Extended heater

Abstract

An electric heating element utilization system for heating a pipe is disclosed, which includes an electrically resistive heating element configured to be connectable to a power source and a substantially rectangular carrier having a certain length. The carrier has a first row of slots transverse to its length (direction), a second row of slots transverse to its length and aligned laterally with the first row of slots, a third row of slots transverse to its length and positioned alternately along its length with respect to the slots of the first and second rows of slots, and a first row of fastening ends and a second row of fastening ends defined by the first and second rows of slots, respectively. Each of the first and second rows of fastening ends is configured to secure the carrier to a pipe. The length of the carrier is adjustable so that it can be mounted on a pipe.

Description

Technical Field

[0001] The present disclosure relates generally to heating elements, and particularly to electric heating elements for heating, for example, pipes and systems using electric heating elements.

[0002] Citation of Related Applications This application is a priority claiming application of U.S. Non-Provisional Patent Application No. 18 / 890,596 filed on September 19, 2024, which in turn is a priority claiming application of U.S. Provisional Patent Application No. 63 / 586,845 filed on September 29, 2023. All of these patent applications are incorporated by reference, and the entire contents of their descriptions are made part of this specification.

Background Art

[0003] Electric heating elements convert electrical energy into thermal energy. A heating element is an electric heating device of the type having an electric resistance wire that emits heat when an electric current is applied thereto. Known heating elements for heating pipes are spirally wound around the pipe from one end of the pipe to the other so as to provide heat to the pipe in the region where the heating element is mounted. However, the known heating elements are difficult to mount on pipes and pipe systems, are not easy to mount over, around, and on objects that are in the way, and moreover cannot heat the pipes uniformly over all of their surface regions. In addition, it is difficult to estimate what the length of various systems using spirally wound heating elements will be. This is because the user must take into account the diameter of the pipe as well as the number of turns per unit length of the heating element required to achieve the desired amount of heat to be applied to a pipe of a given length. Similarly, removing known heating elements from pipes and pipe systems is cumbersome and labor-intensive. This is because the user can only unwind the heating element one turn at a time, and this operation involves unwinding around obstacles.

Summary of the Invention

Problems to be Solved by the Invention

[0004] Thus, there is a need for improved heating element utilization systems that enable easy installation, easy removal, easy heat distribution, and easy estimation of the size and length required for a given application. [Means for solving the problem]

[0005] This specification discloses various embodiments of electric heating element utilization systems. In one embodiment, an electric heating element utilization system for heating a pipe includes an electrically resistive heating element, wherein first and second electrical conductors extend from opposite ends of the heating element, respectively, so as to be connectable to a power source, and the electric heating element utilization system further includes a lengthwise carrier. The carrier has (a) a first row of spaced-apart slots transversely to the length, (b) a second row of spaced-apart slots transversely to the length and aligned laterally with the first row of spaced-apart slots, and (c) a third row of spaced-apart slots transversely to the length and positioned alternately with the first and second rows of spaced-apart slots. A first row of separation slots defines a first row of spaced-apart fastening ends, and a second row of separation slots defines a second row of spaced-apart fastening ends located opposite to the first row of spaced-apart fastening ends. Each of the first and second rows of spaced-apart fastening ends is configured to wrap transversely around the outer circumference of the pipe, and each of the first and second rows of spaced-apart fastening ends has fastening portions that detachably attach their opposite fastening ends to each other to secure the carrier to the pipe. The heating element is attached to the carrier and meanders between the first, second, and third rows of separation slots from the first end to the second end of the carrier, and from the second end to the first end of the carrier. The first and second electrical conductors are located near the first end of the carrier. The first, second, and third rows of separation slots define a long, slanted region when the carrier is stretched along its length.

[0006] The electrically resistive heating element is preferably comprised of a self-regulating heating element utilization system. The carrier is preferably comprised of a heat-resistant fabric, cloth, film, or mesh. The fabric or film is preferably comprised of polytetrafluoroethylene (PTFE) coated glass fibers. The carrier is preferably comprised of a substantially rectangular planar form.

[0007] The first row of separation fastening ends is preferably configured to overlap with the second row of separation fastening ends when wrapped around the pipe. The carrier has a first unstretched length, and the carrier is stretchable up to a second stretched length. The maximum stretched length is preferably a function of the slot length. In some embodiments, the second stretched length of the carrier is preferably at least 80% longer than the first unstretched length. In other embodiments, the second stretched length of the carrier is preferably at least 80% longer than the first unstretched length. The stretched length of the carrier is preferably varied to an arbitrarily desired amount up to a predetermined maximum amount. The first row of separation slots is preferably extended lengthwise from the first outer edge of the carrier toward a longitudinal centerline that bisects the carrier. The second row of separation slots is preferably extended lengthwise from the second outer edge of the carrier toward a longitudinal centerline that bisects the carrier. The third row of separation slots is preferably arranged transversely to its length, extending from the center line that divides the carrier into two equal parts toward the first outer edge of the carrier and toward the second outer edge of the carrier.

[0008] Each fastening portion may have a snap-fastening engagement portion or a snap-fastening receiving portion. Other options include hook-and-loop fasteners, hook-and-lace fasteners, and bandage clips made of metal or heat-resistant polymer (e.g., PEEK or PTFE). The heating element may be attached to the carrier via stitching.

[0009] In another embodiment, the electric heating element utilization system for heating the pipe includes an electrically resistive heating element configured to be connectable to a power source and a carrier of lengthened polytetrafluoroethylene (PTFE) glass fibers. The carrier has (a) a first row of parallel slots in the transverse direction with respect to its length, (b) a second row of parallel slots in the transverse direction with respect to its length, where each of the slots in the second row is parallel to and laterally aligned with the parallel slots in the first row, (c) a third row of parallel slots in the transverse direction with respect to its length and alternately positioned with respect to the parallel slots in the first and second rows, and (d) fastening ends in a first row located along its length and fastening ends in a second row located along its length and opposite to the fastening ends in the first row, where the first and second fastening ends are defined by the first and second rows of slots, respectively, and each of the first and second rows of fastening ends is configured to fix the carrier to a pipe. The heating element is attached to the carrier in a meandering pattern around each of the slots belonging to the first, second, and third rows, from the first end of the carrier to the second end, and from the second end of the carrier to the first end. The length of the carrier is adjustable.

