Expandable heater

Abstract

An electrical heating element system for heating a pipe is disclosed having a resistive heating element configured to be connected to a power source and an approximately rectangular substrate having a length. The substrate includes a first row of slots transverse to the length, a second row of slots transverse to the length and transversely aligned with the first row of slots, a third row of slots transverse to the length and alternately positioned along the length relative to the slots in the first and second rows, and a first row of fastener ends and a second row of fastener ends defined by the first row of slots and the second row of slots, respectively. Each of the first row of fastener ends and the second row of fastener ends is configured to secure the substrate to the conduit. The length of the base plate is adjustable so as to be mounted on the pipeline.

Description

[0001] Cross-reference to related applications This application claims priority to U.S. non-provisional application No. 18 / 890,596, filed September 19, 2024, and U.S. provisional application No. 63 / 586,845, filed September 29, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure generally relates to heating elements, and more particularly to electric heating elements and electric heating element systems for heating, for example, pipes. Background Technology

[0003] Electric heating elements convert electrical energy into heat energy. A heating element is an electric heating device that has a resistance wire used to release heat when energized. Known heating elements for heating pipes are spirally wound around the pipe from one end to the other to provide heat to the pipe in the area where the heating element is installed. However, known heating elements are difficult to install on pipes and pipe systems, cannot be easily installed on, above, or around obstructions, and cannot uniformly heat the entire surface area of ​​the pipe. Furthermore, the length of a spirally wound heating element system is difficult to estimate because the user must consider the pipe diameter and the number of turns per unit length of the heating element required to achieve the desired heat applied to a given length of pipe. Similarly, removing known heating elements from pipes or pipe systems is challenging and laborious because the user must unwrap the heating element one turn at a time from the pipe, including around obstructions.

[0004] Therefore, there is a need to improve heating element systems to facilitate easy installation, removal, heat distribution, and estimation of the required size and length for a given application. Summary of the Invention

[0005] This document discloses various embodiments of an electric heating element system. In one embodiment, an electric heating element system for heating a pipe includes: a resistance heating element including a first electrical conductor and a second electrical conductor extending from respective opposite ends of the heating element to be connected to a power source; and a substrate having a length. The substrate includes: (a) a first row of spaced-apart slots transverse to the length; (b) a second row of spaced-apart slots transverse to the length and laterally aligned with the first row of spaced-apart slots; and (c) a third row of spaced-apart slots transverse to the length and alternately positioned with the first row of spaced-apart slots and the second row of spaced-apart slots. The first row of slots defines first row of spaced-apart fastener ends, and the second row of slots defines a second row of spaced-apart fastener ends opposite to the first row of spaced-apart fastener ends. Each row of the first row of spaced-apart fastener ends and the second row of spaced-apart fastener ends is configured to laterally wrap around the outer diameter of the pipe and includes a fastener portion for detachably connecting the respective opposite fastener ends to each other to secure the substrate to the pipe. A heating element is attached to a substrate and meanders serpentinely from a first end to a second end and from a second end to a first end of the substrate between a first row of spaced-apart slots, a second row of spaced-apart slots, and a third row of spaced-apart slots. A first electrical conductor and a second electrical conductor are located near the first end of the substrate. When the substrate is hinged and / or extended along its length, the first row of slots, the second row of slots, and the third row of slots define a diamond-shaped region.

[0006] The resistance heating element may include a self-regulating heating element. The substrate may include a heat-resistant fabric or cloth, film, mesh, or nonwoven fabric. The fabric, cloth, or film may include polytetrafluoroethylene (PTFE) coated glass fiber or PTFE film. The substrate may have a substantially rectangular planar shape.

[0007] The first row of spaced-apart fastener ends can be configured to overlap with the second row of spaced-apart fastener ends when wrapped around the conduit. The substrate may have a first unextended length and may extend to a second extended length. The maximum extended length may be a function of the slot length. In some embodiments, the second extended length of the substrate may be up to 80% longer than the first unextended length. In other embodiments, the second extended length of the substrate is at least 80% longer than the first unextended length. The extended length of the substrate can vary to any desired amount, up to a predetermined maximum. The first row of spaced-apart slots may extend along the length from a first outer edge of the substrate toward a longitudinal centerline bisecting the substrate. The second row of spaced-apart slots may extend along the length from a second outer edge of the substrate toward a longitudinal centerline bisecting the substrate. A third row of spaced-apart slots may extend from the centerline bisecting the substrate transversely along the length toward the first outer edge of the substrate and toward the second outer edge of the substrate.

[0008] Each fastener portion may include a snap-fit ​​engagement or snap-fit ​​reception. Alternative options include hooks, hook straps, or bandage clips made of metal or high-temperature polymers such as PEEK or PTFE. The heating element may be attached to the substrate via stitching.

[0009] In another embodiment, the electric heating element system for heating a pipe includes a resistance heating element for connection to a power source and a polytetrafluoroethylene (PTFE) fiberglass substrate having a length. The substrate includes: (a) a first row of parallel slots transverse to the length; (b) a second row of parallel slots transverse to the length, wherein each slot in the second row is parallel to and laterally aligned with the slots in the first row; (c) a third row of parallel slots transverse to the length and alternately positioned relative to the slots in the first and second rows; and (d) a first row of fastener ends along the length and a second row of fastener ends opposite to the first row of fastener ends along the length, wherein the first row of fastener ends and the second row of fastener ends are respectively defined by the first row of slots and the second row of slots, and wherein each of the first row of fastener ends and the second row of fastener ends is configured to secure the substrate to the pipe. The heating element is attached to the substrate in a serpentine pattern from a first end to a second end and from a second end to a first end around each slot in the first, second, and third rows. The length of the substrate is adjustable.

