Heater

Abstract

A fin for dissipating heat from a heater element of a heater is disclosed, the fin including a foot attached to the heater element and a leg coupled to and extending away from the foot, the leg including a compressible portion between the foot and a distal end of the leg. The compressible portion may be coupled to the foot portion. The leg may include a dissipater extending in a first plane, the foot extending in a second plane different from the first plane, and the compressible portion includes a first portion extending in another plane different from the first plane.

Description

Technical Field

[0001] The present invention relates to fins for dissipating heat from a heater element of a heater, and a method of manufacturing a heater thereof. Background Art

[0002] Heaters for heating a fluid such as air or liquid in a device typically include a heater element for providing heat and a plurality of metal fins for dissipating the heat into the fluid. The fins may have a generally L-shaped configuration, the bottom of which is pressed onto the heater element and then attached thereto by soldering, for example using a placement system. In the case of using a placement system to attach a plurality of fins to a heater element in a single operation, it is desirable for the heater element to have a relatively flat surface to allow the placement system to apply pressure relatively evenly and equally, so that each fin is firmly attached to the heater element. In order to flatten the surface of the heater element before applying the fins, it is known that the heater element can undergo a smoothing process, such as sintering or grinding. This step increases the manufacturing cost and time. Summary of the Invention

[0003] According to a first aspect of the present invention, there is provided a fin for dissipating heat from a heater element of a heater, the fin including a foot attached to the heater element and a leg coupled to the foot and extending away from the foot, the leg including a compressible portion between the foot and the distal end of the leg.

[0004] The fin having a compressible portion can improve the reliability during the manufacturing process, which uses a placement system to attach the fin to the heater element. For example, during attachment of the foot to the heater element, depending on the flatness of the heater element, the compressible portion can be compressed by different amounts.

[0005] For example, for a given force applied to the compressible portion, in order to push the foot of the fin against the heater element during attachment (e.g., by soldering), if the heater element is slightly closer to the placement system, the compressible portion can be compressed more, or if the heater element is slightly farther from the placement system, the compressible portion can be compressed less, thus addressing variations in the flatness of the heater element.

[0006] Additionally or alternatively, the presence of the compressible portion may mean that for a given distance between the placement system and the heater element, regardless of whether the surface of the heater element is slightly higher or lower than expected relative to the placement system, the force generated between the foot and the heater element can generally be of a similar magnitude.

[0007] In addition, fins with compressible portions may affect the tolerance requirements of other aspects of the manufacturing process, resulting in cost reduction. For example, the heater element may not need to be so flat and may not require the manufacturing steps originally used to increase the flatness of the heater element. Additionally or alternatively, the placement system can be simpler. For example, the placement system may require fewer (or no) sensors to sense differences in the flatness of the heater element and / or differences in the forces applied to different fins at different heater element locations during attachment.

[0008] The compressible portion can also reduce the risk of unwanted deformation of the legs during manufacturing, such as when a force is applied to press the foot against the heater element. In such cases, any excess force can be absorbed by the compressible portion. Since the legs can provide most of the surface area on which heat dissipation to the surrounding environment can occur, this can result in the manufacture of an improved heater. Since it is part of the leg, the compressible portion itself can also dissipate some heat. However, compared to the compressible portion, the remaining extensions of the legs can provide a large surface area.

[0009] The leg and the compressible portion can be an integral piece with independent functions. In other words, the compressible portion can be the area of the leg configured to be compressed, while the remaining leg remains uncompressed.

[0010] The compressible portion can be coupled to the foot. The coupling of the compressible portion and the fin portion positions the compressible portion close to the portion of the fin attached to the heater element. In this way, the force used to push the foot against the heater element can be closer to the foot.

[0011] The leg can include a dissipating body extending in a first plane, where the foot extends in a second plane different from the first plane, and the compressible portion includes a first part extending in another plane different from the first plane. The dissipating body can provide the main surface area for heat dissipation. For this purpose, the dissipating body can be relatively longer than the compressible portion of the fin. Having a portion of the compressible body extend in a plane different from the plane of the dissipating body can provide a surface on which the compressive force can act. This can protect the dissipating body from bending or other forms of deformation that would reduce the surface area and thus the effectiveness of the heater. Additionally, at least a portion of the compressible portion can protrude away from the plane of the dissipating body. In some examples, the compressible portion can protrude from the plane of the dissipating body by a maximum distance of 0.1 mm to 1.6 mm. Thus, the maximum distance of this protrusion can determine the coverage area of the fin. By using the compressible portion, this can advantageously be less than the coverage area of fins in the prior art, thus allowing for an improved attachment of the fin to the heater substrate.

