High-energy-density armored electric heating element

Abstract

The utility model provides a high-energy-density armored electric heating element which comprises a metal outer sleeve with one closed end and one open end, a heat-conducting insulating outer layer is arranged on the inner wall of the metal outer sleeve, a heating body is arranged on the inner wall of the heat-conducting insulating outer layer, and a heat-conducting insulating inner layer is arranged on the inner wall of the heating body. One end of the heating body is connected with an electrode leading-out pipe extending out of the metal outer sleeve, and an electrode leading-out rod connected with the other end of the heating body is inserted into the heat-conducting insulating inner layer. According to the utility model, by arranging the electrode lead-out tube and the electrode lead-out rod, namely a coaxial electrode lead-out structure, the structure effectively optimizes the wiring end design of the electric heating element, so that the integration level is higher, and the structure is more compact; the heating body of the rectangular spiral structure is manufactured through the high-precision subtractive manufacturing forming technology, the surface load is lower, the energy density is higher, and then the service life of the element is prolonged. Meanwhile, the combined design of the double-layer heat-conducting insulation structure and the metal jacket further enhances the heat conduction and structural stability of the element.

Description

Technical Field

[0001] This utility model belongs to the field of electric heating element technology, specifically relating to a high energy density armored electric heating element. Background Technology

[0002] Existing metal tubular heating elements generally employ a single-end double-lead or double-end lead configuration for their electrode leads, requiring connection and fixation to a spiral heating element. This connection process suffers from high complexity and insufficient interfacial bonding strength, increasing the difficulty of element assembly. Regarding heating element fabrication, spiral heating wires / strips are often manufactured using a winding process. This process faces numerous constraints, including high winding precision requirements, poor molding compatibility, and uneven heating. Furthermore, the winding of the heating wire / strip relies primarily on its own elastic deformation for radial and axial support, making it prone to elastic failure under high temperature and vibration conditions. This can lead to reliability issues such as heating wire displacement and loosening, resulting in poor structural stability that fails to meet the requirements of high-pressure and vibration-prone conditions.

[0003] Therefore, a high-energy-density armored heating element is needed. Utility Model Content

[0004] The technical problem this invention aims to solve is to address the shortcomings of the prior art by providing a high-energy-density armored heating element. This heating element, through the use of electrode lead-out tubes and rods—that is, a coaxial electrode lead-out structure—effectively simplifies the wiring port design compared to traditional heating elements. The heating element, manufactured using high-precision subtractive manufacturing technology with a rectangular spiral filament structure, has a lower surface load, higher energy density, and extended material lifespan. Simultaneously, the combination of a double-layer thermally conductive insulation structure and a metal jacket further enhances the element's thermal conductivity and structural stability.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is: a high energy density armored electric heating element, characterized in that the element includes a metal outer tube that is closed at one end and open at the other end, the inner wall of the metal outer tube is provided with a thermally conductive and insulating outer layer, the inner wall of the thermally conductive and insulating outer layer is provided with a heating element, the inner wall of the heating element is provided with a thermally conductive and insulating inner layer, the heating element is also connected to an electrode lead tube extending out of the metal outer tube, and an electrode lead rod that is connected to the heating element and extends out of the electrode lead tube is inserted into the thermally conductive and insulating inner layer.

[0006] The above-mentioned high energy density armored electric heating element is characterized in that the metal outer tube, the thermally conductive and insulating outer layer, the heating element, the thermally conductive and insulating inner layer, the electrode lead tube, and the electrode lead rod are all on the same axis.

[0007] The above-mentioned high energy density armored electric heating element is characterized in that one end of the heating element is a cold end, and the electrode lead-out rod is welded and fixed to the cold end of the heating element.

[0008] The above-mentioned high energy density armored electric heating element is characterized in that the heating element and the electrode lead tube are an integral structure, and the heating element is a rectangular spiral filament structure, which is formed by subtractive manufacturing of electric heating alloy tube.

[0009] The above-mentioned high energy density armored electric heating element is characterized in that both the thermally conductive and insulating outer layer and the thermally conductive and insulating inner layer are high thermal conductivity and high insulation ceramic tubes or ceramic powders.