[0010] In various embodiments, the length of the substrate can be adjusted from the unextended length to the fully extended length. In various embodiments, the substrate can extend to any length between the unextended length and the fully extended length. In various embodiments, the maximum extension length of the substrate can be a function of the slot length.

[0011] The serpentine pattern of the heating element can be repeated mirror-image along the length of the substrate with respect to the longitudinal centerline of the substrate. The substrate can have a first unextended length and can be adjusted up to a second extended length. The substrate can be adjusted to any length from the first unextended length to the second extended length. The maximum extended length can be a function of the slot length. In various embodiments, the second extended length of the substrate can be up to 80% longer than the first unextended length. A first row of parallel slots can extend along the length from a first outer edge of the substrate toward the longitudinal centerline of the substrate. A second row of parallel slots can extend along the length from a second outer edge of the substrate opposite to the first outer edge toward the centerline. A third row of parallel slots can extend transversely to both the first and second outer edges of the substrate with lengths extending from the centerline toward the first and second outer edges.

[0012] In another embodiment, the electric heating element system for heating a pipe includes a resistance heating element configured to be connected to a power source and a generally rectangular substrate having a length. The substrate includes: (a) a first row of slots transverse to the length; (b) a second row of slots transverse to the length and transversely aligned with the first row of slots; (c) a third row of slots transverse to the length and alternately positioned along the length relative to the slots in the first and second rows; and (d) a first row of fastener ends and a second row of fastener ends defined by the first and second rows of slots, respectively. Each of the first and second rows of fastener ends is configured to secure the substrate to the pipe. The heating element is attached to the substrate and meanders serpentinely from a first end to a second end of the substrate and from a second end to a first end of the substrate around the first, second, and third rows of slots. The substrate can be variably adjusted to any desired length from the unextended length to the extended length.

[0013] Various embodiments of this disclosure may include friction-inducing materials and / or mechanisms to minimize or prevent movement of the heating element system after it has been mounted onto a pipe to be heated. Such friction-inducing materials and / or mechanisms include silicone rubber, adhesives, and / or tapes applied to one or more surfaces of a substrate of the heating element system. In various embodiments, the friction-inducing mechanism may include a "friction block," for example, a piece of silicone rubber secured to the pipe-facing surface of the substrate via fasteners. Attached Figure Description

[0014] Figure 1 This is a perspective view of an embodiment of the electric heating element system disclosed herein.

[0015] Figure 2 yes Figure 1 A top view of the electric heating element system.

[0016] Figure 3 This is a top view of several electric heating element systems disclosed in this publication at a representative manufacturing stage.

[0017] Figure 4 This is a top view of the multiple electric heating element systems disclosed in this publication at another representative manufacturing stage.

[0018] Figure 5 This is a partial top view of the electric heating element system disclosed in this publication at another representative manufacturing stage.

[0019] Figure 6 This is a top view of the electric heating element system disclosed herein at another representative manufacturing stage.

[0020] Figure 7 This is a partial perspective view of an embodiment of the heating element disclosed herein.

[0021] Figures 8-12 This is a partial detailed plan view of the electric heating element system disclosed herein at various representative manufacturing stages.

[0022] Figure 13 This is a partial detailed plan view of another embodiment of the electric heating element system disclosed herein, taken at a representative manufacturing stage.

[0023] Figure 14 yes Figure 13 A partial perspective view of the electric heating element system at another representative manufacturing stage.

[0024] Figure 15 This is a partial top view of the electric heating element system disclosed herein in a partially hinged state before it is installed onto the pipe.

[0025] Figures 16-17 This is a perspective view of an electric heating element system installed on a pipe, as disclosed herein.

[0026] Figures 18-21 yes Figures 16-17 A perspective view showing partial details of the electric heating element system.

[0027] Figure 22 This is a partial perspective view of an electric heating element system of the present disclosure, which is mounted on a pipe and above and around an obstacle associated with the pipe.

[0028] Figure 23 This is a partial perspective view of the electric heating element system disclosed herein, which is mounted on a pipe together with an insulating layer.

[0029] Figure 24 This is a screenshot of an electric heating element system installed on a pipe and in use, as disclosed in this publication.

[0030] Figure 25 This is a perspective view of another embodiment of the electric heating element system disclosed herein.

[0031] Figure 26 yes Figure 25 A top view of the electric heating element system.

[0032] Figure 27 yes Figure 25 A top view of the electric heating element system at a representative manufacturing stage.

[0033] Figure 28 This is a perspective view of another embodiment of the electric heating element system disclosed herein.

[0034] Figure 29 yes Figure 28 A top view of the electric heating element system.

[0035] Figure 30 yes Figure 28 A top view of the electric heating element system at a representative manufacturing stage.

[0036] Figure 31 This is a perspective view of another embodiment of the electric heating element system disclosed herein.

[0037] Figure 32 yes Figure 31 A top view of the electric heating element system.

[0038] Figure 33 yes Figure 31 A top view of the electric heating element system at a representative manufacturing stage.

[0039] Figure 34 This is a perspective view of another embodiment of the electric heating element system disclosed herein.

[0040] Figure 35 yes Figure 34 A top view of the electric heating element system.

[0041] Figure 36 yes Figure 34 A top view of the electric heating element system at a representative manufacturing stage.

[0042] Figure 37A This is a perspective view of another embodiment of the electric heating element system disclosed herein.

[0043] Figure 37B yes Figure 37A Another perspective view of an embodiment of an electric heating element system.

[0044] Figure 38 yes Figure 37A A detailed cross-sectional view of a portion of the electric heating element system.

[0045] Figure 39 This is a list of at least some types of electric heating elements suitable for adjustment in accordance with the teachings of this disclosure.