[0010] In various embodiments, the length of the carrier can be adjusted from the unstretched length to the fully stretched length. In various embodiments, the carrier can be stretched to any length between the unstretched length and the fully stretched length. In various embodiments, the maximum length of the carrier is preferably a function of the slot length.

[0011] The meandering pattern of the heating element is preferably repeated along the length of the carrier in a mirror image relationship with respect to the longitudinal centerline of the carrier. The carrier is preferably having a first non-stretched length, and is preferably stretchable up to a second stretched length. The carrier is preferably adjustable to any length from the first non-stretched length to the second stretched length. The maximum stretched length is preferably a function of the slot length. In various embodiments, the second stretched length of the carrier is preferably at least 80% longer than the first non-stretched length. The first row of parallel slots is preferably extending lengthwise from the first outer edge of the carrier toward the longitudinal centerline of the carrier. The second row of parallel slots is preferably extending lengthwise from the second outer edge of the carrier located opposite the first outer edge toward the longitudinal centerline. The third row of parallel slots is preferably extending transversely with respect to the length from the longitudinal centerline toward the first and second outer edges of the carrier.

[0012] In another embodiment, an electric heating element utilization system for heating a pipe includes an electrically resistive heating element configured to be connectable to a power source and a substantially rectangular carrier having a length. The carrier has (a) a first row of slots transversely to its length, (b) a second row of slots transversely to its length and laterally aligned with the first row of slots, (c) a third row of slots transversely to its length and alternately positioned with respect to the slots belonging to the first and second rows, and (d) a first row of fastening ends and a second row of fastening ends defined by the first row of slots and the second row of slots, respectively. Each of the first and second rows of fastening ends is configured to fasten the carrier to the pipe. The heating element is attached to the carrier and meanders around the first, second, and third rows of slots from the first end to the second end of the carrier and from the second end to the first end of the carrier. The carrier is variably adjustable to any desired length from a first unstretched length to a second stretched length.

[0013] Various embodiments of the present disclosure may include friction-inducing materials and / or mechanisms for minimizing or preventing movement of the heating element utilization system once it is mounted on a pipe to be heated. Such friction-inducing materials and / or mechanisms include silicone rubber, adhesives, and / or tapes that are applied to one or more surfaces of the carrier of the electric heating element utilization system. In various embodiments, the friction-inducing mechanisms may include a “friction square” consisting of a piece of silicone rubber fixed, for example, via fasteners or clips to the pipe-facing surface of the carrier. [Brief explanation of the drawing]

[0014] [Figure 1] This is a perspective view of one embodiment of the electric heating element utilization system of the present disclosure. [Figure 2] Figure 1 is a plan view of the electric heating element utilization system. [Figure 3] This is a plan view of a system utilizing multiple electric heating elements as described herein, in a typical manufacturing (secondary processing) stage. [Figure 4] This is a plan view of the numerous electric heating element utilization systems of this disclosure at another typical manufacturing stage. [Figure 5] This is a partial detailed plan view of the electrically heated element utilization system in this disclosure at another typical manufacturing stage. [Figure 6] This is a plan view of the electrically heated element utilization system of this disclosure at another typical stage of manufacturing. [Figure 7] This is a partial detail perspective view of one embodiment of the heating element of the present disclosure. [Figure 8] This is a partial detailed plan view of the electrically heated element utilization system of the present disclosure during the manufacturing stage. [Figure 9] This is a partial detailed plan view of the electrically heated element utilization system in this disclosure at a different stage of manufacturing. [Figure 10] This is a partial detailed plan view of the electrically heated element utilization system in this disclosure at a different stage of manufacturing. [Figure 11]This is a partial detailed plan view of the electric heating element utilization system of the present disclosure at another manufacturing stage. [Figure 12] This is a partial detailed plan view of the electric heating element utilization system of the present disclosure at another manufacturing stage. [Figure 13] This is a partial detailed plan view of another embodiment of the electric heating element utilization system of the present disclosure at a representative manufacturing stage. [Figure 14] This is a partial detailed perspective view of the electric heating element utilization system of Fig. 13 at another manufacturing stage. [Figure 15] This is a partial plan view of the electric heating element utilization system of the present disclosure in a partially articulated state prior to mounting to a pipe. [Figure 16] This is a perspective view of the electric heating element utilization system of the present disclosure before being mounted to a pipe. [Figure 17] This is a perspective view of the electric heating element utilization system of the present disclosure before being mounted to a pipe. [Figure 18] This is a partial detailed perspective view of the electric heating element utilization system of Fig. 16 and Fig. 17. [Figure 19] This is a partial detailed perspective view of the electric heating element utilization system of Fig. 16 and Fig. 17. [Figure 20] This is a partial detailed perspective view of the electric heating element utilization system of Fig. 16 and Fig. 17. [Figure 21] This is a partial detailed perspective view of the electric heating element utilization system of Fig. 16 and Fig. 17. [Figure 22] This is a partial detailed view of the electric heating element utilization system of the present disclosure mounted on a pipe and provided over and around an obstacle associated with the pipe. [Figure 23] This is a partial perspective view of the electric heating element utilization system of the present disclosure mounted to a pipe together with a heat insulating layer. [Figure 24] This is a screenshot view of the electric heating element utilization system of the present disclosure mounted on a pipe and in use. [Figure 25] This is a perspective view of another embodiment of the electric heating element utilization system of the present disclosure. [Figure 26]Figure 25 is a plan view of the electric heating element utilization system. [Figure 27] Figure 25 is a plan view of the electric heating element utilization system during a typical manufacturing stage. [Figure 28] This is a perspective view of another embodiment of the electric heating element utilization system of the present disclosure. [Figure 29] Figure 28 is a plan view of the electric heating element utilization system. [Figure 30] Figure 28 is a plan view of the electric heating element utilization system during a typical manufacturing stage. [Figure 31] This is a perspective view of another embodiment of the electric heating element utilization system of the present disclosure. [Figure 32] Figure 31 is a plan view of the electric heating element utilization system. [Figure 33] Figure 31 is a plan view of the electric heating element utilization system during a typical manufacturing stage. [Figure 34] This is a perspective view of another embodiment of the electric heating element utilization system of the present disclosure. [Figure 35] Figure 34 is a plan view of the electric heating element utilization system. [Figure 36] Figure 34 is a plan view of the electric heating element utilization system during a typical manufacturing stage. [Figure 37A] This is a perspective view of another embodiment of the electric heating element utilization system of the present disclosure. [Figure 37B] Figure 37A is another perspective view of the embodiment of the electric heating element utilization system. [Figure 38] Figure 37A is a detailed cross-sectional view of a portion of the electric heating element utilization system. [Figure 39] This figure lists at least some forms of electric heating elements suitable for applications in accordance with the teachings of this disclosure. [Figure 40] This graph shows experimental data for an exemplary electric heating element system of the present disclosure, reflecting a simplified method for predicting the maximum elongation length of the electric heating element system as a function of pipe diameter. [Modes for carrying out the invention]