[0012] Optionally, the angle between the first plane and the second plane is greater than the angle between the second plane and another plane. In some examples, the angle between the second plane and the another plane is less than 10 degrees. In some examples, the second plane and the another plane are approximately parallel to each other such that the angle between them is approximately zero. By making the foot and the extension of the first part correspond, the force applied to the compression part can be substantially linear. This can make the manufacture of the heater simpler and easier. In some examples, the foot and the first part can be positioned parallel to and / or in a straight line with each other, and the second part separates them. The second part can extend from the first part in the same plane as the dissipating body such that the foot is disposed below the first part. This can reduce the coverage area of the fins, allowing more fins per unit area on the substrate, which can improve the efficiency of the end heater.

[0013] Optionally, the compressible part includes a profile having at least one curve. Having a curve in the profile can help distribute the compression force more evenly around the compressible part. This can help distribute the stress between the second part and the first part and / or the foot. In some examples, the first part and the foot joined by the second part form a flat C-shaped profile. Of course, other curved profiles of the second part can be envisioned, such as forming an S-shape. The dissipating body can be curved towards the first part. This can reduce the stress at the joint between the first part (which receives the force) and the leg that does not receive the direct application of the force.

[0014] Optionally, one or both of the first part and the foot include a profile having a substantially flat cross-section. The flat cross-section can allow for an improved joint between the placement system and the first part or between the foot and the heater element. That is, the flat cross-section can allow for more uniform contact between the placement system and the first part or between the foot and the heater element.

[0015] Optionally, the fins include a metallic material. The metallic material can include a degree of ductility, which makes it easier to form fins having a compressible part. To this end, the compressible part can be stamped into the fins before brazing. Additionally, the metallic material has high thermal conductivity, which is beneficial for heat dissipation.

[0016] According to a second aspect, there is provided a heater including the heater element and the fins as described above.

[0017] Optionally, the heater includes another fin, which includes a leg coupled to the foot and extending away from the foot, and a compressible portion between the foot and the distal end of the other leg. Multiple fins can provide a large surface area to act as a heat sink for heat dissipation, thereby improving the efficiency of the heater. The heater can of course have multiple such fins, and more fins increase the available surface area for heat dissipation. These fins can have different heights, for example, the corresponding dissipating bodies can have extending portions of different lengths. This can allow the entire cross-section of the heater to be shaped to fit various components, such as tubes and pipes. Each fin can have the same compressible portion, regardless of the height of the dispensing body.

[0018] In some examples, the heater can include multiple individual fins that are coupled together to form a heat dissipating element. Thus, the heat dissipating element can include multiple fins, each fin having a corresponding compressible portion. The first fin can be coupled to another fin at the corresponding distal end by the foot or the top. In this way, multiple fins can together form a heat dissipating element having a generally serrated, wavy or sinusoidal profile. In this example, each upper region or peak corresponds to the distal ends of two adjacent / adjacent fins (such as fins 1 and 2 in series), and each valley corresponds to the foot shared by adjacent / adjacent fins (such as fins 2 and 3 in series). This may be easier to manufacture than individual fins. The coupling between adjacent fins itself can have a compressible portion between the corresponding distal ends. This additional compressible portion can further protect the fins from warping, etc. when a force is applied. In this way, each fin can include a compressible portion as described above, and in some examples, each fin can have multiple compressible portions (i.e., additional compressible portions).

[0019] The compressible portion of the fin and the compressible portion of another fin can have the same profile. Having the same profile for the compressible portions of each of the multiple fins can allow for substantially equal compression of the fins during the formation of the heater, or allow for different degrees of compression due to variations in the flatness of the heater surface. The corresponding dissipating bodies can also be the same, but can include variations in other cases. For example, the dissipating bodies can vary in height such that the heater can be shaped for optimal heat dissipation and to fit pipes, etc.

[0020] The corresponding fins can be arranged on the heater element such that each compressible portion is oriented in the same direction. As a result, multiple fins can be uniformly compressed on the heater element. This can reduce the risk of the fins contacting adjacent fins when the compressible portions are compressed. Alternatively, the first fin and another fin can be arranged in a mirror configuration.

