Ceramic IR Reflector with Extended End Walls
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Solution Overview
Problem
Existing ceramic reflectors for infrared lamps in industrial heat treatment processes face issues with connector overheating due to IR radiation, leading to premature failure and requiring excessive cooling airflow.
Innovation Solution
A ceramic reflector design with elongated concave bodies and increased wall height at longitudinal ends to shield connectors from IR radiation, allowing for external connector placement and improved cooling through through holes, using materials like silica or alumina, and featuring a reflective surface layer and transition layers for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If connectors are placed inside the reflector body, then the structure is compact, but connectors overheat due to IR radiation causing premature failure
Solution Approach 1:
The patent extracts the connectors from the interior of the reflector body and relocates them to the exterior surface. This is achieved by forming cavities within the reflector body that accommodate the connectors while extending through the wall thickness, allowing connectors to be positioned outside the main reflector volume where they are shielded from IR radiation by the reflector material itself.
Solution Approach 2:
The reflector body acts as an intermediary barrier between the IR radiation source (IR lamp) and the connectors. By positioning connectors on the exterior surface and using the reflector material as a shield, the harmful IR radiation is blocked before reaching the connectors, protecting them from overheating while maintaining electrical functionality.
2Temperature
If high cooling airflow is applied to connectors, then connector temperature is reduced, but energy consumption increases
Solution Approach 1:
The patent converts the harmful effect of IR radiation into a beneficial shielding mechanism. The same reflector material that reflects IR light toward the target also serves as a thermal barrier protecting the connectors. Additionally, the cavity structure allows for passive cooling paths where hot air rises and is replaced by cooler air, reducing the need for active high-energy cooling systems.
Solution Approach 2:
The reflector body exhibits different functional properties at different locations: the interior surface has high IR reflectivity for directing radiation, while the exterior surface provides thermal protection for connectors. The wall thickness and material composition are optimized to provide adequate thermal shielding while maintaining structural integrity and electrical insulation properties.
3Reliability
If wall height is increased at longitudinal ends, then connectors are shielded from IR radiation, but reflector volume increases
Solution Approach 1:
The reflector body is segmented into distinct functional zones: the main reflector volume for directing IR radiation, and extended wall sections at the longitudinal ends for connector protection. This segmentation allows each zone to be optimized independently - the main body maintains compact dimensions for efficient radiation reflection, while the end walls are extended only where necessary to provide shielding for connector locations.
Solution Approach 2:
Instead of uniformly increasing reflector volume in all directions, the patent extends the wall height specifically at the longitudinal ends where connectors are positioned. This localized dimensional change provides the necessary shielding volume only where required, minimizing overall volume increase while achieving the protective function.
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
The design extends the lifetime of IR lamps by shielding connectors from excessive heat and reducing cooling airflow requirements, while maintaining effective IR light reflection and cooling efficiency.
Implementation Method 1
Each elongated concave reflector body is provided for reflecting the IR light from the at least one IR lamp
Implementation Method 2
the wall height is at both upstanding walls larger than in the middle section of the elongated concave reflector body... effectively shielded from IR radiation from IR lamps
Implementation Method 3
shield connectors from IR radiation
Implementation Method 4
providing for a cooling effect
Data Source
AI summary
A ceramic reflector (100) for at least one IR lamp comprises at least one elongated concave reflector body (102). Each of the at least one elongated concave reflector bodies comprises an elongated bottom section and two elongated upstanding walls. Each of the elongated concave reflector bodies is provided for containing at least one IR lamp (150) and for reflecting the IR light from the at least one IR lamp. Each elongated concave reflector body has in each cross section at both of its upstanding walls a wall height. The wall height is the vertical distance between the deepest level of the bottom section of the reflector body and the highest level of the upstanding wall. At one or at both longitudinal ends of at least one reflector body; the wall height is at both upstanding walls larger than in the middle section of the elongated concave reflector body.