[0015] While the drawings and this disclosure describe one or more embodiments of an electric heating element utilization system, the teachings of this disclosure are not limited to these embodiments, as will be understood by those skilled in the art. It should be understood that any feature of the embodiments described with respect to the drawings of this application may be combined with or used in place of features described in relation to other embodiments of this disclosure.

[0016] This specification discloses various embodiments of electric heating element utilization systems for heating pipes. The electric heating element utilization systems of this disclosure enable easy and labor-free installation on pipes located, for example, inside or outside commercial / industrial buildings. Such pipes may include bends or obstacles, such as unistrats, hangers, T-offs, and pipe flanges, and the heating element utilization systems of this disclosure can be easily installed over such bends or obstacles. Specifically, various embodiments of the heating element utilization systems disclosed herein enable installation on pipes of a certain length without the need to spirally wrap the heating element around the pipe, and without the need to calculate the spiral length of a coiled heating element to heat a desired length of pipe. In contrast, the heating element utilization system as an embodiment of the present disclosure can be unfolded (opened from a rolled-up state), or if already unfolded, can be easily placed longitudinally on a pipe, then wrapped around the pipe circumferentially, and snapped or fastened to itself or to anchors placed at several points along the pipe, thereby surrounding a desired pipe circumference and desired length of the pipe with a heating element (a heating element of a given wattage per foot in length) sufficient to provide a desired amount of heat to the surrounding surface area of ​​the pipe.

[0017] The mounting length of the electric heating element utilization system of this disclosure to a given pipe is customizable by the user during mounting, as it features the ability to linearly expand and contract the heating element utilization system. In other words, the length of the electric heating element utilization system of this disclosure is variable to any desired amount. For example, to extend and / or mount it over a certain length of pipe, various embodiments of the heating element utilization system of this disclosure allow for linear expansion and / or linear stretching of the heating element utilization system to extend by up to 80% or more beyond its pre-extended length.

[0018] Multiple units of the heating element utilization system of this disclosure can be continuously positioned on the pipe to be heated over a long pipe length. In this way, the user can align multiple units of the heating element utilization system to extend the desired overall straight length of the pipe, while truncating any fractions to the nearest multiple of the pre-stretched heating element utilization system length.

[0019] In addition to substantially improving the ease with which a user can estimate the length of a heating element of a given wattage per foot required to heat a pipe of a given length, and the ease with which a heating element utilization system can be mounted on the pipe, various embodiments of the heating element utilization system of the present disclosure can substantially improve the heat distribution along and around the pipe in order to minimize and / or eliminate unacceptably cold or relatively cold spots, sections, or areas on the pipe. To this end, a heating element utilization system as an embodiment of the present disclosure may have heating elements arranged in a meandering manner on a two-dimensional heat-resistant carrier. The two-dimensional carrier may be flexible enough to wrap around the perimeter of the pipe. The heating element utilization system is stretched longitudinally along the pipe to a desired elongation length, and then the heating element utilization system is wrapped around the pipe circumferentially. The meandering arrangement of the heating element on the carrier is such that the heating element extends meanderingly along the length of the pipe, thereby covering the outer surface of the pipe with a three-dimensional meandering pattern that defines three-dimensional quadrilateral and / or rhombic regions that are indirectly heated along the length of the pipe. The user can customize the size of such three-dimensional quadrilateral and / or rhombic regions, and thus the area of ​​the pipe surface directly exposed to heat from the heating element, by adjusting the degree of elongation of the heating element utilization system from its original un-elongated length. In other words, the greater the linear elongation of the heating element utilization system on the pipe, the larger the area defined by the three-dimensional quadrilateral and / or rhombic regions, and vice versa. In some embodiments, the three-dimensional quadrilateral and / or rhombic regions include oblique rectangles. Similarly, as the linear extension of the heating element utilization system increases along the pipe, the degree to which meandering paths or turns become acute decreases, thereby reducing the surface area of ​​the pipe directly exposed to heat from the heating element, and the reverse relationship holds true.However, the ability to customize the extension length of the heating element utilization system of this disclosure as needed offers the advantage of improving heat distribution without requiring any further modifications for different sizes or heat outputs, while using a single dimension and operating mode of the heating element (i.e., watts per foot, i.e., per unit length) and a single dimension and operating mode of the carrier (length × width) for a wide range of pipe diameters and lengths, thereby minimizing the amount of various size and heat output combinations that can be held.

[0020] To further enhance pipe heating performance, the heat-generating system of this disclosure may include an insulating blanket that can be mounted on and around the heat-generating system. The insulating blanket may be configured to contain the heat emitted from the heat-generating element in the intermediate zone of the pipe and to reduce heat loss to the environment. The insulating blanket can further assist the functioning of the heat-generating system by transferring the heat emitted from the heat-generating element to three-dimensional quadrilateral and / or rhombic regions to heat these regions of the pipe.

[0021] During use, when an electric current is passed through the heating element, the meandering heating element releases thermal energy due to the electrical resistance and material properties of the resistance wires provided within it. This thermal energy is transferred to various parts of the pipe's outer wall by conduction, radiation, and convection. The areas of the pipe in direct contact with the heating element / carrier are initially exposed to the highest effective temperature released by the heating element in the heating element utilization system, while the open areas defined by the three-dimensional meandering portion of the heating element receive heat transferred from the heating element to these areas.

