Substrate for a heater assembly and method of manufacture thereof
a technology of substrates and heaters, which is applied in the field of substrates for heater assemblies and their manufacture, can solve the problems of safety risks, inefficiency of conventional wire-based electric heating elements in heating gas, etc., and achieve the effect of boosting the resistivity of the thermally sprayed heater layer
Inactive Publication Date: 2011-05-26
THERMOCERAMIX
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Benefits of technology
The thermally sprayed gas heaters achieve efficient gas heating with reduced radiant heat loss, operate cooler, are more compact, and safer, while being less expensive to manufacture and maintain compared to wire heaters.
Problems solved by technology
The conventional wire-based electric heating elements are therefore not very efficient in heating gas, due to this radiant heat loss.
Furthermore, the intense radiant heat generated by the wire heating element can heat up surrounding structures to dangerous temperatures, which can pose a safety risk.
For example, in the case of a clothes dryer, the radiant heat from the heating element can heat components of the dryer that are accessible to users, which can result in burns.
Method used
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[0029]Resistive heating elements can be formed by a thermal spray process. Thermal spray is a versatile technology for depositing coatings of various materials, including metals and ceramics. It includes systems that use powder as feedstock (e.g., arc plasma, flame spray, and high velocity oxy-fuel (HVOF) systems), systems that use wire as feedstock (e.g., arc wire, HVOF wire, and flame spray systems), and systems using combinations of the same.
[0030]Arc plasma spraying is a method for depositing materials on various substrates. A DC electric arc creates an ionized gas (a plasma) that is used to spray molten powdered materials in a manner similar to spraying paint.
[0031]Arc wire spray systems function by melting the tips of two wires (e.g., zinc, copper, aluminum, or other metal) and transporting the resulting molten droplets by means of a carrier gas (e.g., compressed air) to the surface to be coated. The wire feedstock is melted by an electric arc generated by a potential differen...
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Abstract
A substrate for a heating assembly comprising a mixture of a mica material with an electrically insulating material, the substrate having a thermal coefficient of expansion that is higher than pure mica. A method of manufacturing the substrate is also disclosed.
Description
CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional application of U.S. patent application Ser. No. 12 / 070,713, filed Feb. 20, 2008, and entitled Gas Heating Apparatus and Methods. Through the '713 application, this application claims the benefit of U.S. Provisional Application No. 60 / 902,291, filed Feb. 20, 2007, entitled Gas Heating Apparatus, and the benefit of U.S. Provisional Application No. 60 / 993,262, filed Sep. 11, 2007 entitled Thermal Resistive Heater. Each of the foregoing applications is incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTION[0002]Various devices are known for heating a gas, such as air, and gas heating devices have been employed for numerous industrial and domestic applications, such as cooking and room heating, and in many appliances such as hair dryers and clothes dryers. In an electrical gas heater, an electric heating element is energized and gas is caused to flow past the element. The air may flow past...
Claims
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IPC IPC(8): H05B3/10C04B35/622C04B35/16B05D1/36B05D1/02B05D5/00
CPCC23C4/06Y10T29/49099F24C7/04F24D19/04F24H3/0405Y02T50/67H05B3/10F24C15/325F24H3/0411H05B1/00H05B2203/013C23C24/04Y10T156/10H05B3/16H05B2203/006D06F58/26Y02T50/60
Inventor ABBOTT, RICHARD C.
Owner THERMOCERAMIX