A flexible temperature-controlled explosion-proof heater

Abstract

The present invention provides a flexible temperature-controlled explosion-proof heater, which includes a flexible heating element, a heat-conducting layer, an external protective layer, a distributed temperature sensing module and a modular explosion-proof shell. The flexible heating element adopts a composite structure of a conductive polymer layer and an alloy conductive wire, combined with a silicone rubber matrix and a ceramic fiber reinforced material to ensure efficient heating and good flexibility. The heat-conducting layer adopts an alumina ceramic composite material to achieve uniform heat dissipation. The external protective layer is made of polytetrafluoroethylene material, which has corrosion resistance and high temperature tolerance. The distributed temperature sensing module realizes precise temperature control of the heating area through multi-point thermocouple sensors. The modular explosion-proof shell adopts titanium alloy and polymer composite materials, and is provided with a flameproof chamber, a heat pipe and heat dissipation fins. Through the optimized structural design, effective heat dissipation and explosion-proof functions are achieved.

Description

Technical Field

[0001] The invention relates to a flexible temperature-controlled explosion-proof heater. Background Art

[0002] In many industrial fields, such as petroleum, chemical, natural gas, and aerospace, equipment operates in high-temperature, flammable, and explosive environments, requiring the use of explosion-proof heating equipment. The heating elements of these devices are usually rigid and encapsulated in a hard explosion-proof casing to prevent electric sparks in hazardous environments. However, existing rigid heating equipment has the following drawbacks:

[0003] Traditional heaters typically use rigid metal tubes or heating wires as heating elements. These heaters can only adapt to flat or regularly shaped equipment surfaces. When faced with complex or irregular geometric shapes, heaters with such rigid structures are difficult to install and fix, and cannot achieve a tight fit, resulting in reduced heating efficiency. In addition, the rigid material structure is susceptible to mechanical shock or vibration during operation, increasing the risk of heater damage, especially in application scenarios that require frequent movement or adjustment.

[0004] With the miniaturization and diversification of equipment, flexible heaters have gradually become a technical problem that needs to be solved urgently. Existing rigid heaters cannot provide uniform heat distribution when facing objects with complex geometric structures or irregular surfaces, and are inconvenient to install and operate. Flexible heaters can better adapt to various surface shapes, fit different workpieces, and achieve higher heating efficiency.

[0005] Existing heaters typically rely on constant power output and lack precise temperature control, resulting in excessive energy consumption. In the case of uneven heating, overheating damage may be caused to the heated object. Especially in the explosion-proof field, fluctuations in different ambient temperatures will directly affect the working efficiency and safety of the heater. If the temperature cannot be precisely controlled, it may cause local overheating, increasing the risk of explosion or fire. In addition, due to the complex and changeable environmental conditions, existing technologies find it difficult to automatically adjust the heating power to adapt to temperature changes and cannot maintain stable temperature output under different working conditions.

[0006] Therefore, those skilled in the art are in urgent need of a flexible temperature-controlled explosion-proof heater in order to solve the application limitations and safety hazards caused by the rigidity of the heating elements and the uncontrollable temperature in the prior art. Summary of the Invention

[0007] The purpose of the present invention is to address the deficiencies of the above-mentioned prior art and to provide a flexible temperature-controlled explosion-proof heater. The present invention aims to solve the problem that conventional rigid heaters are difficult to achieve good adaptability and uniform heating effect in application environments with complex shapes or limited space. The present invention also solves the problem that conventional heaters have poor heat dissipation and insufficient explosion-proof performance in high-temperature environments. These objects of the present invention are achieved as follows:

[0008] A flexible temperature-controlled explosion-proof heater, a flexible temperature-controlled explosion-proof heater, comprising a flexible heating element, a heat-conducting layer, an outer protective layer, a distributed temperature sensing module and a modular explosion-proof housing, wherein the flexible heating element comprises a conductive polymer layer and an alloy conductive wire, the conductive polymer layer being arranged on the inner layer, the alloy conductive wire being arranged on the outer layer, the diameter of the alloy conductive wire being 0.2-0.4 mm, the conductive polymer layer being a polyethylene-aluminum oxide composite material, the thickness of the conductive polymer layer being 0.1-0.2 mm, a silicone rubber matrix being further arranged on the outside of the flexible heating element, the thickness of the silicone rubber matrix being 2-3 mm; the thickness of the heat-conducting layer being 1-2 mm, the heat-conducting layer being arranged on the outside of the high-temperature silicone rubber matrix, the heat-conducting layer being composed of The modular explosion-proof shell is composed of an alumina ceramic composite material with a thermal conductivity of 30W / m·K; the outer protective layer is arranged on the outside of the thermal conductive layer, the material of the outer protective layer is polytetrafluoroethylene material, and the thickness of the outer protective layer is 0.6-1mm; the distributed temperature sensing module includes a plurality of thermocouple sensors, and the thermocouple sensors are evenly arranged between the flexible heating element and the thermal conductive layer; the modular explosion-proof shell is covered on the outermost side of the heater, the material of the modular explosion-proof shell is titanium alloy and polymer composite material, the wall thickness of the modular explosion-proof shell is 20cm-30cm, the interior of the modular explosion-proof shell is provided with a flameproof chamber, and the surface of the modular explosion-proof shell is provided with heat dissipation fins with a height of 4-5mm and a spacing of 1-2mm.