[0046] Figure 40 This is an empirical data graph of an exemplary electric heating element system of the present disclosure, reflecting a simplified method for predicting the maximum extension length of the electric heating element system as the pipe diameter varies. Detailed Implementation

[0047] Although the accompanying drawings and this disclosure depict one or more embodiments of an electric heating element system, those skilled in the art will appreciate that the teachings of this disclosure are not limited to these embodiments. It should be understood that any feature of the embodiments discussed with reference to the accompanying drawings may be combined with or substituted for features discussed in conjunction with other embodiments of this disclosure.

[0048] This document discloses various embodiments of an electric heating element system for heating pipes. The electric heating element system of this disclosure can be easily and readily installed on pipes located, for example, inside or outside commercial / industrial buildings. Such pipes may include bends or obstructions, such as single beams, hangers, T-joints, and pipe flanges, on which the heating element system of this disclosure can be easily installed. More specifically, the various embodiments of the heating element system disclosed herein can be installed on a section of pipe without having to spirally wrap the heating element around the pipe and without having to calculate the spiral length of the wound heating element to heat the desired length of pipe. Instead, the various embodiments of the heating element system of this disclosure can be unfolded, or if already unfolded, can simply be placed longitudinally on the pipe and then circumferentially wrapped around the pipe and fastened or secured to itself or to anchors located at various points along the pipe to surround the desired pipe circumference and length with a sufficient number of heating elements per foot of a given wattage, thereby providing the required heat to the outer surface area of ​​the pipe.

[0049] The installation length of the electric heating element system of this disclosure on a given pipe can be customized by the user during installation due to its characteristic of enabling the heating element system to extend and contract linearly. In other words, the length of the electric heating element system of this disclosure can be varied to any desired amount. For example, for extension and / or installation on a section of pipe, various embodiments of the heating element system of this disclosure enable the heating element system to extend linearly, thereby linearly extending and / or extending to a length up to 80% or more longer than its pre-extended length.

[0050] Over longer pipe lengths, multiple heating element system units of this disclosure can be connected in series on the pipe to be heated. This allows the user to order multiple heating element system units to cover the required pipe length while rounding down to the nearest multiple of the pre-extended heating element system length.

[0051] In addition to significantly improving the ease with which users can estimate the length of heating elements with a given wattage per foot required to heat a given length of pipe and the ease with which the heating element system can be installed on the pipe, various embodiments of the heating element system disclosed herein can also significantly improve heat distribution along the pipe surface and its surroundings to minimize and / or eliminate unacceptably cold or cooler places, portions, or areas on the pipe. To this end, various embodiments of the heating element system disclosed herein may include heating elements arranged in a serpentine manner on a two-dimensional heat-resistant substrate. The two-dimensional substrate may be flexible to wrap around the circumference of the pipe. After extending the heating element system longitudinally along the pipe to the desired extension length and then wrapping the heating element system circumferentially around the pipe, the serpentine arrangement of the heating elements on the substrate is configured to meander along the length of the pipe, thereby covering the outer surface of the pipe with a three-dimensional serpentine pattern along the length of the pipe, which defines three-dimensional quadrilateral and / or rhomboid regions to be indirectly heated. Users can customize the size of these three-dimensional quadrilateral and / or rhomboid regions by adjusting the extent to which the heating element system extends from its original unextended length, and thus customize the amount of pipe surface area directly exposed to heat from the heating element. In other words, the greater the linear extension of the heating element system along the pipe, the larger the area defined by the three-dimensional quadrilateral and / or rhomboid regions, and vice versa. In some embodiments, the three-dimensional quadrilateral and / or rhomboid regions comprise rhombuses. Similarly, as the linear extension of the heating element system along the pipe increases, serpentine passages or bends become less sharp, which may result in a reduction in the surface area of ​​the pipe directly exposed to heat from the heating element, and vice versa. However, the ability to customize the installation length of the heating element system of this disclosure as needed provides the advantage of using a single size and operating configuration of heating elements (i.e., watts per foot and length) and substrates (length x width) across a wide range of pipe diameters and lengths, while also improving heat distribution, all without having to be changed to different sizes or heat outputs, thereby minimizing the inventory of different combinations of sizes and heat outputs.

[0052] To further improve the heating performance of the pipeline, the heating element system disclosed herein may include an insulating blanket that can be installed above and around the heating element system. This insulating blanket can be configured to contain the heat emitted from the heating element within the adjacent area of ​​the pipeline and reduce heat loss to the environment. The insulating blanket can further enhance the functionality of the heating element system by facilitating the migration of heat emitted from the heating element to three-dimensional quadrilateral and / or rhomboid regions of the pipeline.

[0053] During use, when the heating element is energized, the serpentine heating element emits heat due to the resistive characteristics and material properties of the resistance wire disposed within it, and this heat migrates to various parts of the outer wall of the pipe through conduction, radiation, and convection. The pipe area in direct contact with the heating element / substrate is initially exposed to the highest usable temperature emitted by the heating element system, while the open areas defined by the three-dimensional serpentine shape of the heating element receive the heat that migrates from the heating element to these areas.

[0054] Now turn to the attached diagram, especially Figures 1-2 This image shows a portion of an embodiment of an electric heating element system 100 for heating pipes. Figure 1 A perspective view of system 100 is shown, while Figure 2 A plan view of system 100 is shown. System 100 includes a heating element 10 fixed to a substrate 20 and a terminal 5 for connecting the heating element 10 to a power source via a pair of leads 65, 67. Figure 23 As shown, the heating element system 100 may include a heat insulation blanket 96 that covers and circumferentially surrounds the heating element system 100 and the conduit 99. The heating elements 100 are mounted on the conduit 99 to enhance heat distribution to the conduit surface. The heating elements 10 are arranged in a serpentine pattern on the substrate 20, with corresponding portions 1 and 2 of the heating elements 10 located in a pair of adjacent serpentine rows, for example... Figure 2 As shown, one is on top of the other and is in a continuous loop, such that the two conductor ends 62, 64 of the heating element 10 are located at or near the terminal 5. In this embodiment, as Figure 6 As shown, each serpentine channel or bend 3a, 3b of portion 1 of heating element 10 is symmetrical to each serpentine channel or bend 4a, 4b of portion 2 of heating element 10 about an imaginary centerline that longitudinally bisects the substrate 20. Heating element 10 can be secured to substrate 20 via stitch 12, which allows for a certain amount of movement of heating element 10 relative to substrate 20, allowing for flexibility and articulation of heating element system 100, thus facilitating installation onto conduits. In other embodiments, heating element 10 can be secured to substrate 20 using spaced clamps, straps, hook clips, rings and straps, straps and buckles, ties and quick hooks (commonly found on boots), or any other suitable fastening device.