[0021] Optionally, the legs of the fin are less than 200 micrometers (μm) from the legs of another fin.

[0022] Arranging the fins close to each other allows for a greater number of fins, and thus the surface area for heat dissipation can be optimized. In the case where the heater has multiple fins, the multiple fins can be spaced equidistantly from each other, which can give a substantially uniform heating distribution across the heater.

[0023] According to a third aspect of the present invention, there is provided a hair care appliance including a heater as described above.

[0024] According to a fourth aspect of the present invention, there is provided a method of manufacturing a heater, the method comprising:

[0025] Providing a fin including a foot and a leg coupled to the foot and extending away from the foot, the leg including a compressible portion between the foot and the distal end of the leg;

[0026] Applying a force to the fin to urge the foot against the heater element, wherein the force is applied through the compressible portion of the fin; and

[0027] When the force is applied, attaching the foot and the heater element together.

[0028] As described above, applying a force to the fin during heater manufacturing to compress the compressible portion can improve the reliability of the manufacturing process. That is, by compressing the compressible element, the foot can be more easily pushed against the heater element. There can be particular improvements when using a placement system. For example, during attachment of the foot to the heater element, the compressible portion can be compressed by different amounts depending on the flatness of the heater element.

[0029] The heater element can include a ceramic material such as aluminum nitride, alumina, or silicon nitride or a combination thereof. The heater element can be a heat conducting element, or in some cases can encapsulate a heat conducting element therein. Thus, in use, the heater operates by heating the heater element, and the heater element transfers heat to the fins to dissipate into the surrounding environment. Therefore, the connection between the heater element and the foot (and the extended fins) is an important factor in providing an efficient heater. Therefore, the step of compressing the compressible portion can improve the connection, thereby enhancing the efficiency and effectiveness of the heater.

[0030] The surface for soldering the fin and the heater element can include placing the fin and the heater element in a furnace at a temperature between 550 °C and 900 °C.

[0031] Optionally, the force is applied through a placement system. Using a placement system can allow for better control of the compression force and / or the compression of the compressible fin. Additionally, the placement system can maintain the compression force during soldering, which can improve the bonding of the fin to the surface of the heater element. The placement system can be adapted to correspond to the shape of the compressible fin such that the placement system can provide a uniform compression force over a first portion.

[0032] Optionally, the method includes applying a force until the flange approaching the heater element contacts the heater element as the force applied to the fin increases. Then, the method includes holding the placement system in that position while attaching the foot and the heater element together. For example, the flange can be a protrusion extending from the body of the placement system. Thus, the protrusion can form a stop mechanism to prevent over-compression of the compressible portion of the fin.

[0033] Optionally, the method further includes arranging the placement system such that the dissipator extends into and / or through the cavity of the placement system. In this way, no force is applied to the upper region of the fin. For example, by applying a compressive force only on the compressible portion, the heater portion of the dissipator that dissipates most of the heat can be protected from any force that may cause deformation or other damage.

[0034] Optionally, the method further includes applying a brazing filler to the surface of the heater element, and wherein attaching the foot and the heater element together includes brazing. The brazing filler may melt during the brazing process and cause the filler and the surface of the heater element to react together, thereby attaching the foot of the fin to the surface of the heater element. In this way, the brazing filler can provide a medium for attaching the fin to the surface of the heater element. The brazing filler can also fill any space between the foot and the heater element. As described above, using a compressible portion in the fin can allow for better contact between the fin and the surface of the heater element, which may require less brazing filler to fill any gaps. This can save material costs in the manufacturing process and also reduce the chance of the brazing filler being sucked upward in the extending direction of the leg. In addition, the placement system contacts the fin on the compressible portion spaced apart from the heater element. In contrast, previous placement systems would contact the foot of the L-shaped fin closer to the heater element. Thus, compared with the previous manufacturing method, the compressible portion can allow the placement system to apply compression to the fin at a greater distance from the heater element. In this way, even if some brazing filler is sucked upward along the leg, the chance of the brazing filler reaching the placement system is reduced. Therefore, this reduces the chance of the positioning system being brazed to the heater incorrectly during the brazing process.

