Coupling box hairpin replacement for high voltage heating element

Solution Overview

Problem

Conventional resistive heating elements with hairpin bends or non-linear paths in high voltage applications face dielectric material compromise during manufacturing, reducing dielectric strength.

Innovation Solution

A heater assembly design featuring a pair of heating sections connected by a coupling assembly with a dielectric material inside a coupling enclosure, replacing traditional hairpin bends with a coupling member to enhance dielectric strength and electrical insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If hairpin bends or non-linear paths are used in resistive heating elements, then heating element density is increased, but dielectric strength is compromised during manufacturing

Engineering Contradiction:

Improveheating element densityVSAvoiddielectric strength

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The heating element is divided into linear sections that are separately manufactured with intact dielectric material, then connected through a coupling assembly. This segmentation allows each section to maintain full dielectric strength while achieving the desired non-linear path configuration through the coupling mechanism.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A coupling assembly acts as an intermediary component between linear heating sections. This coupling assembly contains its own dielectric material and coupling member, providing the necessary electrical connection while maintaining dielectric strength at the connection point, thus enabling high voltage operation without compromising insulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If hairpin bends are used in high voltage heating elements, then space utilization is improved, but dielectric material integrity is reduced

Engineering Contradiction:

Improvespace utilizationVSAvoiddielectric material integrity

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The heating element is divided into linear sections that are separately manufactured with intact dielectric material, then connected through a coupling assembly. This segmentation allows each section to maintain full dielectric strength while achieving the desired non-linear path configuration through the coupling mechanism.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A coupling assembly acts as an intermediary component between linear heating sections. This coupling assembly contains its own dielectric material and coupling member, providing the necessary electrical connection while maintaining dielectric strength at the connection point, thus enabling high voltage operation without compromising insulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If conventional heating sections are connected directly, then device complexity is reduced, but electrical insulation at high voltage is compromised

Engineering Contradiction:

Improveconnection structureVSAvoidelectrical insulation

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

A coupling assembly acts as an intermediary component between linear heating sections. This coupling assembly contains its own dielectric material and coupling member, providing the necessary electrical connection while maintaining dielectric strength at the connection point, thus enabling high voltage operation without compromising insulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The coupling assembly utilizes composite construction with dielectric material surrounding the coupling member, combining insulating and conductive properties in a single integrated component. This composite structure provides both electrical connection and insulation necessary for high voltage applications.

Inventive Principle:

Principle #40Composite materials

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 solution improves dielectric strength and operational reliability at high voltages by eliminating hairpin bends and increasing dielectric material around the heating sections, ensuring a robust and sealed interface.

Implementation Method 1

a dielectric material disposed inside the coupling enclosure for electrically insulating the coupling member

Methodology Applied

Scientific EffectDielectric insulation: Dielectric

Implementation Method 2

Conventional resistive heating elements may be arranged to have a serpentine configuration

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

a sheath surrounding the resistive heating element

Methodology Applied

Scientific EffectMechanical protection:

Implementation Method 4

The sheaths of the pair of heating sections are welded to the coupling enclosure

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20220104314A1Coupling box hairpin replacement for high voltage heating element

Publication Date: 2022.03.31 WATLOW ELECTRIC MANUFACTURING CO

AI summary

A heater assembly includes a pair of heating sections and a coupling assembly. The heating sections each include a conductive portion. The coupling assembly includes a coupling enclosure and a coupling member disposed inside the coupling enclosure. The conductive portions of the pair of heating sections are connected by the coupling member inside the coupling enclosure.