[0010] The aforementioned high-energy-density armored heating element is characterized in that the electrode lead rod, electrode lead tube, thermally conductive insulating inner layer, heating element, thermally conductive insulating outer layer, and metal outer sleeve are tightly fixed together through a tube shrinking and diameter reduction process.

[0011] This utility model has the following advantages compared with the prior art:

[0012] 1. This utility model forms a high-energy-density armored electric heating element by designing a mutually cooperating metal outer tube, a thermally conductive and insulating outer layer, a heating element, a thermally conductive and insulating inner layer, an electrode lead-out tube, and an electrode lead-out rod. It adopts a coaxial electrode lead-out structure, which effectively simplifies the wiring port design of the electric heating element, improves the connection reliability between the lead-out rod and the spiral heating element, and solves the problems of high assembly difficulty, complex wire winding process, poor structural stability, uneven heating, and short service life of existing electric heating elements.

[0013] 2. The heating element of this utility model is a rectangular spiral heating element. It is manufactured using high-precision subtractive manufacturing technology, which avoids the winding and forming technology of traditional spiral heating wires / belts. It has easy-to-control manufacturing characteristics and higher processing precision, lower surface load, higher energy density, and improved material service life.

[0014] 3. The combination design of the double-layer thermally conductive and insulating structure and the metal jacket of this utility model enhances the thermal conductivity and structural stability of the component, enabling the electric heating element to be used in strong vibration environments.

[0015] The technical solution of this utility model will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the high energy density armored electric heating element of this utility model.

[0017] Figure 2 This is a schematic diagram of the structure of the electrode lead-out rod, the thermally conductive insulating inner layer, and the heating alloy tube assembled according to this utility model.

[0018] Figure 3 This is a schematic diagram of the structure of the electrode lead-out rod, thermally conductive insulating inner layer, and electric heating alloy tube after a single tube reduction and material reduction process.

[0019] Explanation of reference numerals in the attached figures:

[0020] 1—Metal outer sheath; 2—Thermal conductive and insulating outer layer; 3—Heating element; 4—Thermal conductive and insulating inner layer;

[0021] 5—Electrode lead-out tube; 6—Electrode lead-out rod; 7—Heating alloy tube. Detailed Implementation

[0022] like Figure 1 and Figure 3 As shown, the high energy density armored heating element of this utility model includes a metal outer tube 1 that is closed at one end and open at the other end. The inner wall of the metal outer tube 1 is provided with a thermally conductive and insulating outer layer 2. The inner wall of the thermally conductive and insulating outer layer 2 is provided with a heating element 3. The inner wall of the heating element 3 is provided with a thermally conductive and insulating inner layer 4. The heating element 3 is also connected to an electrode lead tube 5 that extends out of the metal outer tube 1. An electrode lead rod 6 that is connected to the heating element 3 and extends out of the electrode lead tube 5 is inserted into the thermally conductive and insulating inner layer 4.

[0023] It should be noted that by making the metal outer tube 1 a tube with one end closed and the other end open, it is easy to insert other components to form an armored structure. By setting a thermally conductive insulating outer layer 2 on the inner wall of the metal outer tube 1, which is also a tube with one end closed and the other end open, the heating element 3 and the electrode lead tube 5 are insulated and protected from the metal outer tube 1, and the heat generated by the heating element 3 is discharged. The heating element 3 and the electrode lead tube 5 are set on the inner wall of the thermally conductive insulating outer layer 2. The heating element 3 and the electrode lead tube 5 are in the form of one end closed and the other end open. By setting the electrode lead tube 5 and the electrode lead rod 6 connected to the heating element 3 respectively, it is easy to connect the heating element 3 to the positive and negative poles of the external power supply to form a circuit, so that the heating element 3 generates heat and achieves the effect of electrothermal heating. The tubular thermally conductive insulating inner layer 4 is used to insulate and protect the heating element 3 and the electrode lead tube 5 and the electrode lead rod 6.