[0022] Now, referring to the drawings, and in particular to Figures 1 and 2, a portion of one embodiment of an electric heating element utilization system 100 for heating a pipe is shown. Figure 1 shows the system 100 in a perspective view, and Figure 2 shows the system 100 in a plan view. The system 100 includes a heating element 10 fixed to a carrier or support 20 and an end portion 5 for connecting the heating element 10 to a power unit by a pair of lead wires 65, 67. As shown in Figure 23, an insulating blanket 96 is preferably provided on the heating element utilization system 100 and the pipe 99 and around them in the circumferential direction, and the heating element utilization system 100 is mounted on the pipe 99 to help distribute heat to the surface of the pipe 99. The heating element 10 is arranged on the carrier 20 in a meandering pattern, in which case each part 1,2 of the heating element 10 is located in close proximity to each other, forming a pair of meandering columns positioned above and below each other, as shown in Figure 2, for example, and is positioned in a continuous loop such that both conductive ends 62,64 of the heating element 10 are located at or near the end 5. In this embodiment, as shown in Figure 6, each meandering path or turn 3a,3b of part 1 of the heating element 10 is symmetrical with each meandering path 2 or turn 4a,4b of part 2 of the heating element 10 with respect to an imaginary centerline that bisects the carrier 20 in the longitudinal direction. The heating element 10 is preferably fixed to the carrier 20 via stitches 12, so that the amount of movement of the heating element 10 relative to the carrier 20 can be calculated to enable flexibility and articulated movement of the heating element utilization system 100 and facilitate attachment to the pipe. In other embodiments, the heating element 10 can be fixed to the carrier 20 using clamps, cable ties, clips with hooks, ring and belt assemblies, belt and buckle assemblies, lace and speed hook assemblies (typically seen in use on boots), or any other suitable fastening means, spaced apart from each other.

[0023] As best shown in Figure 6, the carrier 20 has a plurality of spaced-apart transverse slots 80a, 80b. Slot 80a begins at the longitudinal outer edge of the carrier 20 and extends perpendicularly toward the centerline (when the carrier 20 is oriented as shown in Figure 6). Slot 80b begins at the outer outer edge of the carrier 20 and extends perpendicularly toward the centerline and in a line laterally aligned with each lateral position of slot 80a (when the carrier 20 is oriented as shown in Figure 6). Thus, in this embodiment, slots 80a and 80b are oriented symmetrically with respect to an imaginary longitudinal centerline of the carrier 20. The positions and transverse lengths of slots 80a, 80b define a plurality of fastening ends 50a, 50b and end tabs 52a, 52b of the carrier 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. In addition, in some embodiments, slot 80a may be offset from slot 80b. In such embodiments, the meandering pattern of the heating element 10 may differ from the illustrated pattern, without departing from the scope of this disclosure.

[0024] The carrier 20 further has a plurality of transverse slots 82 spaced apart from each other and from the slots 80a and 80b. The slots 82 are positioned between the slots 80a and 80b, and the transverse spacing between the slots 80a, 80b and the slots 82 is substantially the same. The slots 82 straddle the imaginary longitudinal centerline of the carrier 20 and extend in opposite directions from each other, i.e., both upward and downward from the centerline (as seen in Figure 6). The heating element 10 is configured to be positioned on the carrier 20 by routing the heating element 10 and fixing it to the carrier 20 in a meandering manner around each of the slots 80a, 80b, and 82. It should be understood that the vertical length of the slots 82 may be longer or shorter than this, and this does not deviate from the scope of the present disclosure. As described and illustrated in more detail below, the slots 80a, 80b, and 82 are preferably sized and positioned so that the carrier 20 can be stretched longitudinally over the length of the pipe 99 from a first non-stretched length to a second stretched length, and so as to cover obstacles associated with the pipe 99 and allow for easy navigation around them without impairing the heat distribution to the pipe 99.

[0025] As best shown in Figure 6, the carrier 20 has a plurality of fastening portions 56, 58. Each of the fastening portions 56, 58 is positioned at the respective fastening holes 60a, 60b provided in the respective fastening ends 50a, 50b and end tabs 52a, 52b of the carrier 20. Each fastening portion 58 is preferably configured to receive each fastening portion 56 fixedly, but removablely. The fastening portion 58 is preferably configured to have a receiving portion that receives each engaging portion of the fastening portion 56. In other embodiments, the fastening portion 56 is preferably configured to have a receiving portion that receives each engaging portion of the fastening portion 58. In one embodiment, the fastening portions 56, 58 have snap fasteners made of durable heat-resistant plastic or metal material for easily and fixedly, but removablely mounting the heating element utilization system 100 on and around the pipe 99. In other embodiments, the heating element utilization system 100 may be equipped with various fastening systems, such as hook-and-loop fasteners, spring clips, high-strength magnets (e.g., rare-earth element type), or any other general fastening systems suitable for high-temperature environments in accordance with the present disclosure.

[0026] The carrier 20 is preferably at least partially or entirely flexible to allow for easy positioning and fastening of the heating element utilization system 100 onto the pipe 99. In various embodiments, the carrier 20 is made of a heat-resistant material, such as PTFE-coated fiberglass cloth or fabric, ePTFE cloth or fabric, PTFE laminate film, 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 thin films include heat-resistant nonelastic polymer sheets with a thickness of less than 1 / 16 inch (1.5875 mm). In one embodiment, the carrier 20 is configured to be mounted on a pipe with a diameter of 1.5 inches (3.81 cm). In another embodiment, the carrier 20 is preferably sized and / or configured to be mounted on any pipe 99 with an outer diameter of 0.25 inches (0.63 cm) to 15 inches (40.64 cm). For example, the height 45 of the carrier 20 may be configured to allow vertical positioning of each fastening portion 56 relative to the corresponding fastening portion 58 such that it is approximately equal to the outer circumference length of the pipe 99 on which the heating element utilization system 100 can be mounted. Similarly, the length 48 of the carrier 20 may be configured to be approximately 47 inches (119.38 cm) in its unextended length and approximately 84 inches (213.36 cm) in its fully extended length. In other embodiments, the length 48 of the carrier 20 may be any desired length. Large diameter pipes may require relatively long heating elements 10 to prevent or minimize the watt density from dropping below a desired level.

