Angled Resistance Heating Bands to Prevent Furnace Hot Spots
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Solution Overview
Problem
Conventional electric heating elements in furnaces experience temperature differences of up to 200°C and hot spots due to the arrangement of electric resistance heating bands facing each other, leading to material fatigue and reduced longevity.
Innovation Solution
The electric resistance heating bands are configured with angles between sections less than 90°, allowing heat to be radiated away from the element towards heat sinks, reducing temperature differences and increasing longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electric resistance heating bands are arranged facing each other in conventional heating elements, then the heating element can be compact and simple in structure, but temperature differences of up to 200°C and hot spots occur leading to material fatigue and reduced longevity
Solution Approach 1:
The patent applies asymmetry by configuring the heating bands at angles between sections of 45° to 60° instead of the conventional parallel arrangement. This asymmetric angular configuration ensures that adjacent heating bands do not face each other directly, thereby eliminating the formation of hot spots and excessive temperature differences while maintaining structural simplicity
Solution Approach 2:
The patent introduces angular orientation as an additional dimensional parameter in the arrangement of heating bands. By configuring heating bands at specific angles (45° to 60°) relative to each other rather than simply arranging them parallel or facing each other, the invention adds angular dimensionality to the spatial arrangement, thereby distributing heat more uniformly and preventing localized overheating
2Reliability
If heating elements are configured to radiate heat towards heat sinks, then temperature uniformity improves and longevity increases, but the configuration becomes more complex with specific angle requirements
Solution Approach 1:
The patent uses asymmetric angular configuration (45° to 60°) to direct heat radiation toward heat sinks while avoiding direct facing arrangements. This asymmetric design achieves improved temperature uniformity and extended longevity without requiring complex control systems, as the geometric configuration itself inherently directs heat flow in the desired manner
3Ease of manufacture
If conventional heating element arrangement is used, then manufacturing is simple, but material fatigue occurs due to temperature differences
Solution Approach 1:
The patent applies asymmetric angular arrangement (45° to 60°) of heating bands to eliminate direct facing configurations that cause hot spots. This asymmetric geometry is straightforward to manufacture using conventional processes while significantly reducing temperature gradients and preventing material fatigue, thereby improving the strength and durability of the heating element
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces temperature differences and extends the lifespan of the heating elements by maximizing heat radiation towards the heat sinks, thereby improving furnace efficiency and durability.
Implementation Method 1
electrical conductors, through which a current flows, are used. These electric conductors transform the electric energy into heat energy which is then radiated from the electric conductors
Implementation Method 2
The heat transfer takes place predominantly or exclusively in the form of radiant heat
Data Source
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AI summary
The invention relates to an electric heating element (30, 30'), in particular for arrangement in a furnace, configured to provide radiant heat, the electric heating element (30, 30') comprising an electric resistance heating band (31, 31') having a width and a thickness, wherein the width is greater than the thickness. The electric resistance heating band (31, 31') comprises a plurality of reverse bends (31a, 31a') arranged along a first direction and a plurality of sections (31b, 31b') arranged between adjacent reverse bends (31a, 31a') and an angle between a width direction of the plurality of sections (31b, 31b') and the first direction is less than 90°. The invention further relates to a furnace (100) comprising one or more of the electric heating elements (30, 30') and a method for performing a chemical process and/or heating a process medium using the furnace (100).