[0055] like Figure 6 As shown, the substrate 20 includes a plurality of laterally spaced grooves 80a and 80b. Groove 80a begins at the outer longitudinal peripheral edge of the substrate 20 and extends perpendicularly toward the centerline (if the substrate 20 is in...). Figure 6 (In the direction shown). Groove 80b begins at the outer longitudinal peripheral edge of substrate 20 and extends perpendicularly toward the centerline (if substrate 20 is in the direction shown). Figure 6The direction shown is laterally aligned with the lateral position of each slot 80a. Therefore, in this embodiment, slots 80a and 80b are symmetrically oriented about an imaginary longitudinal centerline of the substrate 20. The positions and lateral lengths of slots 80a and 80b define a plurality of fastener ends 50a, 50b and end tabs 52a, 52b of the substrate 20. It should be understood that the vertical lengths of slots 80a and 80b may be longer or shorter without departing from the scope of this disclosure. Furthermore, in some embodiments, slot 80a may be offset from slot 80b. In these embodiments, the serpentine pattern of the heating element 10 may differ from the pattern shown in the figures without departing from the scope of this disclosure.

[0056] The substrate 20 also includes a plurality of transverse grooves 82, which are spaced apart from each other and from grooves 80a and 80b. The grooves 82 are located between the corresponding grooves 80a and 80b, such that the transverse spacing between grooves 80a, 80b and groove 82 is approximately the same. The grooves 82 cross an imaginary longitudinal centerline of the substrate 20 and extend upwards and downwards from the centerline in opposite directions (e.g., ...). Figure 6 (As shown). The heating element 10 is configured to be positioned on the substrate 20 by wiring and securing the heating element 20 to the substrate 20 in a serpentine manner and around each of the slots 80a, 80b, 82. It should be understood that the vertical length of the slot 82 may be longer or shorter without departing from the scope of this disclosure. As will be discussed more fully below and as shown in the figures, the dimensions and positions of the slots 80a, 80b, and 82 allow the substrate 20 to extend longitudinally from a first unextended length to a second extended length along the length of the conduit 99, and to be able to navigate easily over and around obstacles associated with the conduit 99 without affecting the heat distribution to the conduit 99.

[0057] like Figure 6As shown, the substrate 20 includes a plurality of fastener portions 56, 58. Each of the fastener portions 56, 58 is located at a corresponding fastener hole 60a, 60b on a corresponding fastener end 50a, 50b and end tab 52a, 52b of the substrate 20. The corresponding fastener portion 58 may be configured to securely but removably receive the corresponding fastener portion 56. The fastener portion 58 may include a receiving portion for receiving an engagement of each fastener portion 56. In other embodiments, the fastener portion 56 may include a receiving portion for receiving an engagement of each fastener portion 58. In one embodiment, the fastener portions 56, 58 include snaps made of durable, heat-resistant plastic or metal material for easy, secure, and removable mounting of the heating element system 100 to and around the conduit 99. In other embodiments, the heating element system 100 may be configured with different fastener systems, such as hook and loop fasteners, spring clips, high-strength magnets (such as rare-earth type), or any other common fastening system suitable for heating temperature environments consistent with this disclosure.

[0058] The substrate 20 may be at least partially or fully flexible to allow the heating element system 100 to be easily positioned and secured to the conduit 99. In various embodiments, the substrate 20 comprises a heat-resistant material such as PTFE-coated fiberglass cloth or fabric, ePTFE cloth or fabric, PTFE laminate, polyamide film, fiberglass paper, silicone-coated fiberglass, raw silicone sheet, fiberglass bonded raw silicone sheet, nonwoven polymer cloth, fiberglass mesh, nonwoven fabric, or rubber sheet. Suitable films include heat-resistant, non-elastic polymer sheets with a thickness less than 1 / 16 inch. In one embodiment, the substrate 20 is configured to be mounted on a conduit with a diameter of 1.5 inches. In other embodiments, the size and / or configuration of the substrate 20 is adapted to be mounted on any conduit 99 with an outer diameter from 0.25 inches to 15 inches. For example, the height 45 of the substrate 20 may be configured such that a corresponding fastener portion 56 can be vertically positioned relative to a corresponding fastener portion 58 near the outer periphery of the conduit 99 on which the heating element system 100 may be mounted. Similarly, the length 48 of substrate 20 can be configured to be approximately 47 inches in its unextended length and approximately 84 inches in its fully extended length. In other embodiments, the length 48 of substrate 20 can be any desired length. Large-diameter pipes may require longer heating elements 10 to prevent or minimize power density drops below the desired level.