[0027] Referring to Figure 7, a typical heating element 10 used in the heating element utilization system 100 of this disclosure is shown. In some embodiments, the heating element 10 may include a self-regulating heating element of this type, which may have a resistance wire 14, a sleeve 15, insulation layers 16, 17, and a ground (earth) layer 18. In this embodiment, the resistance wire 14 consists of multiple strands 14a of 37 gauge (approximately 0.0045 inch (0.1143 mm) diameter) made of nickel-copper alloy, with each strand configured to be oriented at 8.88 ohms ± 8% per foot. In this embodiment, the sleeve 15 consists of Kapton layers 16, 17, both made of glass fiber, and the ground layer 18 consists of a 36 gauge braid of tin-plated copper material. In this embodiment, the heating element 10 is 104 feet (31.70 m) long and 0.0625 inches (1.5875 mm) in diameter, and is rated at 120 VAC and 1.34 watts per foot, with a total output of 139.8 watts for that length. The heating element 10 in this configuration is preferably set to 180°C to transfer heat to the pipe 99 on which the heating element utilization system 100 is wrapped. Heating elements in this configuration are available from BriskHeat Corporation in Columbus, Ohio. Other embodiments of the heating element utilization system 100 may include any heating element in a suitable configuration without departing from the scope of this disclosure. For example, another configuration of the heating element 10 suitable for use in the heating element utilization system 100 of this disclosure may include a single solid-core resistance wire 14 instead of the numerous strands shown in Figure 7. Similarly, the heating element 10 may include various insulating layers, such as layers made of TFE, PTFE, ePTFE, and stainless steel wires.

[0028] Referring to Figures 8 to 14, various stages and embodiments of coupling the conductor ends 62, 64 of the heating element 10 to a power source are shown. As described above, the heating element 10 is fixed to the carrier 20 and is a continuous element routed around slots 80a, 80b, 82, respectively, with both conductor ends 62, 64 joined to each other at or near the end 5 of the heating element utilization system 100. The carrier 20 has tabs 7, 8 and flaps 9 that house and / or surround the conductor joints 72, 74 of the heating element 10. The conductor joints 72, 74 surround the electrical conductor connection between the lead wires 65, 67 and the conductor ends 62, 64 of the heating element 10. As shown in Figures 9 and 10, the conductor joints 72, 74 may be sewn to the carrier 20 by stitches 76a, 76b or otherwise secured. The lead wires 65 and 67 that exit the conductor joint are preferably housed in a sleeve 69 to provide abrasion resistance and heat resistance.

[0029] Figures 11 and 12 show tab 7 after it has been folded along crease 30 to align with tab 8, and after the flap 9 has been folded along crease 32 to enclose the conductor joints 72, 74. Stitches 42a and 42b are preferably configured to secure tab 7 to tab 8, secure flap 9 to tab 7, and enclose the conductor joints 72, 74. Figures 13 and 14 show one embodiment of the heating element 10 including a ground wire 84. In this embodiment, the 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 by a crimp connector 90, while the conductor end 62 of the heating element 10 is connected to the lead wire 65 by a crimp connector 88.

[0030] Referring to Figure 15, a partially stretched and / or articulated heating element utilization system 100 of the present disclosure is shown. Figure 15 shows how the slots 80a, 80b, 82 cooperate to configure the carrier 20 with alternately spaced elongated holes 92, alternately spaced webbings 94, and alternately spaced elongated holes 93a, 93b when the heating element utilization system 100 is at least partially stretched in the longitudinal direction. Figure 15 also shows how the heating element 10 may be routed in a meandering arrangement around the slots 80a, 80b, 82 in two adjacent rows that are mirror images of each other with respect to the longitudinal centerline of the carrier 20. Figure 15 further shows the flexibility of the carrier 20 and the potential ease with which the fastening ends 50a, 50b can be routed around the perimeter of the pipe 99 and joined to each other.

[0031] Figures 16 to 23 show various views of the heating element utilization system 100 mounted on an exemplary pipe 99. As shown in these figures, the heating element utilization system 100 is extended in an accordion-like manner along the length of the pipe 99 to a desired extent, while the fastening ends 50a, 50b and tabs 52a, 52b of the carrier 20 are joined together by wrapping around the pipe 99 and fastening to each other using fastening portions 56, 58. Although the effective wattage per foot of a given heating element 10 is fixed, the user can still customize the amount of heat applied to the pipe 99 and the heat distribution between adjacent turns of the heating element 10 on the carrier 20 by extending or retracting the heating element 10 along the length of the pipe 99. Figure 22 shows how various embodiments of the heating element utilization system 100 of this disclosure are adjustable to extend on and around an obstacle 70. Figure 23 shows one embodiment of a heat-generating system 100 (optionally equipped with a thermocouple) having an insulating blanket 96 positioned on and around the pipe 99 to further aid in heat distribution to the pipe 99 and minimize heat loss. The insulating blanket 96 is preferably secured to itself and around the pipe 99 using fasteners or clips 97, the fasteners 97 of which may consist of, for example, hook-and-loop fasteners or any other fastening system.

[0032] Figure 24 is a screenshot of the temperature distribution captured by a thermal imaging camera over an exemplary heating element utilization system 100 and a region of a pipe 99 located adjacent to the heating element utilization system 100 during use. The insulating blanket 96 covers and surrounds the pipe 99, but is partially peeled off from the bottom, sides, and upper left portion of the horizontal pipe 99 to allow the camera to capture this image. This image shows that the highest temperature is located in the center of the heating element 10, with the next highest temperature in zone 98 located along the upper right of the image, adjacent to the insulating blanket 96. In contrast, the lowest temperature is located in zone 95, mainly along the bottom of the pipe 99 and between each path or turn of the heating element 10. The empirical temperature measurement results suggest that the temperature distribution along the length of the pipe 99 and around the entire perimeter of the pipe 99 is more uniform along the surface of the pipe 99 when the insulating blanket 96 covers and surrounds the pipe 99.