[0035] The brazing filler can be an alloy including silver, copper, and titanium. For example, the alloy is formed from an initial composition of 72% silver and 28% copper, with 1 - 5 wt% of titanium added. Titanium can increase the reactivity and react with the surface of the heater element to form a complex intermetallic phase. The brazing filler can at least partially adhere the fin to the surface of the heater element and then provide a fixed connection between them during brazing.

[0036] Optionally, the method further includes providing another fin including a foot and a leg coupled to and extending away from the foot, the leg including a compressible portion between the foot and a distal end of the leg; applying a force to the another fin to urge the foot against the heater element, wherein the force is applied through the compressible portion; and attaching the foot and the heater element together while applying the force.

[0037] Multiple fins allow the heater to effectively exchange heat with the external environment. The force can be applied simultaneously to the respective compressible portions of each of the fin and the another fin. For example, a placement system can be used to achieve compression simultaneously. Simultaneous compression of multiple fins can accelerate the manufacturing process. In these examples, the placement system can have one or more flanges to prevent over-compression of the fins. The flanges can be spaced around the placement system to provide multiple stop regions.

[0038] Optionally, the fin and the another fin are disposed on a first side of the heater element, and the method further includes disposing additional fins and additional another fins on a side of the heater element opposite the first side. The second fin can be the same as the fin described above. Having two (or more) fins on each side of the heater element can allow the heater element to have a rod-like form with fins on either side, thereby maximizing the surface area of the final heater. This can provide an effective heater.

[0039] Optionally, the method includes providing a plurality of first fins and another fin.

[0040] According to a fifth aspect, there is provided a placement system for the method. The placement system can include, for example, a clip or a clamp.

[0041] Other features and advantages of the present invention will become apparent from the following description of the preferred embodiments of the invention with reference to the accompanying drawings, which are given by way of example only. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1a is a schematic side view of a heater showing an example according to the present invention;

[0043] Figure 1b is a schematic perspective view of a heater showing Figure 1a ;

[0044] Figure 1c is a schematic view showing Figure 1a the components assembled;

[0045] Figure 2 is a flow chart showing a method of forming a heater according to an example of the present invention;

[0046] Figure 3 is a schematic view showing according to Figure 2Schematic diagram of how the degree of compression between two fins can vary when they are pushed against an uneven heater element, an example of the method;

[0047] Figure 4a Schematic diagram showing a heater having first and second pluralities of fins respectively attached to first and second sides of a heater element, and a placement system for performing the connection, an example according to the present invention;

[0048] Figure 4b Schematic diagram showing, an example according to the present invention, the removal of the placement system of Figure 4a the heater; and

[0049] Figure 5 Schematic diagram showing another example of a fin arrangement, an example according to the present invention.

[0050] In all the figures and the description, the same reference numerals refer to the same components. Detailed Description

[0051] Now referring to Figure 1a and 1b , there is shown a heater 50 according to an example. The heater 50 has fins 100 attached to a surface 152 of a heater element 150 so as to dissipate heat generated by the heater element 150 to the external environment. For this purpose, the fins 100 include a metal material having a high thermal conductivity. The fins 100 have a thickness of 0.1 mm to 0.3 mm.

[0052] The heater element 150 includes a ceramic material that encloses a metal heating member (not shown). The structure of the heater element is not relevant to the present invention and will not be described in detail herein.

[0053] The fins 100 are attached to the heater element 150 by feet 102. The feet 102 are shaped and arranged to contact the surface 152 of the heater element 150. To facilitate a firm attachment between the feet 102 and the surface 152, the profile of the feet 102 has a substantially flat portion 104. This flat portion 104 corresponds to at least a partially flat surface 152 of the heater element 150. In other words, a part of the feet 102 (i.e., the flat portion 104) and the surface 152 of the heater element 150 extend along parallel planes. In this example, the feet 102 have a width W of about 0.1 mm and a length L of about 0.1 mm (other dimensions can be contemplated). The feet 102 have a covering area that allows heat to be transferred from the heater element 150 to the fins 100.

[0054] Extending away from the foot 102, the fin 100 also has legs 106. The legs 106 provide a surface for dissipating heat from the heater element 150. To this end, the legs 106 have a dissipation body 108 that extends in a plane perpendicular to the plane in which the foot 102 extends. As a result, the dissipation body 108 is substantially perpendicular to the surface of the heater element 150 and has a relatively long extension to provide as large a surface area as possible within any available space.