[0059] Go to Figure 7 , Figure 7A representative heating element 10 for the heating element system 100 of this disclosure is shown. In some embodiments, the heating element 10 may include a self-regulating heating element category and may include a resistance wire 14, a sleeve 15, insulating layers 16, 17, and a grounding layer 18. In this embodiment, the resistance wire 14 comprises a plurality of strands 14a of a No. 37 (approximately 0.0045 mm in diameter) alloy 180, which comprises a nickel-copper alloy, each strand configured to 8.88 ohms + / - 8% per foot. In this embodiment, the sleeve 15 comprises Kapton, layers 16 and 17 both comprise glass fiber, and the grounding layer 18 comprises a No. 36 tin-plated copper braid. In this embodiment, the heating element 10 may be 104 feet long and 0.0625 mm in diameter. It is rated at 120 VAC and 1.34 watts per foot, totaling 139.8 watts for that length. The heating element 10 of this configuration may be set to 180°C to transfer heat to the surrounding conduit 99 around which the heating element system 100 is mounted. Heating elements of this configuration are available from BriskHeat, Columbus, Ohio. Other embodiments of the heating element system 100 may include heating elements of any suitable construction without departing from the scope of this disclosure. For example, other heating element 10 configurations suitable for the heating element system 100 of this disclosure may include a single solid core of resistance wire 14, rather than as shown in the example. Figure 7 The multiple strands shown. Similarly, the heating element 10 may include different insulating layers, such as layers including TFE, PTFE, ePTFE and stainless steel threads.

[0060] Go to Figures 8-14 , Figures 8-14 Various stages and embodiments of coupling the conductor ends 62, 64 of the heating element 10 to a power source are illustrated. As described above, the heating element 10 is a continuous element fixed to the substrate 20 and wired around each of the slots 80a, 80b, 82, such that the two conductor ends 62, 64 meet at or near the terminal 5 of the heating element system 100. The substrate 20 includes tabs 7, 8 and a cover plate 9 for receiving and / or surrounding the conductor joints 72, 74 of the heating element 10. The conductor joints 72, 74 surround the electrical conductor connection between the leads 62, 64 and the conductor ends 62, 64 of the heating element 10. Figures 9-10 As shown, conductor connectors 72 and 74 can be sewn or otherwise secured to substrate 20 via stitches 76a and 76b. Leads 62 and 64 exiting the conductor connectors can be additionally housed in sleeves 69 for abrasion protection and heat resistance.

[0061] Figures 11-12A tab 7, folded along fold line 30 to align with tab 8, and a cover plate 9, folded along fold line 32 to wrap around conductor connectors 72, 74, are shown. Seams 42a, 42b can be configured to secure tab 7 to tab 8, cover plate 9 to tab 7, and wrap around conductor connectors 72, 74. Figures 13-14 An embodiment of a heating element 10 including a ground wire 84 is shown. In this embodiment, an outer ground layer 18 is partially stripped from a portion of the conductor end 62 of the heating element 10 and connected to the ground wire 84 via a crimp connector 90, while the conductor end 62 in the heating element 10 is connected to a lead 65 via a crimp connection device 88.

[0062] Go to Figure 15 , Figure 15 A heating element system 100 with partial extension and / or hinge is shown in this disclosure. Figure 15 It is shown how, when the heating element system 100 extends at least partially in the longitudinal direction, the slots 80a, 80b, 82 together define alternating spaced elongated holes 92, alternating spaced webbing 94, and alternating elongated holes 93a, 93b in the substrate 20. Figure 15 The diagram also shows how the heating element 10 is wired in a serpentine arrangement around slots 80a, 80b, 82 in two adjacent rows, the two rows of slots being mirror images of each other about the longitudinal centerline of the substrate 20. Figure 15 The illustration further illustrates the flexibility of the substrate 20 and the potential ease with which the fastener ends 50a, 50b can be brought together around the circumference of the conduit 99.

[0063] Figures 16-23 The figures illustrate various aspects of a heating element system 100 mounted on an exemplary conduit 99. As shown in these figures, the heating element system 100 extends along the length of the conduit 99 in a folded manner to the desired length, while the fastener ends 50a, 50b and end tabs 52a, 52b of the substrate 20 are gathered together around the circumference of the conduit 99 and secured together using fastener portions 56, 58. Although the available wattage per foot of a given heating element 10 is fixed, the user can still customize the heat applied to the conduit 99 and the heat distribution between adjacent rings of the heating element 10 on the substrate 20 by extending or retracting the heating element 10 along the length of the conduit 99. Figure 22 The illustration shows how an embodiment of the heating element system 100 of this disclosure is adjustable to extend above and around an obstacle 70. Figure 23An embodiment of a heating element system 100 (with optional thermocouples) is illustrated, which includes an insulating blanket 96 located above and around a conduit 99 to further enhance heat distribution to the conduit 99 and minimize heat loss. The insulating blanket 96 can be secured to itself and around the conduit 99 using fasteners 97, which may include, for example, hook and loop fasteners or any other fastening system.

[0064] Figure 24 This is a screenshot of the temperature distribution taken by a thermal imaging camera of the exemplary heating element system 100 during use, showing the area of ​​the pipe 99 near the heating element system 100. A thermal insulation blanket 96 is positioned above and around the pipe 99, but is partially stripped from the bottom, sides, and upper left portion of the horizontal pipe 99 to allow the camera to capture the image. The image reveals that the hottest temperature is located at the center of the heating element 10, with the second hottest temperature located in region 98, which runs along the upper right of the image near the thermal insulation blanket 96. In contrast, the coldest temperature is located in region 95, which runs primarily along the bottom of the pipe 99 and between the various channels or bends of the heating element 10. Empirical temperature measurements indicate that when the thermal insulation blanket 96 is installed above and around the pipe 99, the temperature distribution along the length of the pipe 99 and around its entire circumference is more uniform along the surface of the pipe 99.

