A 3D printed heating element

Abstract

The utility model relates to the technical field of electric heaters, and in particular to a 3D printed heating element. It comprises: a plurality of arrays of micro units, the micro units comprising: a plurality of arrays of heating elements; and a plurality of equipotential supports arranged between each two adjacent heating elements; the heating element is a plurality of arrays of honeycomb hole structures, and a heating element of a honeycomb structure is formed by the plurality of arrays of micro units. The heating element is made of high-temperature resistant metal or alloy material and is made by 3D printing; the alloy material is a high-temperature resistant nickel-chromium alloy or iron-chromium-aluminum alloy. The volume of the electric heater of the utility model is 1 / 6 of the volume of the traditional electric heater, that is, for the same size of the device, the electric heater of the utility model is 6 times the power of the traditional electric heater, which greatly reduces the volume.

Description

Technical Field

[0001] The utility model relates to the technical field of electric heaters, in particular to a 3D printed heating element. Background Art

[0002] At present, traditional circulating electric heaters or channel electric heaters generally use tubular electric heating elements, which usually consist of electric heating filaments, magnesium oxide and metal shells. Due to the temperature difference between the electric heating wire and the metal shell, the characteristics of magnesium oxide itself, and the uniformity of the temperature area, the maximum temperature in general fluid heating applications is only 650°C. If the heating temperature needs to be further increased, the life of the electric heater involved will be very short. Therefore, this is a bottleneck in high-temperature heating applications. Utility Model Content

[0003] The purpose of the utility model is to provide a 3D printed heating element. The heating element of the utility model can significantly increase the outlet temperature of the heated fluid. According to the current materials, if iron-chromium-aluminum materials are used, the temperature of the heated fluid can reach 1300°C, which is impossible for traditional heaters to implement.

[0004] In order to solve the above technical problems, the utility model provides a 3D printed heating element, comprising:

[0005] A plurality of arrays of micro-units, wherein the micro-units include: a plurality of arrays of heating elements; and a plurality of equipotential support members arranged between each two adjacent heating elements;

[0006] The heating element is a honeycomb hole structure of several arrays, and the heating element of the honeycomb structure is formed by the micro units of several arrays.

[0007] Preferably, the heating element is made of high-temperature resistant metal or alloy material and is manufactured by 3D printing; the alloy material is a high-temperature resistant nickel-chromium alloy or iron-chromium-aluminum alloy.

[0008] Preferably, the arrangement points of the equipotential support members are several equipotential points formed by current passing through each micro unit to generate the same voltage drop.

[0009] Preferably, the heating element and the flow direction of the fluid form an angle of 90 degrees to ensure that the heated fluid can sweep across the heating element.

[0010] Preferably, the heat-generating outer surface of the heating element further includes a high surface roughness, or point-distributed heat dissipation points, or a coating with a high emissivity, so as to increase the heat transfer coefficient between the fluid and the heating element.

[0011] Preferably, the surface heating power of the heating element decreases from the inlet to the outlet of the fluid; and the heating element also includes a temperature sensor to prevent the heating element from overheating.

[0012] Preferably, the heating element further comprises two electrode plates for applying power, and the electrode plates further comprise welding electrodes for wiring.

[0013] Preferably, it further comprises a junction box, the connection terminals of which are connected to the welding electrodes on the electrode plate; and the junction box also comprises a cable inlet.

[0014] Preferably, it also includes a ceramic insulating member, and a plurality of the heating elements can be supported and installed in the pressure vessel or channel through the ceramic insulating member.

[0015] Preferably, it further comprises a heat dissipation area, wherein the heat dissipation area is located between the pressure vessel or the channel and the junction box.

[0016] Compared with the prior art, the utility model has the following beneficial effects:

[0017] 1. The 3D printing heating element of the utility model forces the fluid to flow through the flow channel. The direction of the fluid is at a 90-degree angle to the heating element, which means that the fluid sweeps across the heating element, greatly increasing the turbulence of the fluid and reducing the temperature of the heating element. The purpose of the roughness of the surface of the heating element or the increase in the heat dissipation points is to further sweep the fluid across the heat dissipation points, further increase the turbulence of the fluid, increase the heat exchange coefficient between the fluid and the heating element, further reduce the temperature of the heating element, and extend the service life of the heating element.