[0024] In this embodiment, the metal outer sleeve 1, the thermally conductive and insulating outer layer 2, the heating element 3, the thermally conductive and insulating inner layer 4, the electrode lead-out tube 5, and the electrode lead-out rod 6 are all on the same axis. By ensuring that all components are on the same axis, the heat generated by the heating element 3 is uniform, and the heat can be dissipated uniformly, thus ensuring uniform heating of the heating element.

[0025] like Figure 1 and Figure 3As shown, in this embodiment, one end of the heating element 3 is a cold end, and the electrode lead-out rod 6 is welded and fixed to the cold end of the heating element 3. The cold end facilitates the connection between the electrode lead-out rod 6 and the heating element 3, and the welding fixation provides excellent connection results.

[0026] like Figure 2 As shown, in this embodiment, the heating element 3 and the electrode lead-out tube 5 are an integral structure. The heating element 3 is a rectangular spiral filament structure, which is manufactured by subtractive processing of the heating alloy tube 7.

[0027] It should be noted that both the heating element 3 and the electrode lead tube 5 are manufactured by subtractive processing of a single-end sealed electric heating alloy tube 7. The part of the electric heating alloy tube 7 inserted into the metal outer tube 1 is manufactured by high-precision subtractive processing technology to obtain a rectangular spiral filament structure. This area is the heating element 3. The sealed end of the electric heating alloy tube 7 is the cold end. The area of ​​the electric heating alloy tube 7 that is not manufactured by subtractive processing is the electrode lead tube 5. Since the resistance of the cold end and the electrode lead tube 5 is relatively small, their temperature is lower than that of the rectangular spiral filament structure.

[0028] It should be noted that, compared with round wires, the rectangular spiral filament structure has a lower surface load, higher energy density, and longer material lifespan for the same size. In addition, the use of subtractive manufacturing process enables the processing of small-gap rectangular spiral filament structures, with the gap in the rectangular spiral filament structure being less than 1.5mm, thereby achieving high energy density per unit area.

[0029] In this embodiment, both the thermally conductive and insulating outer layer 2 and the thermally conductive and insulating inner layer 4 are made of highly thermally conductive and highly insulating ceramic tubes or ceramic powders. By using highly thermally conductive and highly insulating ceramic tubes or ceramic powders, insulation protection is achieved between the electrode lead-out rod 6, the electrode lead-out tube 5, and the heating element 3; the ceramic tube is a hexagonal boron nitride ceramic tube, and the ceramic powder is hexagonal boron nitride powder.

[0030] In this embodiment, the electrode lead-out rod 6, electrode lead-out tube 5, thermally conductive insulating inner layer 4, heating element 3, thermally conductive insulating outer layer 2, and metal outer sleeve 1 are tightly fixed together by a tube shrinking and diameter reduction process.

[0031] It should be noted that the electrode lead-out rod 6, the thermally conductive insulating inner layer 4, and the heating alloy tube 7 are assembled as follows: Figure 2 Then, the tube is compressed and reduced in diameter to achieve a tight fixation. Subsequently, the reduced-diameter electric heating alloy tube 7 is manufactured by subtractive processing to obtain the heating element 3 and the electrode lead-out tube 5, see... Figure 3 Then, it is assembled with the metal outer tube 1 and the thermally conductive and insulating outer layer 2, ensuring that the heating element 3 is completely located inside the metal outer tube 1. A tight fixation is then achieved through secondary tube shrinking and diameter reduction. See [link to documentation]. Figure 1This is to further enhance thermal conductivity and protective properties, as well as improve its thermal conductivity and structural strength.