[0065] Figures 25-38 Alternative embodiments of the electric heating element system of this disclosure are shown. For example, Figures 25-28 An electric heating element system 200 is shown, which includes a parallel-line type electric heating element 210 suitable for use according to the teachings of this disclosure. Using the parallel-line type electric heating element 210 allows for a lower range of resistance and higher wattage without increasing electrical safety risks. The system 200 includes a heating element 210 fixed to a substrate 20 and a terminal 205 for connecting the heating element 210 to a power source via a pair of leads 65, 67. Figure 23 As shown, the heating element system 200 may include a heat insulation blanket 96 that covers and circumferentially surrounds the heating element system 100 and the conduit 99. The heating elements 200 are mounted on the conduit 99 to enhance heat distribution to the conduit surface. Heating elements 210 are arranged in a serpentine pattern on the substrate 20, with corresponding portions 1 and 2 of the heating elements 210 located in a pair of adjacent serpentine rows, for example, as shown... Figure 27 As shown, one is on top of the other and is in a continuous loop, such that the two conductor ends 262, 264 of the heating element 210 are located at or near the terminal 205. In this embodiment, as Figure 27As shown, each serpentine channel or bend 3a, 3b of portion 1 of heating element 210 is symmetrical to each serpentine channel or bend 4a, 4b of portion 2 of heating element 210 about an imaginary centerline that longitudinally bisects the substrate 20. Heating element 210 can be secured to substrate 20 via stitch 12, which allows for a certain amount of movement of heating element 210 relative to substrate 20, allowing for flexibility and articulation of the heating element system 200, thus facilitating installation onto conduits. In other embodiments, heating element 210 can be secured to substrate 20 using spaced clamps, nails, ties, hook clips, rings and straps, straps and buckles, ties and quick hooks (typically found on boots) or any other suitable fastening device.

[0066] Figures 29-30 An electric heating element system 300 is shown, comprising an electric heating element 310 adapted for use according to the teachings of this disclosure. In this embodiment, conductor ends 362a, 364a and 362b, 264b are respectively located on opposing terminals 305a and 305b to provide the ability to connect multiple electric heating element systems of this disclosure in series. System 300 includes a heating element 310 fixed to a substrate 20 and terminals 305a and 305b for connecting the heating element 310 to a power source via a pair of leads 65, 67 connected to each of terminals 305a, 305b. Figure 23 As shown, the heating element system 300 may include a heat insulation blanket 96 that covers and circumferentially surrounds the heating element system 200 and the conduit 99. The heating element system 300 is mounted on the conduit 99 to enhance heat distribution to the conduit surface. Heating elements 310 are arranged in a serpentine pattern on the substrate 20, with corresponding portions 1 and 2 of the heating elements 310 located in a pair of adjacent serpentine rows, for example, as shown... Figure 30 As shown, one is on top of the other. In this embodiment, as... Figure 30 As shown, each serpentine channel or bend 3a, 3b of portion 1 of heating element 310 is symmetrical to each serpentine channel or bend 4a, 4b of portion 2 of heating element 310 about an imaginary centerline that longitudinally bisects the substrate 20. Heating element 310 can be secured to substrate 20 via stitch 12, which allows for a certain amount of movement of heating element 310 relative to substrate 20, enabling flexibility and articulation of heating element system 300, thus facilitating installation onto conduits. In other embodiments, heating element 310 can be secured to substrate 20 using spaced clamps, nails, ties, hook clips, rings and straps, straps and buckles, ties and quick hooks (typically found on boots) or any other suitable fastening device.

[0067] Figures 31-33An electric heating element system 400 is shown, which includes a heating band or heat trace type electric heating element 410 suitable for use according to the teachings of this disclosure. The system 400 includes a heating element 410 fixed to a substrate 20 and a terminal 405 for connecting the heating element 410 to a power source via a pair of leads 65, 67. Figure 23 As shown, the heating element system 400 may include a heat insulation blanket 96 that covers and circumferentially surrounds the heating element system 400 and the conduit 99. The heating element system 400 is mounted on the conduit 99 to enhance heat distribution to the conduit surface. Heating elements 410 are arranged in a serpentine pattern on the substrate 20, with corresponding portions 1 and 2 of the heating elements 410 located in a pair of adjacent serpentine rows, for example, as shown... Figure 33 As shown, one is on top of the other and is in a continuous loop, such that the two conductor ends 462, 464 of the heating element 410 are located at or near the terminal 405. In this embodiment, as Figure 33 As shown, each serpentine channel or bend 3a, 3b of portion 1 of heating element 410 is symmetrical to each serpentine channel or bend 4a, 4b of portion 2 of heating element 410 about an imaginary centerline that longitudinally bisects substrate 20. If heating element 410 is a heating band type electric heating element, heating element 410 can be secured to substrate 20 via stitch 12 (which allows for a certain amount of movement of heating element 410 relative to substrate 20 to allow for flexibility and articulation of heating element system 400, thereby facilitating installation on a conduit), or otherwise laminated or adhered to substrate 20. If heating element 410 is a thermal trace type heating element, thermal trace type heating element can be screen-printed, deposited, or digitally printed on substrate 20.

[0068] Figures 34-36 An electric heating element system 500 is shown, which includes a self-adjusting electric heating element 510 suitable for use according to the teachings of this disclosure. The system 500 includes a heating element 510 fixed to a substrate 20 and a terminal 505 for connecting the heating element 510 to a power source via a pair of leads 65, 67. Figure 23 As shown, the heating element system 500 may include a heat insulation blanket 96 that covers and circumferentially surrounds the heating element system 50 and the conduit 99. The heating element system 500 is mounted on the conduit 99 to enhance heat distribution to the conduit surface. Heating elements 510 are arranged in a serpentine pattern on the substrate 20, with corresponding portions 1, 2 of the heating elements 510 located in a pair of adjacent serpentine rows, for example, as shown... Figure 36 As shown, one is on top of the other and is in a continuous loop, such that the two conductor ends 562, 564 of the heating element 510 are located at or near the terminal 505. In this embodiment, as... Figure 36As shown, each serpentine channel or bend 3a, 3b of portion 1 of heating element 510 is symmetrical to each serpentine channel or bend 4a, 4b of portion 2 of heating element 510 about an imaginary centerline that longitudinally bisects the substrate 20. Heating element 510 can be secured to substrate 20 via stitch 12, which allows for a certain amount of movement of heating element 510 relative to substrate 20, allowing for flexibility and articulation of the heating element system 500, thus facilitating installation onto conduits. In other embodiments, spaced clamps, nails, ties, hook clips, rings and straps, straps and buckles, ties and quick hooks (typically found on boots) or any other suitable fastening device can be used to secure heating element 510 to substrate 20.