[0018] 2. The 3D heating element of the utility model adopts 3D printing technology, and the entire structure is similar to a honeycomb structure, which is very strong. The maximum fluid temperature can be heated to 1300°C, which is currently unattainable by all resistive material heating, filling the gap in high-temperature applications of resistive material heating.

[0019] 3. The 3D heating element of the utility model cleverly utilizes the equipotential advantage between the heating elements to provide appropriate support and reinforcement, making the entire structure stronger while not lacking in the elasticity of high-temperature stress release.

[0020] 4. The 3D heating element of the utility model can be designed and used with variable power, that is, when the inlet temperature is low, the power density can be designed to be larger, and when the outlet temperature is high, the power density can be designed to be smaller. Under the same output power, the volume of the electric heater of the utility model is 1 / 6 of the volume of the traditional electric heater, that is, for the same size of equipment, the power of the electric heater of the utility model is 6 times that of the traditional electric heater, which greatly reduces the volume. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a three-dimensional diagram of the micro-unit structure of a 3D printed heating element of the utility model.

[0022] Figure 2 This is a top view of a micro unit of a 3D printed heating element of the utility model.

[0023] Figure 3 This is a three-dimensional diagram of the overall structure of a 3D printing heating element of the utility model.

[0024] Figure 4 This is a top view of the overall structure of a 3D printing heating element of the utility model.

[0025] In the figure: 1-micro unit, 2-heating element, 3-equipotential support, 4-electrode plate. DETAILED DESCRIPTION

[0026] The utility model is further described in detail below in conjunction with the accompanying drawings and specific embodiments. According to the following description, the advantages and features of the utility model will become clearer. It should be noted that the drawings are all in a very simplified form and are not in precise proportions, and are only used to conveniently and clearly assist in explaining the purpose of the embodiments of the utility model.

[0027] Embodiment 1:

[0028] like Figures 1 to 4 As shown, the embodiment of the utility model provides a 3D printed heating element, characterized in that it includes:

[0029] A plurality of arrays of micro units 1, each micro unit 1 comprises: a plurality of arrays of heating elements 2; and a plurality of equipotential support members 3 arranged between each two adjacent heating elements 2, and the arrays are usually in the form of linear arrays.

[0030] The heating element 2 is a honeycomb hole structure of several arrays, and the heating element of the honeycomb structure is formed by several arrays of micro units 1.

[0031] The heating element 2 is made of high-temperature resistant metal or alloy material and is manufactured by 3D printing; the alloy material is high-temperature resistant nickel-chromium alloy or iron-chromium-aluminum alloy.

[0032] The arrangement points of the equipotential support members 3 are several equipotential points formed by the same voltage drop generated by the current passing through each micro unit 1. Power is applied through both ends of the micro unit 1. Since the micro unit 1 adopts an array structure, when the current flows through each micro unit 1, the same voltage drop will be generated. There are many equipotential points between the micro units 1. These equipotential points are supported by metal parts, namely the equipotential support members 3, that is, the equipotentials are fully utilized between the heating elements 2 according to the flow direction of the current and the level of the power-on potential. In principle, no current flows through these equipotential support members 3.

[0033] The heating element 2 and the flow direction of the fluid form an angle of 90 degrees to ensure that the heated fluid can pass across the heating element 2 .

[0034] All electrode plates 4, heating elements 2, and equipotential supports 3 are made of 3D printing technology. The electrode plates 4, heating elements 2, and equipotential supports 3 can be made of the same material or different materials. Commonly used materials are: nickel-chromium alloy or iron-chromium-aluminum alloy. The flow direction of the fluid is at a 90-degree angle to the heating element 2. In other words, the fluid sweeps across the heating element 2, forcing the fluid to sweep across the heating element 2, increasing the turbulence of the fluid, reducing the temperature of the heating element 2, and extending the service life of the heating element 2.

[0035] Since the 3D heating element is designed in 3D, it is first simulated by the computer flow field, and then modified to avoid dead zones before printing. Therefore, the 3D heating element does not have dead zones like traditional electric heaters, and the heating temperature is very uniform.

[0036] This 3D printed heating element is particularly suitable for high-temperature heating occasions, such as heating high-temperature gas or non-conductive liquid. The maximum heating temperature can reach 1300°C, which is a blank spot of traditional heaters.

[0037] The heating element further comprises two electrode plates 4 for applying power, and the electrode plates 4 further comprise welding electrodes for wiring.