[0009] The design of the flexible heating element adopts a combination of a conductive polymer layer and alloy conductive wire, ensuring efficient and uniform heating on surfaces with complex shapes. The conductive polymer layer is composed of a polyethylene-aluminum oxide composite material with a thickness of 0.1-0.2mm. This composite material has excellent conductivity and high temperature resistance, can effectively carry current and prevent performance degradation caused by high temperature; the alloy conductive wire is located in the outer layer, which increases the mechanical strength and conductivity of the heating element. This design ensures that the flexible heating element has sufficient flexibility and can provide efficient heat transfer.

[0010] A silicone rubber matrix is ​​set on the outside of the flexible heating element. As the main load-bearing material in high-temperature environments, silicone rubber has the advantages of high temperature resistance, chemical corrosion resistance, and aging resistance. In addition, a small amount of ceramic fiber reinforcement material is added to the matrix to further improve the mechanical strength and durability of the matrix, especially under high-frequency usage conditions, its toughness and life are enhanced. This material combination provides effective mechanical support and achieves an ideal balance between flexibility and rigidity.

[0011] To improve heat transfer efficiency, the present invention incorporates a heat-conducting layer, located outside the high-temperature silicone rubber substrate. This layer is composed of an alumina-ceramic composite material with a thermal conductivity of 30 W / m·K. The high thermal conductivity of alumina ceramic ensures that the heat generated by the heating element is rapidly transferred to the exterior of the device and evenly distributed across the heated surface, preventing localized overheating. This heat-conducting structure improves the heater's overall energy efficiency while reducing energy consumption.

[0012] The outer protective layer is made of polytetrafluoroethylene material with a thickness of 0.6-1mm. Polytetrafluoroethylene material has excellent corrosion resistance and high temperature resistance. It can provide effective protection for the heater in extreme working environments and extend its service life. At the same time, the smooth surface of the protective layer helps to reduce the accumulation of dust and other particulate matter, thereby reducing maintenance costs.

[0013] In order to achieve precise temperature control, the present invention designs multiple thermocouple sensors, which are evenly distributed between the flexible heating element and the heat-conducting layer. By monitoring the temperature distribution in real time, the heating power can be dynamically adjusted to ensure uniform and precise heating. This distributed design avoids the problem of uneven temperature control of traditional heaters and is particularly suitable for occasions that require fine temperature control.

[0014] Furthermore, a heat dissipation pipe is provided in the flameproof chamber of the modular explosion-proof housing. The length of the heat dissipation pipe is the height of the modular explosion-proof housing, and the outer diameter of the heat dissipation pipe is 22 cm-28 cm.

[0015] The outermost layer of the heater is a modular explosion-proof shell made of titanium alloy and polymer composite material with a wall thickness of 20-30cm. This design not only has extremely high mechanical strength and impact resistance, but also achieves effective dissipation of internal heat through the design of explosion-proof chamber and heat dissipation fins, preventing dangers caused by excessive temperature. The graphite colloid filled inside further improves the thermal insulation and heat dissipation performance, ensuring the safety of the equipment in high temperature and high pressure environments.

[0016] Furthermore, the heat dissipation fins are arranged on the side and front of the heater, the heat dissipation fins are made of aluminum alloy, and the heat dissipation pipes are made of aluminum nitride ceramics, which makes it easier to handle the waste heat generated by the equipment itself during the heating process.

[0017] Furthermore, the gap between the modular explosion-proof housing and the heat dissipation pipe is filled with graphite colloid.

[0018] Furthermore, the flexible heating element has a power of 1kW per square meter, an operating voltage of 220V, and a maximum current of 4.5A.