[0032] It should be noted that the electrode lead-out rod 6 is made of Ta alloy and has a diameter of 6mm; the heating alloy tube 7 is made of Ta alloy, has an outer diameter of 12mm and a thickness of 1mm; in the first tube shrinking and diameter reduction process, the outer diameter of the heating alloy tube 7 is reduced from 12mm to 10mm; the heating element 3 has a length of 500mm and a thickness of 0.5mm. After high-precision subtractive manufacturing technology, the width of the heating wire in the rectangular spiral filament structure is 3.5mm, the spiral pitch is 4.5mm, and the total length of the heating wire is 2.78m; the length of the electrode lead-out tube 5 is 70mm; the thermally conductive and insulating outer layer 2 is a hexagonal boron nitride ceramic tube, and its dimensions are consistent with the interface gap dimensions between the electrode lead-out tube 5, the heating element 3, and the metal outer sleeve 1; the thermally conductive and insulating inner layer 4 is a hexagonal boron nitride ceramic tube, and its dimensions are consistent with the interface gap dimensions between the electrode lead-out tube 5, the heating element 3, and the electrode lead-out rod. The interface gap dimensions between 6 are consistent; the metal outer tube 1 is made of Ta alloy, with an outer diameter of 16mm and a thickness of 1mm. In the secondary tube shrinking and diameter reduction process, the outer diameter of the metal outer tube 1 is reduced from 16mm to 14mm; using Ta alloy as the heating element material and hexagonal boron nitride as the thermally conductive and insulating material effectively improves the temperature resistance and insulation performance of the heating element, significantly reduces the risk of insulation material and heating wire failure, improves the reliability, stability and safety of the heating element, and extends the service life of the heating element; the heating element uses a high-temperature resistant and high-strength Ta alloy tube shell as armor protection. Through the secondary tube shrinking process, the Ta alloy armor shell and the highly thermally conductive insulating filling layer are tightly fixed. The synergistic effect of the two can effectively improve its heat transfer performance, reduce heat loss compared with traditional elements, and at the same time, its vibration resistance is greatly improved.

[0033] In actual use, the electrode lead tube 5 and the electrode lead rod 6 are connected to the positive and negative terminals of the power supply, respectively. Then, the heating element is placed in the area that needs to be heated, and then the power is turned on to heat it. The operation is simple and easy to promote and apply.

[0034] The above description is merely a preferred embodiment of this utility model and does not constitute any limitation on this utility model. Any simple modifications, alterations, and equivalent changes made to the above embodiments based on the technical essence of this utility model shall still fall within the protection scope of this utility model.

Claims

1. A high energy density sheathed electrocaloric element, characterized in that, The element comprises a metal outer sleeve (1) with one end closed and one end open, the inner wall of the metal outer sleeve (1) is provided with a heat-conducting insulating outer layer (2), the inner wall of the heat-conducting insulating outer layer (2) is provided with a heating body (3), the inner wall of the heating body (3) is provided with a heat-conducting insulating inner layer (4), the heating body (3) is further connected with an electrode lead-out pipe (5) extending out of the metal outer sleeve (1), and the heat-conducting insulating inner layer (4) is inserted with an electrode lead-out rod (6) connected with the heating body (3) and extending out of the electrode lead-out pipe (5).

2. A high energy density sheathed electrocaloric element according to claim 1, wherein, The metal outer sleeve (1), the heat-conducting insulating outer layer (2), the heating body (3), the heat-conducting insulating inner layer (4), the electrode lead-out pipe (5) and the electrode lead-out rod (6) are all on the same axis.

3. A high energy density sheathed electrocaloric element according to claim 1, wherein, The heating body (3) is closed at one end as a cold end, and the electrode lead-out rod (6) is welded and fixed with the cold end of the heating body (3).

4. A high energy density sheathed electrocaloric element according to claim 1, wherein, The heating body (3) and the electrode lead-out pipe (5) are an integral structure, the heating body (3) is a rectangular spiral wire structure, and is formed by subtractive machining of an electric heating alloy pipe (7).

5. A high energy density sheathed electrocaloric element according to claim 1, wherein, The heat-conducting insulating outer layer (2) and the heat-conducting insulating inner layer (4) are both ceramic pipes or ceramic powders with high heat conduction and high insulation.

6. A high energy density sheathed electrocaloric element according to claim 1, wherein, The electrode lead-out rod (6), the electrode lead-out pipe (5), the heat-conducting insulating inner layer (4), the heating body (3), the heat-conducting insulating outer layer (2) and the metal outer sleeve (1) are tightly fixed through a pipe shrinking and compression reducing process.

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