[0055] There is a compressible portion 110 between the leg 106 and the foot 104. The compressible portion 110 couples the leg 106 to the foot 102. The compressible portion 110 has a first part 112 that extends away from the dissipation body 108 of the leg 106. As shown, in this example, the plane in which the first part 112 extends is substantially perpendicular to the plane in which the dissipation body 108 extends. In other words, at least a portion of the compressible portion 110 protrudes away from the dissipation body 108.

[0056] The first part 112 is spaced from and substantially parallel to at least the flat portion 104 of the foot 102. The first part 112 is also in line with the foot 102 because at least a portion of the first part 112 is directly above at least a portion of the foot 102.

[0057] To couple the first part 112 to the foot 110, the compressible portion 110 also includes a second part 114. The second part 114 curves away from the plane of the dissipation body 108 and the curved middle portion has a tangent that is substantially parallel to the dissipation body 108.

[0058] As Figure 1a shown, the first, second, and foot have a smooth and curved profile such that together they form a flattened C-shape. The compressible portion 110 can be formed by stamping the desired profile (in this case the described flattened C-shape) into a copper or aluminum plate that then forms the fin 100.

[0059] Figure 1c A method of attaching the foot 102 to the heater element 150 to assemble the heater 50 is schematically shown, Figure 2 as a flowchart.

[0060] The surface 152 of the heater element 150 is coated with a brazing filler 154. In this example, the brazing filler 154 is a silver alloy with an initial composition of 72% silver and 28% copper, with 1 - 5 wt% titanium added.

[0061] In a first step S200, a fin 100 of the above type, for example, is provided. The foot 102 of the fin 100 is located on a brazing filler 154 on the surface 152 of the heater element 150. The brazing filler 154 serves as an adhesive to help hold the foot 102 against the fin 100 on the surface 152 of the heater element 150 during this assembly.

[0062] In step S202, a force 170 is applied to the fin 100 by the placement system 172. The force 170 is applied in a direction towards the surface 152 of the heater element 150 to the compressible portion 110. A first portion 112 of the compressible portion 110 receives the force 170. As the first portion 112 projects away from the dissipation body 108, the force 170 is also applied away from the dissipation body 108. The force 170 is transmitted through the compressible portion 110 to the foot 102 to urge the foot 102 against the heater element 150. The force 170 compresses the compressible portion 110 by an amount such that the first portion 112 moves towards the foot 102. The compressible portion 110 is deformed by the applied force 170. More specifically, when the force is applied to the first portion 112, the C - shape of the compressible portion is compressed or flattened by an amount.

[0063] The placement system 172 includes an external structure shaped to push on the first portion 112 of the compressible portion 110. In this example, the placement system 172 includes a clamp. The shape of the placement system 172 corresponds to the shape of the fin 100. In this way, the placement system 172 is shaped such that when pushed against the fin 100 it does not apply pressure to the dissipation body 108.

[0064] During the pushing of the foot 102 against the heater element 150, the brazing filler 154 may shift slightly and be suctioned upwards around the foot 102. By applying the force 170 to the compressible portion 110 instead of directly to the foot, the placement system 172 is less likely to contact the brazing filler 154 and / or be contaminated by the brazing filler 154.

[0065] When the heater element 150 and the fin 100 are heated, the placement system 172 maintains the force 170 on the compressible portion 110. This heating is achieved by placing the heater element, the fin 100, and the placement system 172 (assembled as described) in a brazing furnace at approximately 900 °C. The high temperature causes the brazing filler 154 to react with the surface 152 of the heater element 150. In step S204, this reaction attaches the foot 102 of the fin 100 to the surface 152 of the heater element in a known manner. The foot 102 is attached along the flat portion 104. Once removed from the brazing furnace, the placement system 172 is removed. The heater 50 can then be placed in various devices, such as a hair care appliance.

[0066] Figure 3Shows the first fin 300a and the second fin 300b mounted on a heater element 350 having an uneven surface. The first and second fins 300a, b have substantially the same structure as the fin 100 described above. In fact, the heater element 350 may have an uneven surface 352, for example due to thickness variations, warping or surface undulations. In any case, for illustrative purposes, the potential unevenness is exaggerated in Figure 3 As shown, the surface 352 has a portion 352a that is in a different plane from another portion 352b: the portion 352a is lower in the figure than the other portion 352b.