[0069] Figure 37A / B- Figure 38 An electric heating element system 600 is shown, which includes a heating element 10 fixed to a substrate 20, similar to... Figures 1-2 As shown. In this embodiment, friction blocks 52 are included to prevent or at least inhibit the substrate 20 from sliding or moving on the conduit where the system 600 is mounted, to help ensure that the substrate 20 continues to extend along the conduit to the desired length. Figure 37B As shown, the friction block 52 is located on a selected one of the fastener ends 50a and end tabs 52a of the substrate 20. In other embodiments, the friction block 52 may be located on more or fewer fastener ends 50a and end tabs 52a. Figures 37B-38 As shown, the width of the friction block 52 can be approximately the width of the fastener end 50a and end plate 52a to which it is fixed. The friction block 52 can be of any suitable thickness, and in some embodiments, the thickness of the friction block 52 can be approximately the same as the thickness of the substrate 20. The friction block 52 can include any suitable friction-inducing material, such as silicone rubber, adhesive, or tape. The friction block 52 can be fixed to selected of the fastener end 50a and end tab 52a of the substrate 20 via the fastener portion 56. Those skilled in the art will appreciate that the friction block 52 can be incorporated into any of the electric heating element systems described herein.

[0070] Figure 39 A non-exhaustive list of different types of electric heating elements applicable to the teachings of this disclosure is shown. Those skilled in the art will be able to adapt these different types of electric heating elements according to the teachings of this disclosure.

[0071] The mathematical expression used to predict the maximum linear extension or expansion coefficient of the heating element system along the pipe in this disclosure is: Wherein, "groove length" is the vertical length of each groove (assuming each groove has a similar length), "maximum expansion angle" is the acute angle between the centerlines of each "rib" measured from the longitudinal axis of the pipe (assuming the flexibility of the material of substrate 20 is constant), and "rib width" is the lateral width of each "rib," defined as the lateral spacing between adjacent grooves. Simply put, "groove length" is the hypotenuse of a right triangle forming a right angle with the longitudinal axis of the pipe, the longitudinal axis being the adjacent side of the right triangle (whose length is defined as "rib width"), and the acute angle between the hypotenuse and the adjacent longitudinal side is the "maximum expansion angle."

[0072] Using empirical measurements and data points, a simplified equation for estimating the maximum expansion coefficient based on the heating element's inner diameter (i.e., the pipe's outer diameter) as the independent variable can be expressed as: Figure 40 Examples illustrating the maximum predicted expansion factor of the heating element system of this disclosure for various pipe diameters are provided. Using the above equation, the maximum expansion factor can be predicted for any given pipe diameter: Therefore, for example, for a 1.5-inch diameter pipe, the electric heating element of this disclosure is expected to extend to at least about 1.7 times the original unextended length of the substrate. Similarly, for example, for a 6-inch pipe diameter, the electric heating element system of this disclosure is expected to extend to at least about 4.7 times the original unextended length of the substrate.

[0073] Go to Figures 3-5 , Figures 3-5 Various steps in a method for manufacturing an embodiment of the heating element system 100 of this disclosure are illustrated. For example, in Figure 3 In the illustrated embodiment, a Tajima sewing machine can be used to sew heating elements 10 to substrate 20 using thread 12, wherein the plurality of heating element units 10 are positioned on the plurality of substrate 20 units before the plurality of substrate 20 units are cut or separated from a larger substrate unit. Figure 4As shown in the embodiment, each substrate 20 unit is marked at: (i) position 23 for locating the future positions of fastener portions 56, 58; (ii) position 25 for locating the future positions of slots 80a, 80b, and 82; and (iii) position 27 for locating future cutting lines used to divide the larger unit into multiple independent substrates 20. The process of marking all positions 25 continues until the substrate 20 is completely marked. The next step is to cut the larger substrate 20 into independent substrate 20 units by hand or machine, each unit having corresponding slots 80a, 80b, and 82, fastener holes 60a, 60b, and tabs 7, 8, 9 for terminals 5. In other embodiments, the task of marking and cutting the substrate 20 can be replaced by the following steps: loading the larger substrate unit onto a laser cutting table, programming the laser cutter to cut the substrate 20 according to coordinate programming in the software, and cutting the substrate 20 accordingly. The next step may be to insert the fastener portions 56, 58 at the corresponding positions 23 in the substrate 20. The next step may be to connect and crimp a pair of leads 65, 67 and an optional ground wire 84 to the corresponding conductor ends 62, 64 to form conductor joints 72, 74 (see [link to documentation]). Figures 8-14 ).like Figure 10 As shown in the embodiment, the next step may be to fix the conductor connector to the substrate 20 via stitches 76a, 76b, and assemble the sleeve 69 onto the leads 65, 67. The next step may be to fold the tabs 7, 8, 9 along fold lines 30, 32, and assemble the tabs 7, 8, 9 using stitches 42a, 42b, as shown. Figures 11-12 As shown in the embodiments.

[0074] While specific embodiments have been described in detail, those skilled in the art will appreciate that various modifications and alternatives to these details can be developed based on the general teachings of this disclosure. Therefore, the disclosure herein is illustrative only and does not limit its scope, and the full scope of the appended claims and any equivalents should be given.