[0038] It also includes a junction box, the connection terminals of which are connected to the welding electrodes on the electrode plate 4; the junction box also includes a cable inlet.

[0039] It also includes a ceramic insulating member, and a plurality of heating elements can be supported and installed in the pressure vessel or the channel through the ceramic insulating member to form an electric heater.

[0040] It also includes a heat dissipation area, which is located between the pressure vessel or channel and the junction box.

[0041] Embodiment 2:

[0042] On the basis of the above-mentioned embodiment 1, it also includes the following: when 3D printing, the heating outer surface of the 3D printed heating element can increase the roughness of the heating surface or increase the point-distributed heat dissipation points as needed, or the heating outer surface can be coated with a high emissivity coating as needed to increase the heat transfer coefficient between the fluid and the heating element 2.

[0043] Embodiment 3:

[0044] On the basis of the above-mentioned embodiment 1, it also includes the following: the surface heating power of the heating element 2 decreases from the inlet to the outlet of the pressure vessel or channel, and can be designed and printed into different power densities according to the flow direction of the fluid, and can be printed by different materials, or different thicknesses of the same material, etc. to achieve different power densities, truly realizing equal load design, which will greatly extend the service life of the equipment. The heating element 2 adopts variable power design technology, that is, high power density is used where the fluid temperature is low, and low power density is used where the fluid temperature is high; it also includes a temperature sensor, and the temperature sensor is installed on the heating element 2.

[0045] The heating element 2 is designed with variable power. Under the condition of the same output power, the volume of the electric heater of the utility model is 1 / 6 of the volume of the traditional electric heater. That is, for equipment of the same size, the power of the electric heater of the utility model is 6 times that of the traditional electric heater, which greatly reduces the volume.

[0046] The above description is only a description of the preferred embodiment of the utility model, and is not any limitation on the scope of the utility model. Any changes and modifications made by ordinary technicians in the field of the utility model based on the above disclosure shall fall within the scope of protection of the claims.

Claims

1. A 3D printed heating element, characterized in that: include: A plurality of arrays of micro units (1), the micro units (1) comprising: a plurality of arrays of heating elements (2); and a plurality of equipotential support members (3) arranged between each two adjacent heating elements (2); The heating element (2) is a honeycomb hole structure of several arrays, and a heating element of the honeycomb structure is formed by several arrays of micro units (1).

2. A 3D printed heating element as claimed in claim 1, characterized in that: The heating element (2) is made of high-temperature resistant metal or alloy material and is manufactured by 3D printing; the alloy material is a high-temperature resistant nickel-chromium alloy or an iron-chromium-aluminum alloy.

3. A 3D printed heating element as claimed in claim 1, characterized in that: The arrangement points of the equipotential support members (3) are a number of equipotential points formed by the current passing through each micro unit (1) to generate the same voltage drop.

4. A 3D printed heating element as claimed in claim 1, characterized in that: The heating element (2) forms an angle of 90 degrees with the flow direction of the fluid, so as to ensure that the heated gas can pass across the heating element (2).

5. A 3D printed heating element as claimed in claim 1, characterized in that: The heating outer surface of the heating element (2) further includes a high surface roughness, or point-distributed heat dissipation points, or a coating with a high emissivity, so as to increase the heat exchange coefficient between the fluid and the heating element (2).

6. A 3D printed heating element as claimed in claim 1, characterized in that: The surface heating power of the heating element (2) decreases from the inlet to the outlet of the fluid; the heating element (2) also includes a temperature sensor to prevent the heating element (2) from overheating.

7. A 3D printed heating element as claimed in claim 1, characterized in that: The heating element further comprises two electrode plates (4) for applying power, and the electrode plates (4) further comprise welding electrodes for wiring.

8. A 3D printed heating element as claimed in claim 7, characterized in that: It also comprises a junction box, the connection terminals of which are connected to the welding electrodes on the electrode plate (4); and the junction box also comprises a cable inlet.

9. A 3D printed heating element as claimed in claim 8, characterized in that: It also includes a ceramic insulating member, and a plurality of the heating elements can be supported and installed in the pressure vessel or channel through the ceramic insulating member.

10. A 3D printed heating element as claimed in claim 9, characterized in that: It also includes a heat dissipation area, which is located between the pressure container or channel and the junction box.

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