Method for making heating elements using electrical resistors and heating element made according to said method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing heating elements with electric resistors are time-consuming and costly, particularly in the production of heat exchangers and steam/hot water generators, where efficient and uniform heat distribution is needed.
Innovation Solution
A process involving a shaped metal container with a centrally placed electric resistor and an outer coil, where conductive metal powder enhances heat exchange, and cold compression achieves efficient and uniform heating without the need for molds or hot casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for heating elements, then manufacturing precision and reliability are maintained, but production time increases and costs increase
Solution Approach 1:
The invention changes the manufacturing process parameters by using cold compression instead of traditional hot casting or molding methods. This allows the heating element components to be assembled and compressed at room temperature, significantly reducing production time and complexity while maintaining structural integrity and thermal performance
Solution Approach 2:
The heating element is divided into separate modular components (resistor, metal powder, container) that can be independently prepared and then assembled through cold compression. This segmentation enables parallel production of components and simplifies the overall manufacturing process
2Reliability
If traditional heating elements without conductive metal powder are used, then manufacturing simplicity is maintained, but heat exchange efficiency decreases and temperature uniformity is poor
Solution Approach 1:
The invention creates a composite structure by dispersing conductive metal powder throughout the heating element assembly. This metal powder acts as a thermal conductor that distributes heat uniformly from the resistor to the surrounding fluid, significantly improving heat exchange efficiency and temperature uniformity
Solution Approach 2:
The conductive metal powder serves as an intermediary thermal medium between the electric resistor and the fluid. It absorbs heat from the resistor and distributes it throughout the container, ensuring efficient and uniform heat transfer without requiring direct contact between the resistor and fluid
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 approach significantly reduces production time and costs while ensuring quick and homogeneous heating, with improved thermal efficiency and uniform fluid temperature in heat exchangers and generators.
Implementation Method 1
an electric resistor inserted inside a tube, both placed centrally in a metal casing... an immersion electrical resistor, which is employed as a heating element able to deliver heat
Implementation Method 2
A conductive element, such as metal powder, is dispersed in the container and is able to cause an efficient heat exchange, thus ensuring a quick and homogeneous heating of the fluid
Data Source
Figure 1~3
Figure 4~9
AI summary
A method for making heating elements using electrical resistors, comprising the following steps: - arranging a metal casing (12), inside which at least one electric resistor (10) is placed, said resistor (10) being inserted inside a tube (11) made of conductive material; - arranging at least one coil (14) containing a fluid, such as water, outside said tube (11) and within said metal casing (12); - inserting in said metal casing (12) a conductive powder and/or conductive fragments; - compressing the metal casing (12) from the outside, so as to model said casing (12) according to a desired shape, thus obtaining an effective heat exchange and a rapid and uniform heating of the fluid contained inside the coil (14).