Claims

1. An electric heating element system for heating pipes, comprising: A resistance heating element, the resistance heating element including a first electrical conductor and a second electrical conductor extending from respective opposite ends of the heating element to be connected to a power source; as well as A substrate having a length, the substrate comprising: The first row of spaced-apart slots transverse to the stated length; The second row of spaced-apart slots, transverse to the length and transversely aligned with the slots spaced apart in the first row; and The third row of slots is spaced apart transversely to the length and is alternately positioned with the slots spaced apart in the first row and the slots spaced apart in the second row. The first row of grooves defines a first row of spaced-apart fastener ends, and the second row of grooves defines a second row of spaced-apart fastener ends opposite to the first row of fastener ends. Each row of the first and second rows of spaced-apart fastener ends is configured to laterally wrap around the outer diameter of the pipe and includes a fastener portion for detachably connecting corresponding opposing fastener ends to each other to secure the substrate to the pipe. The heating element is attached to the substrate and meanders in a serpentine pattern from a first end to a second end and from a second end to a first end of the substrate between the first row of spaced-apart slots, the second row of spaced-apart slots, and the third row of spaced-apart slots, wherein the first electrical conductor and the second electrical conductor are close to the first end of the substrate. When the substrate extends along the length, the first row of slots, the second row of slots, and the third row of slots define a rhomboid region.

2. The electric heating element system of claim 1, wherein the resistance heating element includes a self-regulating heating system.

3. The electric heating element system of claim 1, wherein the substrate comprises heat-resistant fabric, cloth, film or mesh.

4. The electric heating element system of claim 3, wherein the fabric or cloth comprises polytetrafluoroethylene (PTFE) coated glass fiber.

5. The electric heating element system of claim 1, wherein the substrate is approximately rectangular in planar shape.

6. The electric heating element system of claim 1, wherein the first row of spaced-apart fastener ends are configured to overlap with the second row of spaced-apart fastener ends when wrapped around the conduit.

7. The electric heating element system of claim 1, wherein the substrate has a first unextended length and is capable of extending up to a second extended length.

8. The electric heating element system of claim 7, wherein the second extended length of the substrate is at least 80% longer than the first unextended length.

9. The electric heating element system of claim 1, wherein the first row of spaced slots extends along the length from the first outer edge of the substrate toward a longitudinal centerline bisecting the substrate.

10. The electric heating element system of claim 1, wherein the second row of spaced slots extends along the length from the second outer edge of the substrate toward a longitudinal centerline bisecting the substrate.

11. The electric heating element system of claim 1, wherein the third row of spaced slots extends transversely to the length of the center line bisecting the substrate toward the first outer edge of the substrate and toward the second outer edge of the substrate.

12. The electric heating element system of claim 1, wherein each of the fastener portions includes a snap-fit ​​engagement portion or a snap-fit ​​receiving portion.

13. The electric heating element system of claim 1, wherein the heating element is attached to the substrate via a stitch.

14. An electric heating element system for heating pipes, comprising: A resistance heating element, the resistance heating element being configured to be connected to a power source; as well as A polytetrafluoroethylene (PTFE) glass fiber substrate, the substrate having a length, the substrate comprising: The first row of parallel slots extends transversely to the stated length; The second row of parallel slots is transverse to the length, and each slot in the second row is arranged parallel to and laterally aligned with the slots in the first row. A third row of parallel slots, transverse to the length and alternately positioned relative to the slots in the first and second rows; and A first row of fastener ends along the length and a second row of fastener ends opposite the first row of fastener ends along the length, the first row of fastener ends and the second row of fastener ends being defined by a first row groove and a second row groove, respectively, each row of the first row of fastener ends and the second row of fastener ends being configured to secure the substrate to the conduit; The heating element is attached to the substrate in a serpentine pattern around each slot in the first row, the second row, and the third row, from a first end to a second end and from a second end to a first end of the substrate. The length of the substrate can be adjusted from a first unextended length to a second extended length.

15. The electric heating element system of claim 14, wherein the serpentine pattern of the heating element is repeated in a mirror image with respect to the longitudinal centerline of the substrate along the length of the substrate.

16. The electric heating element system of claim 1, wherein the substrate has a first unextended length and is adjustable to a maximum extended length.

17. The electric heating element system of claim 16, wherein the substrate is adjustable to any length from the first unextended length to the second extended length.

18. The electric heating element system of claim 16, wherein the second extended length of the substrate is at most 80% longer than the first unextended length.

19. The electric heating element system of claim 14, wherein the first row of parallel grooves extends along the length from a first outer edge of the substrate toward a longitudinal centerline of the substrate, and wherein the second row of parallel grooves extends along the length from a second outer edge of the substrate opposite to the first outer edge toward the centerline, and wherein the third row of parallel grooves extends from the centerline transversely to the length toward both the first and second outer edges of the substrate.

20. An electric heating element system for heating pipes, comprising: A resistance heating element, the resistance heating element being configured to be connected to a power source; as well as A substrate that is generally rectangular in shape, the substrate having a length, the substrate comprising: The first row of slots extends transversely to the stated length; The second row of slots is transverse to the length and is transversely aligned with the first row of slots; The third row of slots is transverse to the length and alternately positioned relative to the slots in the first and second rows along the length; and A first row of fastener ends and a second row of fastener ends are defined by the first row of grooves and the second row of grooves, respectively, and each of the first row of fastener ends and the second row of fastener ends is configured to secure the substrate to the pipe; The heating element is attached to the substrate and meanders in a serpentine pattern from the first end to the second end of the substrate and from the second end to the first end of the substrate around the first row of slots, the second row of slots, and the third row of slots. The length of the substrate can be adjusted from a first unextended length to a second extended length.

Images