[0019] Furthermore, the volume resistivity of the polyethylene-aluminum oxide composite material of the conductive polymer layer is 10^-4 to 10^-6 Ω·m.

[0020] Furthermore, a small amount of ceramic fiber reinforcement material is mixed into the silicone rubber matrix of the flexible heating element, and the content of the reinforcement material is 0.5%-1%.

[0021] Furthermore, the surface of the alloy conductive wire of the flexible heating element is coated with an aluminum oxide coating with a thickness of 5-10 μm.

[0022] Furthermore, an anti-corrosion coating is provided between the conductive polymer layer and the silicone rubber matrix, and the material of the anti-corrosion coating is polyethylene terephthalate resin.

[0023] Beneficial effects: Through the design of flexible heating elements, the present invention can adapt to the heating needs of different shapes, especially in curved surfaces or small spaces, and can still maintain excellent heating effects, which overcomes the defect of traditional rigid heaters that cannot be flexibly fitted;

[0024] The temperature sensing module enables the heater to achieve precise temperature regulation to avoid overheating or underheating. The system combines thermocouple sensors and conductive polymer layers to form a real-time feedback and adjustment mechanism to ensure uniform and safe heating.

[0025] The modular explosion-proof housing is designed with multi-layer flameproof chambers and heat dissipation pipes, which can achieve both heat dissipation and explosion protection. The internal space of the heat dissipation pipe can absorb vibration and impact well. The gap between the heat dissipation pipe and the housing is also filled with graphite colloid, which ensures the fixed connection of the heat dissipation pipe while conducting heat. The combination of titanium alloy and polymer composite materials provides the equipment with extremely high impact resistance and chemical corrosion resistance, enabling it to operate stably for a long time in extreme environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic diagram of a flexible temperature-controlled explosion-proof heater from a top view;

[0027] Figure 2 It is a cross-sectional structural diagram of a flexible temperature-controlled explosion-proof heater;

[0028] In the figure: 1. Flexible heating element, 12. Alloy conductive wire, 13. Conductive polymer layer, 14. Silicone rubber matrix, 2. Thermal conductive layer, 3. External protective layer, 4. Distributed temperature sensing module, 5. Modular explosion-proof housing, 6. Graphite colloid, 7. Heat pipe, 8. Heat sink fins. DETAILED DESCRIPTION

[0029] In order to deepen the understanding of the present invention, the present invention will be further described in detail below with reference to embodiments and drawings. The embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0030] Please see Figure 1-2 A flexible temperature-controlled explosion-proof heater comprises a flexible heating element 1, a heat-conducting layer 2, an outer protective layer 3, a distributed temperature sensing module 4 and a modular explosion-proof housing 5. The flexible heating element 1 comprises a conductive polymer layer 13 and an alloy conductive wire 12. The conductive polymer layer 13 is arranged on the inner layer, and the alloy conductive wire 12 is arranged on the outer layer. The diameter of the alloy conductive wire 12 is 0.2-0.4 mm. The conductive polymer layer 13 is a polyethylene-aluminum oxide composite material. The thickness of the conductive polymer layer 13 is 0.1-0.2 mm. A silicone rubber matrix 14 is further provided on the outside of the flexible heating element 1. The thickness of the silicone rubber matrix 14 is 2-3 mm. The thickness of the heat-conducting layer 2 is 1-2 mm. The heat-conducting layer 2 is arranged on the outside of the high-temperature silicone rubber matrix 14. The heat-conducting layer 2 is made of conductive The flexible heating element 1 is composed of an alumina ceramic composite material with a thermal coefficient of 30W / m·K; the outer protective layer 3 is arranged on the outside of the heat-conducting layer 2, the material of the outer protective layer 3 is polytetrafluoroethylene material, and the thickness of the outer protective layer 3 is 0.6-1mm; the distributed temperature sensing module 4 includes a plurality of thermocouple sensors, and the thermocouple sensors are evenly arranged between the flexible heating element 1 and the heat-conducting layer 2; the modular explosion-proof shell 5 is covered on the outermost side of the heater, the material of the modular explosion-proof shell 5 is titanium alloy and polymer composite material, the wall thickness of the modular explosion-proof shell 5 is 20cm-30cm, and an explosion-proof chamber is provided inside the modular explosion-proof shell 5. The surface of the modular explosion-proof shell 5 is provided with heat dissipation fins 8 with a height of 4-5mm and a spacing of 1-2mm.