[0033] Figures 25 to 38 show modified embodiments of the electric heating element utilization system of the present disclosure. For example, Figures 25 to 28 show an electric heating element utilization system 200 including a parallel-wire electric heating element 210 modified for use in accordance with the teachings of the present disclosure. By using the parallel-wire electric heating element 210, it may be possible to achieve a low electrical resistance range and high wattage without increasing electrical safety risks. The system 200 includes a heating element 210 fixed to a carrier 20 and an end portion 205 for connecting the heating element 210 to a power unit via a pair of lead wires 65, 67. As shown in Figure 23, an insulating blanket 96 is often provided on the heating element utilization system 200 and the pipe 99 and around them circumferentially, and the heating element utilization system 200 is mounted on the pipe 99 to help distribute heat to the surface of the pipe 99. The heating element 210 is arranged on the carrier 20 in a meandering pattern, in which case each portion 1,2 of the heating element 210 is located in close proximity to each other, forming a pair of meandering columns positioned above and below each other, as shown in Figure 27, and is positioned in a continuous loop such that both conductive ends 262,264 of the heating element 210 are located at or near the end portion 5. In this embodiment, as shown in Figure 27, each meandering path or turn 3a,3b of portion 1 of the heating element 210 is symmetrical with each meandering path 2 or turn 4a,4b of portion 2 of the heating element 210 with respect to an imaginary centerline that bisects the carrier 20 in the longitudinal direction. The heating element 210 is preferably fixed to the carrier 20 via stitches 12, so that the amount of movement of the heating element 210 relative to the carrier 20 can be calculated to enable flexibility and articulated movement of the heating element utilization system 200 and facilitate mounting to the pipe. In other embodiments, the heating element 210 can be fixed to the carrier 20 using clamps, staples, cable ties, clips with hooks, ring and belt assemblies, belt and buckle assemblies, lace and speed hook assemblies (typically seen in use on boots), or any other suitable fastening means, spaced apart from each other.

[0034] Figures 29 and 30 show an electric heating element utilization system 300 including an electric heating element 310 modified for use in accordance with the teachings of this disclosure. In this embodiment, the conductor ends 362a, 364a and conductor ends 362b, 364b are located on opposite ends 305a, 305b to allow multiple electric heating element utilization systems of this disclosure to be connected in series. The system 300 includes a heating element 310 fixed to a carrier 20 and ends 305a, 305b for connecting the heating element 310 to a power unit via a pair of lead wires 65, 67. As shown in Figure 23, an insulating blanket 96 is preferably provided on the heating element utilization system 300 and the pipe 99 and around them circumferentially, and the heating element utilization system 300 is mounted on the pipe 99 to help distribute heat to the surface of the pipe 99. The heating element 310 is arranged on the carrier 20 in a meandering pattern, in which case each part 1,2 of the heating element 310 is located in close proximity to each other and is positioned as a pair of meandering columns located above and below each other, as shown in Figure 30. In this embodiment, as shown in Figure 30, each meandering path or turn 3a,3b of part 1 of the heating element 310 is symmetrical with each meandering path 2 or turn 4a,4b of part 2 of the heating element 310 with respect to an imaginary centerline that bisects the carrier 20 in the longitudinal direction. The heating element 310 is preferably fixed to the carrier 20 via stitches 12, so that the amount of movement of the heating element 310 relative to the carrier 20 can be calculated to enable flexibility and articulated movement of the heating element utilization system 300 and facilitate mounting to a pipe. In other embodiments, the heating element 310 can be fixed to the carrier 20 using clamps, staples, cable ties, clips with hooks, ring and belt assemblies, belt and buckle assemblies, lace and speed hook assemblies (typically seen in use on boots), or any other suitable fastening means, spaced apart from each other.

[0035] Figures 31 to 33 show an electric heating element utilization system 400 including a heated ribbon type or heat trace-type electric heating element 410 modified for use in accordance with the teachings of this disclosure. The system 400 includes the heating element 410 fixed to a carrier 20 and an end portion 405 for connecting the heating element 410 to a power unit via a pair of lead wires 65, 67. As shown in Figure 23, an insulating blanket 96 is preferably provided on the heating element utilization system 400 and the pipe 99 and around them circumferentially, and the heating element utilization system 400 is mounted on the pipe 99 to help distribute heat to the surface of the pipe 99. The heating element 410 is arranged on the carrier 20 in a meandering pattern, in which case each portion 1, 2 of the heating element 410 is located in close proximity to each other, forming a pair of meandering columns positioned above and below each other, as shown in Figure 33, for example, and is positioned in a continuous loop such that both conductive ends 462, 464 of the heating element 410 are located at or near the end portion 405. In this embodiment, as shown in Figure 33, each meandering path or turn 3a, 3b of portion 1 of the heating element 410 is symmetrical with each meandering path 2 or turn 4a, 4b of portion 2 of the heating element 410 with respect to an imaginary centerline that bisects the carrier 20 in the longitudinal direction. If the heating element 410 is a heated ribbon type electric heating element, the heating element 410 may be fixed to the carrier 20 by stitches 12 (so that the amount of movement of the heating element 410 relative to the carrier 20 can be taken into account to enable flexibility and articulation of the heating element utilization system 400 and to facilitate attachment to the pipe), or it may be laminated or attached to the carrier 20 in a different way. If the heating element 410 is a heat trace type heating element, such a heat trace type heating element may be screen printed, deposited, or digitally printed on the carrier 20.

[0036] Figures 34 to 36 show an electric heating element utilization system 500 including a self-regulating electric heating element 510 modified for use in accordance with the teachings of this disclosure. The system 500 includes the heating element 510 fixed to a carrier 20 and an end portion 505 connecting the heating element 510 to a power unit by a pair of lead wires 65, 67. As shown in Figure 23, an insulating blanket 96 is preferably provided on the heating element utilization system 500 and the pipe 99 and around them circumferentially, and the heating element utilization system 500 is mounted on the pipe 99 to help distribute heat to the surface of the pipe 99. The heating element 510 is arranged on the carrier 20 in a meandering pattern, in which case each portion 1, 2 of the heating element 510 is located in close proximity to one another, forming a pair of meandering rows located above and below each other, as shown in Figure 36, and positioned in a continuous loop such that both conductor ends 562, 564 of the heating element 510 are located at or near the end portion 505. In this embodiment, as shown in Figure 36, each meandering path or turn 3a,3b of part 1 of the heating element 510 is symmetrical with each meandering path 2 or turn 4a,4b of part 2 of the heating element 510 with respect to an imaginary centerline that bisects the carrier 20 in the longitudinal direction. The heating element 510 is preferably fixed to the carrier 20 via stitches 12, so that the amount of movement of the heating element 510 relative to the carrier 20 can be taken into account to enable the flexibility and articulated movement of the heating element utilization system 500 and to facilitate attachment to the pipe. In other embodiments, the heating element 510 can be fixed to the carrier 20 using clamps, staples, cable ties, clips with hooks, ring and belt assemblies, belt and buckle assemblies, lace and speed hook assemblies (typically seen in use on boots), or any other suitable fastening means, spaced apart from each other.