[0067] Due to the unevenness of the surface 352, the feet 302a of the first fin 300a and the feet 302b of the second fin 300b are in different planes. A placement system 372 applies a force 370 to the heater element 350. Accordingly, the respective compressible portions 310a, b of each fin 300a, b are compressed. Due to the unevenness of the surface 352, the compressible portions 310a, b are compressed by different amounts. As shown, the second fin 300b is compressed more than the first fin 300a. The resulting deformation is concentrated in the compressible portions 310a, b. That is, the distance between the first portion 312b of the second fin 300b and the corresponding foot 302b is less than the distance between the first portion 312a of the first fin 300a and the corresponding foot 302a. At the same time, the lengths of the dissipating bodies 308a, b of the fins remain unaffected. In this way, the same amount of compressive force 370 applied to the first and second fins 300a, b by the placement system 372 compresses the compressible portions 310a, b differently to compensate for the uneven surface 352.

[0068] As Figure 3 shown, the placement system 372 includes a clamp 371 for supporting the fin 300 and applying pressure thereto. More specifically, the clamp 371 has a recess or cavity 374 for receiving the dissipating body 308, and a protrusion or pressure area 376 that contacts and applies pressure to the first portion 312 of the fin. In this example, the size and configuration of the cavity 374 are designed such that when a force is applied to the first portion 312, a downward pressure is not applied to the dissipating body 308 of the inserted fin 300. In other words, the pressure area 376 of the placement system 372 is slotted between adjacent distribution bodies 308 and applies the force 370 directly to the compressible portion 310.

[0069] Figure 4a Shows an example of a heater 54 having a first plurality of fins 480. The individual fins 400 have been described above, and thus will not be described here for the sake of brevity. The first plurality of fins 480 are located on the surface 452 of a bar heater element 450.

[0070] The plurality of fins 480 are each equally spaced along the length of the surface 452. In this way, the plurality of fins 480 are positioned along the surface 452 of the bar heater element 450. When taking values between two distribution bodies 408 of adjacent fins, the distance between adjacent fins is approximately 0.8 mm to 1.6 mm. Although not shown, each individual fin 400 also extends to substantially cover the entire width of the surface 452 of the heater element 54. Other examples may have additional pluralities of fins spaced apart after those shown. Thus, the plurality of fins 480 cover most of the area of the surface 452 of the heater element 450.

[0071] The heater element 450 has a second surface 453 opposite the upper surface 452. The second surface 453 has a second plurality of fins 482. The second plurality of fins 482 are a mirror image of the first plurality of fins 480 such that the heater 54 has a line of symmetry along the central longitudinal axis of the heater element 450.

[0072] There are first and second placement systems 472, 473 similar to those described above. These placement systems 472, 473 apply forces that clamp each of the first and second pluralities of fins 480, 482 to the surface 452 of the heater element 450. Each of the placement systems 472, 473 has a plurality of cavities 474, 475 corresponding to the dissipation bodies 408 of each individual fin 400. In this example, the size and configuration of the cavities 474, 475 are designed such that no pressure is applied to any of the dissipation bodies 408 of the first and second pluralities of fins 480, 482 when the force is applied.

[0073] Each of the placement systems 472, 473 also has flanges 478, 479. The flanges 478, 479 are used to prevent the placement systems 472, 473 from over-compressing the first and second pluralities of fins 480, 482. To this end, the flanges 478, 479 project outwardly from the remainder of the placement systems 472, 473. That is, the flanges 478, 479 extend further from the clamps 471 of the placement systems 472, 473 than the pressure regions 476. The pressure regions 476 are the same as the pressure regions described above and are used to contact the compressible portions 410 of each fin 400. In this way, when a force is applied to the heater element 450, the placement systems 472, 473 are pushed towards the heater element 450 until the corresponding flanges 478, 479 contact the surfaces 452, 453. This contact causes the placement systems 472, 473 to stop further pushing towards the heater element 450.

[0074] As shown, the surface 452 is uneven as it includes protrusions 484 and depressions 486 (shown in exaggerated form for purposes of explanation). The fins 400 positioned on the protrusions 484 or depressions 486 are referenced Figure 3is compressed in the same manner described, because the compressible portion 410 of the fin 400 absorbs any height difference of the surface 452. In Figure 4a the example shown, all of the compressible portions 410 of the plurality of fins 480, 482 are compressed, but are compressed to different amounts at the protrusions 484 and depressions 486. Once the placement systems 472, 473 are removed after brazing, as Figure 4b shown, each fin 400 remains compressed. Thus, even when the placement systems 472, 473 are removed, the corresponding fins 400 at the protrusions 484 and depressions 486 remain in a compressed state different from the other fins.