[0031] A heat pipe 7 is provided within the explosion-proof chamber of the modular explosion-proof housing 5. The length of the heat pipe 7 is equal to the height of the modular explosion-proof housing 5, and the outer diameter of the heat pipe 7 is 22 cm to 28 cm. Heat sink fins 8 are provided on the sides and front of the heater. The heat sink fins 8 are made of aluminum alloy, and the heat pipe 7 is made of aluminum nitride ceramic. The gap between the modular explosion-proof housing 5 and the heat pipe 7 is filled with graphite colloid 6. The flexible heating element 1 has a power of 1 kW per square meter, an operating voltage of 220 V, and a maximum current of 4.5 A. The volume resistivity of the polyethylene-alumina composite material of the conductive polymer layer 13 is 10^-4 to 10^-6 Ω·m; the silicone rubber matrix 14 of the flexible heating element 1 is doped with a trace amount of ceramic fiber reinforcement material, with the reinforcement material content being 0.5%-1%; the surface of the alloy conductive wire 12 of the flexible heating element 1 is coated with a layer of aluminum oxide coating with a thickness of 5-10μm; an anti-corrosion coating is provided between the conductive polymer layer 13 and the silicone rubber matrix 14, and the material of the anti-corrosion coating is polyethylene terephthalate resin.

[0032] For the purpose of greater clarity, the present invention is described in detail with reference to the following examples.

[0033] In a specific embodiment, the flexible heating element 1 is composed of an inner conductive polymer layer 13 and an outer alloy conductive wire 12; the conductive polymer layer 13 is made of a polyethylene-aluminum oxide composite material with a thickness of 0.15 mm, providing good electrical conductivity and thermal stability; the outer alloy conductive wire 12 has a diameter of 0.3 mm, ensuring that the heating element has good mechanical strength and uniform thermal conductivity; at the same time, the surface of the alloy conductive wire 12 is coated with an 8 μm thick aluminum oxide coating to improve oxidation resistance and extend service life; a 2.5 mm thick silicone rubber matrix 14 is provided on the outside of the heating element, and the silicone rubber matrix 14 is doped with 0.8% ceramic fiber reinforcement material to improve heat resistance and flexibility.

[0034] In a specific embodiment, a 1.5 mm thick heat-conducting layer 2 is provided on the outside of the heating element. The heat-conducting layer 2 is made of an alumina ceramic composite material with a thermal conductivity of 30 W / m·K, which can quickly and evenly conduct heat to the outside of the heater. The design of the heat-conducting layer 2 prevents local overheating and improves the overall heating efficiency. The outside of the heat-conducting layer 2 is covered with a 0.8 mm thick polytetrafluoroethylene outer protective layer 3. This material has excellent corrosion resistance and high temperature resistance, providing important protection for the heater in harsh chemical and high temperature environments, thereby extending the service life of the equipment. In order to achieve precise temperature control, in this embodiment, a plurality of thermocouple sensors are evenly arranged between the flexible heating element 1 and the heat-conducting layer 2. Each thermocouple sensor monitors the temperature of different areas of the heater in real time, and transmits the data to the control unit for dynamic adjustment to ensure the entire The temperature of the heating area is uniform and stable; the system is combined with a temperature control circuit to achieve precise control of the heating power; the outermost layer of the entire heater is a modular explosion-proof shell 5 with a wall thickness of 25 cm. It is made of titanium alloy and polymer composite materials and has extremely high mechanical strength and impact resistance; an explosion-proof chamber is provided inside the shell, and a heat dissipation pipe 7 with a length of the shell height and an outer diameter of 26 cm is installed in the chamber. The heat dissipation pipe 7 is made of aluminum nitride ceramic material to ensure good thermal conductivity and heat dissipation capabilities in high temperature environments; aluminum alloy heat dissipation fins 8 with a height of 4.5 mm and a spacing of 1.5 mm are set on the surface of the shell to further improve the heat dissipation efficiency; the gap between the shell and the heat dissipation pipe 7 is filled with graphite colloid 6, which has excellent thermal conductivity and high temperature resistance, ensuring rapid heat dissipation when working at high temperatures to prevent the risk of explosion caused by excessive temperature inside the shell.

[0035] The specific working principle is as follows: When the heater is working, the flexible heating element 1 is energized, the alloy conductive wire 12 converts electrical energy into thermal energy, the flexible polyethylene-alumina composite conductive layer ensures evenly distributed current transfer, and the silicone rubber matrix 14 provides mechanical support and flexibility for the heating element, allowing it to conform to heated surfaces of different shapes; the thermocouple sensor monitors the temperature in real time. When the sensor detects that the temperature exceeds the set value, the control system automatically adjusts the heating power to avoid damage or danger to the equipment due to excessive temperature.