[0037] Figures 37A, 37B, and 38 show an electric heating element utilization system 600 including a heating element 10 fixed to a carrier 20 similar to the carrier 20 shown in Figures 1 and 2. In this embodiment, a friction square or square friction section 52 is provided to prevent or at least restrain the carrier 20 from sliding or moving on the pipe to which the system 600 is mounted, in order to help the carrier 20 remain stretched along the pipe to a desired length. As shown in Figure 37B, the friction square 52 is positioned on a selected fastening end 50a and end tab 52a of the carrier 20. In other embodiments, the friction square 52 may be positioned on more or fewer fastening ends 50a and end tab 52a. As shown in Figures 37B and 38, the friction square 52 is preferably approximately the same width as the fastening ends 50a and end tab 52a to which it is fixed. The friction square 52 may be of any suitable thickness, and in some embodiments, it may be approximately the same thickness as the carrier 20. The friction square 52 may be made of any suitable friction-inducing material, such as silicone rubber, adhesive, or tape. The friction square 52 may be fastened by the fastening portion 56 to a selected fastening end 50a and end tab 52a of the carrier 20. As will be recognized by those skilled in the art, the friction square 52 may be provided in any of the electric heating element utilization systems of this disclosure.

[0038] Figure 39 shows a non-exhaustive list of different types of electric heating elements suitable for use in the teachings of this disclosure. Those skilled in the art can modify different types of electric heating elements in accordance with the teachings of this disclosure.

[0039] The following is a mathematical expression for predicting the maximum linear extension or maximum expansion rate of the heating element utilization system of this disclosure along a pipe:

number

[0040] In the above formula, “slot length” is the vertical length of each slot (assuming each slot has approximately the same length), “maximum expansion angle” is the acute angle between the centerlines of each “rib” measured from the longitudinal axis of the pipe (assuming to be constant based on the flexibility of the material of the carrier 20), and “rib width” is the transverse length of each “rib,” which is defined as the transverse spacing between adjacent slots. Regarding basic terminology, “slot length” is the hypotenuse of a right triangle containing the longitudinal axis of the pipe, the longitudinal axis is the adjacent side of the right triangle (the side adjacent to the right angle) (the length of this side is defined as “rib width”), and the acute angle between the hypotenuse and the longitudinal adjacent side is the “maximum expansion angle”.

[0041] Using experimental measurement results and data points, a simplified equation for estimating the maximum expansion rate based on the internal diameter of the heating element (i.e., the outer diameter of the pipe) as an independent variable can be expressed as follows: JPEG2026533902000003.jpg6150

[0042] Figure 40 provides examples of the maximum predicted expansion rate of the heat-generating system of this disclosure for various pipe diameters. Using the above equation, the maximum expansion rate can be predicted for any given pipe diameter. TIFF2026533902000004.tif45153

[0043] Thus, for example, with respect to a pipe with a diameter of 1.5 inches (3.81 cm), the electric heating element of the present disclosure is expected to stretch to at least approximately 1.7 times the original unstretched length of the carrier. Similarly, for example, with a pipe diameter of 6 inches (15.24 cm), the heating element utilization system of the present disclosure is expected to stretch to at least approximately 4.7 times the original unstretched length of the carrier.

[0044] Referring to Figures 3 to 5, various steps of a method for manufacturing an embodiment of the heating element utilization system 100 of the present disclosure are shown. For example, in the embodiment shown in Figure 3, a Tajima sewing machine can be used to sew the heating element 10 to the carrier 20 using stitches 12, in which case multiple units of the heating element 10 are positioned on multiple units of the carrier 20, and then multiple units of the carrier 20 are cut or separated from larger carrier units. As shown in the embodiment of Figure 4, each unit of the carrier 20 is marked at (i) position 23 for determining the future positions of fastening portions 56, 58, (ii) position 25 for determining the future positions of slots 80a, 80b, 82, and (iii) position 27 for determining future cutting lines for separating larger units into multiple separate carriers 20. The process of marking position 25 continues until the carrier 20 is fully marked. In the next step, the large carrier is manually or mechanically cut into separate units of carrier 20, each having its own slots 80a, 80b, 82, fastening holes 60a, 60b, and tabs 7, 8, 9 for the end portions 5. In other embodiments, instead of marking and cutting the carrier 20, the steps of stacking the large units of carrier on a laser cutting table, programming the laser cutter to cut the carrier 20 according to coordinates programmed in the software, and cutting the carrier 20 accordingly can be used. In the next step, it is preferable to insert the fastening portions 56, 58 at their respective positions 23 on the carrier 20. In the next step, it is preferable to connect a pair of lead wires 65, 67 and optionally a ground wire 84 onto their respective conductor ends 62, 64 and then crimp them to form conductor joints 72, 74 (see Figures 8 to 14). As shown in the embodiment of Figure 10, in the next step, the conductor joint is fixed to the carrier 20 with stitches 76a and 76b, and the sleeve 69 is assembled on and covering the lead wires 65 and 67. In the next step, the tabs 7, 8, and 9 are folded along the folds 30 and 32, and the tabs 7, 8, and 9 are assembled using stitches 42a and 42b as shown in the embodiments of Figures 11 and 12.

[0045] While specific embodiments have been described in detail, various modifications and variations of these details can be made in light of the teachings of this disclosure, as will be apparent to those skilled in the art. Therefore, the disclosures herein are illustrative and not intended to limit the scope of the disclosure, and the disclosure should be given the full scope of the invention as set forth in the appended claims and any equivalents thereof.