[0075] Now turning to Figure 5 , an alternative example is shown, in which a plurality of fins 500a-d are joined together to form a single heat dissipating element 590. The heat dissipating element 590 in this example has a generally sinusoidal profile, with each fin 500 forming a peak and a valley. The heat dissipating element 590 extends along the length of the heater element 550 and is attached to the heater element 550 at a plurality of points.

[0076] Considering a single fin 500a-d, a single fin 500b has a foot 502 located on the surface 552 of the heater element 550. In this example, the foot 502 corresponds to the valley of the sinusoidal profile.

[0077] A leg 506 extends away from the foot 502. The leg 506 extends upward to the top 509 at the distal end of the fin 500b. The top 509 corresponds to the peak of the sinusoidal profile. The leg 506 is coupled to the top 509 on one side, and the leg 506 of another fin 500c extends from the opposite side of the same top 509. The leg 506 of the other fin 500c extends downward to another foot 502. This foot 502 is also on the surface 552 of the heater element 550. Thus, the fins 500b and 500c are adjacent fins 500b,c. These adjacent fins 500b,c are mirror images of each other.

[0078] The plurality of fins 500a-d repeat this pattern to form a continuous profile of the heat dissipating element 509. Thus, the fins 500a-d have a common foot 502 and a common top 509 with adjacent fins. In this way, each fin 500a-d is connected to its adjacent fin. In this example, the top 509 of each fin 500a-d is also the same height along the length of the heat dissipating element 590. The foot 502 and the top 509 have a curved profile, which gives the heat dissipating element 590 a substantially sinusoidal appearance.

[0079] In this example, each fin 500a-d has two compressible portions 510 that project from the leg 506. The two compressible portions are thus located between the foot 502 and the top 509 of each fin 500a-d. In this example, the two compressible portions 510 project from the leg 506 in opposite directions from each other. The shape of the compressible portion 510 is similar to those described above, having a protrusion away from the body 508 of the leg 506. In this example, each compressible portion 510 has a curve 511 that returns to the leg 506.

[0080] To attach the fins 500a-d to the heater element 550, the placement system 572 applies a force 570 to the top of each fin 500a-d. In this example, the placement system 572 has a substantially flat surface that contacts each top 509. The force 570 from the placement system 572 is transmitted along the leg 506 to the corresponding compressible portion 510. This means that the compression of the fin 500a-d is restricted within the compressible portion 510 of that fin 500a-d.

[0081] When the force 570 is applied, the compressible portion 510 compresses, which changes the total length of the leg 506. The compression is within the compressible portion 510 such that the body 508 of the leg 506 does not compress or bend. This change in length absorbs any unevenness in the surface 552 of the heater element 550, because the compressible portion 510 will compress different amounts based on the flatness of the surface 552 of the heater element 550.

[0082] As referenced above Figure 2 described, when the fins 500a-d are placed into a brazing furnace, the placement system 572 remains clamped onto the fins 500a-d. Although not shown, prior to brazing, a brazing filler is applied to the surface 552 of the heater element 550. Thus, each foot 502 is attached to the heater element 550 through the brazing process. Once brazed, the placement system 572 can be removed from the final heater. Similar to Figure 4b that, the heater element 550 can have another heat dissipating element (not shown) on the side opposite the shown heat dissipating element 590 such that the heater element 550 is located between the two heat dissipating elements.

[0083] The above embodiments should be understood as illustrative examples of the present invention. Further embodiments of the present invention are envisioned. For example, although illustrated as being directly adjacent to the foot, it is envisioned that the compressible portion can be spaced apart from the foot. In other words, the leg can have two portions on either side of the compressible portion, with one portion being coupled to the foot. For example, this can give the fin a T-shaped profile.

[0084] Although shown as substantially flat, the dissipating body of the fin's leg can have some slight curvature or undulation (to provide additional surface area), for which the extended plane should be considered as the average extending direction.

[0085] Although the compressible portion and the foot are shown throughout as having a C-shaped profile, it should be understood that the profile can include further compressible shapes, such as an S-shaped or Z-shaped profile.

