering layer selected to meet specific heat transfer and melting point criteria to prevent overheating and structural damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional electrical heated tube heating or PTC heating is used, then heating function is achieved, but thermal efficiency is low and structure is bulky
Solution Approach 1:
The patent extracts the heating function from conventional bulky heated tubes and PTC ceramics, isolating the essential thick film heating element that can be integrated directly onto substrates. This removes the need for separate heating assemblies, reducing overall structure size while maintaining heating efficiency through direct contact heat transfer.
Solution Approach 2:
The patent replaces conventional electrical heating mechanisms (heated tubes, PTC elements) with a thick film heating element that uses printed conductive patterns on flexible substrates. This substitution enables direct heating of the substrate surface, eliminating the need for mechanical heating assemblies and improving thermal efficiency through direct heat transfer.
2Temperature
If conventional heating elements are used, then heating is achieved, but heating uniformity is poor
Solution Approach 1:
The patent applies local quality by using printed conductive patterns that can be strategically positioned and shaped to distribute heat uniformly across specific areas. The thick film heating element can be designed with varying trace widths, spacing, and patterns to optimize heat distribution in different regions, achieving uniform temperature across the substrate surface.
Solution Approach 2:
The patent transitions from point or linear heating sources to areal heating distributions by printing conductive patterns across the substrate surface. This two-dimensional heat distribution approach enables uniform heating across the entire surface area, eliminating hot spots and cold zones associated with conventional point-source heating methods.
3Reliability
If thick film heating plate is coated with insulating medium, then electrical insulation is improved, but heat transfer capability is reduced
Solution Approach 1:
The patent applies local quality by selectively positioning insulating materials only where electrical insulation is required, rather than coating the entire heating surface. This allows heat transfer regions to remain exposed for efficient thermal contact, while insulating areas provide necessary electrical isolation. The insulating medium is applied locally at edges, terminals, or specific zones where insulation is needed.
Solution Approach 2:
The patent uses an intermediary approach by employing transparent or thin insulating layers that allow thermal radiation or conduction while providing electrical isolation. The insulating medium acts as a mediator that permits heat transfer through radiation or thin-film conduction while blocking electrical current, thus maintaining both insulation and heat transfer capabilities.
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 provides a compact, efficient, and environmentally friendly thick film element with uniform heat generation on both sides, enhancing heat transfer efficiency and extending the service lifespan while ensuring safety and energy savings.
Implementation Method 1
The thick film coating is a heating material, and the mode of heating is electrical heating
Implementation Method 2
the carrier and the covering layer are selected from a material that fulfills every of the following equations: Q2≥Q3; Q2≥Q1; and Q1=a×Q3, Q2=b×Q1, Q2=c×Q3
Data Source
AI summary
The present invention provides a thick film element with high heat conductivity on two sides thereof, which comprises a carrier, a thick film coating deposited on the carrier, and a covering layer overlays on the coating; the thick film coating is heating materials, and mode of heating is electrical heating, wherein the carrier, the thick film coating and the covering layer are selected from the material that fulfill every following equations: Q2≥Q3; Q2≥Q1; and Q1=a×Q3, Q2=b×Q1, Q2=c×Q3; and 0.1≤a≤150, 1≤b≤2500, 100≤c≤10000. The thick film element of the present invention has high heat conductivity and uniform heat generating rate on both sides thereof, thus improving heat transfer efficiency of the product; it could be applied in products that require double-sided high heat conductivity, meeting the market demand for multifunctional heating products.