Claims

1. An electric heating element system for heating pipes, It includes an electrically resistive heating element, with first and second electrical conductors extending from opposite ends of the heating element, respectively, so as to be connectable to a power source. The carrier includes a carrier having a length, A first row of spaced slots in the transverse direction relative to the aforementioned length, A transverse direction with respect to the aforementioned length, and a second row of spaced-apart slots that are aligned laterally with the first row of spaced-apart slots, and It has a third row of spaced-apart slots that are positioned alternately with the first and second rows of spaced-apart slots, and are in a transverse direction with respect to the aforementioned length. The first row of spacing slots defines a first row of spaced-apart fastening ends, and the second row of spacing slots defines a second row of spaced-apart fastening ends located opposite to the first row of spaced-apart fastening ends, and each of the first and second rows of spaced-apart fastening ends is configured to wrap transversely around the outer circumference of the pipe and also has fastening portions that detachably attach their opposite fastening ends to each other in order to fix the carrier to the pipe. The heating element is attached to the carrier and meanders between the first, second, and third rows of separation slots from the first end to the second end of the carrier, and from the second end to the first end of the carrier, and the first and second electrical conductors are located near the first end of the carrier. An electric heating element utilization system wherein the first, second, and third rows of separation slots define an oblong region when the carrier is stretched along the length.

2. The electrical heating element utilization system according to claim 1, wherein the electrical resistive heating element comprises a self-regulating heating element utilization system.

3. The electric heating element utilization system according to claim 1, wherein the carrier is made of a heat-resistant fabric, cloth, film, or mesh.

4. The electric heating element utilization system according to claim 3, wherein the fabric or cloth is made of polytetrafluoroethylene (PTFE) coated glass fiber.

5. The electric heating element utilization system according to claim 1, wherein the carrier has a planar shape that is substantially rectangular.

6. The electric heating element utilization system according to claim 1, wherein the first row of spaced fastening ends is configured to overlap with the second row of spaced fastening ends when wrapped around the pipe.

7. The electric heating element utilization system according to claim 1, wherein the carrier has a first non-stretched length and the carrier is stretchable up to a second stretched length.

8. The electric heating element utilization system according to claim 7, wherein the second elongated length is at least 80% longer than the first non-elongated length.

9. The electric heating element utilization system according to claim 1, wherein the first separation slot row extends from the first outer edge of the carrier along the length toward a longitudinal center line that bisects the carrier.

10. The electric heating element utilization system according to claim 1, wherein the second row of separation slots extends from the second outer edge of the carrier along the length toward a longitudinal centerline that bisects the carrier.

11. The electric heating element utilization system according to claim 1, wherein the third spacing slot row extends transversely with respect to the length from a center line dividing the carrier into two equal parts toward the first outer edge of the carrier and toward the second outer edge of the carrier.

12. The electric heating element utilization system according to claim 1, wherein each of the fastening portions has a snap fastening engagement portion or a snap fastening receiving portion.

13. The electric heating element utilization system according to claim 1, wherein the heating element is attached to the carrier via a stitch.

14. An electric heating element system for heating pipes, An electrically resistive heating element configured to be connectable to a power supply, It comprises a carrier of polytetrafluoroethylene (PTFE) glass fibers having length, the carrier being It has a first row of parallel slots in the transverse direction with respect to the aforementioned length, With respect to the aforementioned length, it has a second row of parallel slots in the transverse direction, and each of the slots belonging to the second row is parallel to the parallel slots forming the first row and is aligned laterally with the slots. It has parallel slots forming a third row that is transverse to the aforementioned length and alternately positioned with respect to the parallel slots belonging to the first and second rows, and has fastening ends forming a first row located along the aforementioned length and fastening ends forming a second row located along the aforementioned length and on the opposite side from the fastening ends forming the first row, the first and second fastening ends being defined by the slots forming the first and second rows, and each of the first and second rows of fastening ends being configured to fix the carrier to the pipe, The heating element is attached to the carrier in a meandering pattern from the first end to the second end of the carrier, and from the second end to the first end of the carrier, around each of the slots belonging to the first, second, and third rows. The aforementioned carrier is an electrically heated element utilization system in which the length can be adjusted from a first non-stretched length to a second stretched length.

15. The electric heating element utilization system according to claim 14, wherein the meandering pattern of the heating element is repeated along the length of the carrier in a mirror image relationship with respect to the longitudinal center line of the carrier.

16. The electric heating element utilization system according to claim 14, wherein the carrier has a first non-stretched length and the carrier is stretchable up to a second stretched length.

17. The electric heating element utilization system according to claim 16, wherein the carrier is adjustable to any length from a first non-stretched length to a second stretched length.

18. The electric heating element utilization system according to claim 16, wherein the second elongated length is at least 80% longer than the first non-elongated length.

19. The electric heating element utilization system according to claim 14, wherein the first row of parallel slots extends from the first outer edge of the carrier toward the longitudinal centerline of the carrier along the length, the second row of parallel slots extends from the second outer edge of the carrier located opposite to the first outer edge toward the longitudinal centerline along the length, and the third row of parallel slots extends transversely with respect to the length toward the first and second outer edges of the carrier from the longitudinal centerline.

20. An electric heating element system for heating pipes, An electrically resistive heating element configured to be connectable to a power supply, A substantially rectangular carrier having a length, the carrier is A first row of slots in the transverse direction relative to the aforementioned length, A second row of slots is aligned laterally with the first row of slots, which is in the transverse direction with respect to the aforementioned length. Slots forming a third row that is transverse to the aforementioned length and is positioned alternately with respect to the slots belonging to the first and second rows, and It has a first row of fastening ends and a second row of fastening ends defined by the first row of slots and the second row of slots, respectively, and each of the first and second rows of fastening ends is configured to fix the carrier to the pipe, The heating element is attached to the carrier and meanders around the first, second, and third rows of slots from the first end to the second end of the carrier, and from the second end to the first end of the carrier. The aforementioned carrier is an electrically heated element utilization system in which the length can be adjusted from a first non-stretched length to a second stretched length.

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