[0086] It is contemplated that, depending on the intended use of the heater, the dissipating body of the heater can have different extending lengths. For example, the dissipating body can have a shorter extending length towards the end of the bar heater element. This can result in a circular cross-section of the heater, for example, it can be fitted into a tube. Although described as being substantially the same, there can also be some differences in the fin structure in addition to just the distributed body length. For example, the fins can be arranged such that the compressible portion projects in a direction different from that shown and / or adjacent fins. Further, although multiple fins are described as being mirror images (such that they face the same direction in the image), in other examples, the first and second multiple fins can be rotated versions of each other (so they face opposite directions). Additionally, some minor form variations can occur, for example, during the manufacturing process of the fins.

[0087] It should be understood that any feature described with respect to any one embodiment can be used alone, or in combination with other features described, and can also be used in combination with one or more features of any other embodiment, or with any combination of any other embodiments. Additionally, equivalents and modifications not described above can also be employed without departing from the scope of the invention as defined by the appended claims.

Claims

1. A fin for dissipating heat from a heater element of a heater, the fin including a foot attached to the heater element and a leg coupled to the foot and extending away from the foot, the leg including a compressible portion between the foot and a distal end of the leg.

2. The fin according to claim 1, wherein, The compressible portion is coupled to the foot.

3. The fin according to claim 2, wherein, The leg includes a dissipating body extending in a first plane, the foot extends in a second plane different from the first plane, and the compressible portion includes a first portion extending in another plane different from the first plane.

4. The fin according to claim 3, wherein, An angle between the first plane and the second plane is greater than an angle between the second plane and the another plane.

5. The fin according to claim 4, wherein, The compressible portion includes a profile having at least one curve.

6. The fin according to any one of claims 3 to 5, wherein One or both of the first portion and the foot includes a profile having a substantially flat cross-section.

7. The fin according to any one of the preceding claims, wherein, The fin includes a metallic material.

8. A heater, including a heater element and a fin according to any one of claims 1 to 7.

9. The heater according to claim 8, wherein, The heater includes another fin, the another fin including a leg coupled to the foot and extending away from the foot, and a compressible portion between the foot and a distal end of the additional leg.

10. The heater according to claim 8 or 9, wherein, The compressible portion of the fin and the compressible portion of the another fin have the same profile.

11. The heater according to any one of claims 8 to 10, wherein, The leg of the fin is less than 200 micrometers away from the leg of the another fin.

12. The heater according to any one of claims 8 to 11, wherein, The first fin is coupled to the another fin at respective distal ends.

13. A hair care appliance, including a heater according to any one of claims 8 to 12.

14. A method of manufacturing a heater, the method including: providing a fin including a foot and a leg coupled to the foot and extending away from the foot, the leg including a compressible portion between the foot and a distal end of the leg; applying a force to the fin to urge the foot against the heater element, wherein the force is applied via the compressible portion of the fin and causes at least some compression of the compressible portion; and and attaching the foot and the heater element together while the force is applied.

15. The method according to claim 14, wherein, The force is applied by a placement system.

16. The method according to claim 15, wherein, The placement system includes a flange that approaches the heater element as the force applied to the fin is increased, the method including increasing the force until the flange contacts the heater element and then holding the placement system in that position while attaching the foot and the heater element together.

17. The method according to claim 15 or 16, further including arranging the placement system such that the dissipating body extends into and / or through a cavity of the placement system.

18. The method according to any one of claims 14 to 17, further comprising applying a brazing filler to the surface of the heater element, and wherein, Attaching the foot and the heater element together includes soldering.

19. The method according to any one of claims 14 to 18, further including: providing another fin including a foot and a leg coupled to the foot and extending away from the foot, the leg including a compressible portion between the foot and a distal end of the leg; applying a force to the another fin to urge its foot against the heater element, wherein the force is applied via the compressible portion of the fin and causes at least some compression of the compressible portion; and attaching the foot and the heater element together while the force is applied.

20. The method according to claim 19, wherein, The force is applied simultaneously to respective compressible portions of each of the fin and the another fin.

21. The method according to claim 19 or 20, wherein The fin and another fin are disposed on a first side of the heater element, and the method further includes disposing additional fins and additional another fins on a side of the heater element opposite the first side.

22. The method according to any one of claims 19 to 21, wherein The method includes providing a plurality of first fins and another fin.

23. A placement system for use in the method according to any one of claims 16 to 22.

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