[0036] The heat generated by the heating element is quickly transferred to the external protective layer 3 through the heat-conducting layer 2. The high thermal conductivity of the heat-conducting layer 2 makes the temperature distribution of the entire heater more uniform. At the same time, the external protective layer 3 provides chemical and high-temperature resistance while ensuring that the surface temperature of the heater does not exceed the safe value. The modular explosion-proof housing 5 quickly dissipates the heat generated during operation through the design of heat pipes 7 and heat dissipating fins 8, preventing the inside of the heater from being dangerous due to excessive temperature. The graphite colloid 6 in the explosion-proof chamber acts as a heat shield, effectively reducing the formation of local high-temperature areas inside, thereby further improving the explosion-proof performance.

[0037] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A flexible temperature-controlled explosion-proof heater, characterized in that: A flexible temperature-controlled explosion-proof heater, comprising a flexible heating element, a heat-conducting layer, an outer protective layer, a distributed temperature sensing module and a modular explosion-proof housing, wherein the flexible heating element comprises a conductive polymer layer and an alloy conductive wire, wherein the conductive polymer layer is arranged on the inner layer, and the alloy conductive wire is arranged on the outer layer, wherein the diameter of the alloy conductive wire is 0.2-0.4 mm, and the conductive polymer layer is a polyethylene-aluminum oxide composite material, and the thickness of the conductive polymer layer is 0.1-0.2 mm. A silicone rubber matrix is ​​further provided on the outer side of the flexible heating element, and the thickness of the silicone rubber matrix is ​​2-3 mm; the thickness of the heat-conducting layer is 1-2 mm, and the heat-conducting layer is arranged on the outer side of the high-temperature silicone rubber matrix, and the heat-conducting layer is composed of a heat-conducting coefficient of 30 W / m·K alumina ceramic composite material; the outer protective layer is arranged on the outside of the heat-conducting layer, the material of the outer protective layer is polytetrafluoroethylene material, and the thickness of the outer protective layer is 0.6-1mm; the distributed temperature sensing module includes multiple thermocouple sensors, and the thermocouple sensors are evenly arranged between the flexible heating element and the heat-conducting layer; the modular explosion-proof shell is covered on the outermost side of the heater, the material of the modular explosion-proof shell is titanium alloy and polymer composite material, the wall thickness of the modular explosion-proof shell is 20cm-30cm, the interior of the modular explosion-proof shell is provided with a flameproof chamber, and the surface of the modular explosion-proof shell is provided with heat dissipation fins with a height of 4-5mm and a spacing of 1-2mm.

2. A flexible temperature-controlled explosion-proof heater according to claim 1, characterized in that A heat dissipation pipe is provided in the flameproof chamber of the modular explosion-proof housing. The length of the heat dissipation pipe is the height of the modular explosion-proof housing, and the outer diameter of the heat dissipation pipe is 22cm-28cm.

3. A flexible temperature-controlled explosion-proof heater according to claim 2, characterized in that: The heat dissipation fins are arranged on the side and front of the heater. The material of the heat dissipation fins is aluminum alloy, and the material of the heat dissipation pipe is aluminum nitride ceramic.

4. A flexible temperature-controlled explosion-proof heater according to claim 3, characterized in that: The gap between the modular explosion-proof housing and the heat dissipation pipe is filled with graphite colloid.

5. The flexible temperature-controlled explosion-proof heater according to claim 1, characterized in that: The flexible heating element has a power of 1kW per square meter, an operating voltage of 220V and a maximum current of 4.5A.

6. The flexible temperature-controlled explosion-proof heater according to claim 1, characterized in that: The volume resistivity of the polyethylene-aluminum oxide composite material of the conductive polymer layer is 10^-4 to 10^-6 Ω·m.

7. The flexible temperature-controlled explosion-proof heater according to claim 1, characterized in that: A trace amount of ceramic fiber reinforcement material is mixed into the silicone rubber matrix of the flexible heating element, and the content of the reinforcement material is 0.5%-1%.

8. The flexible temperature-controlled explosion-proof heater according to claim 1, characterized in that: The surface of the alloy conductive wire of the flexible heating element is coated with an aluminum oxide coating with a thickness of 5-10 μm.

9. The flexible temperature-controlled explosion-proof heater according to claim 1, characterized in that: An anti-corrosion coating is provided between the conductive polymer layer and the silicone rubber matrix, and the material of the anti-corrosion coating is polyethylene terephthalate resin.

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