Crushable Ceramic Heater Core for Compacted Multi-Zone Heating

Solution Overview

Problem

Conventional electric heater devices lack superior heat transfer and dielectric properties, making them less durable and less effective in high-temperature applications, and they are not easily customizable for specific industrial processes.

Innovation Solution

A crushable ceramic core with keyhole-shaped grooves is used, wound with heating wire, and compacted within metal sleeves with magnesium oxide insulation, allowing for distributed wattage and independent heat zones, enhancing heat transfer and insulation resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional electric heater devices are used, then the device structure is simple and easy to manufacture, but the heat transfer properties and dielectric properties are inferior

Engineering Contradiction:

Improveheat transfer properties and dielectric propertiesVSAvoiddevice construction complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heater is divided into multiple independent heating zones along the longitudinal axis, each zone controlled by separate heating elements that can be independently adjusted. This segmentation allows optimization of heat transfer in different zones while maintaining manufacturing feasibility through modular assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heater employs composite construction combining stainless steel sheath, ceramic insulation material, and heating elements. This composite structure provides superior heat transfer properties through the stainless steel, excellent dielectric properties through the ceramic insulation, while maintaining manufacturability through standardized material combinations

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If conventional heater construction is used, then the manufacturing process is straightforward, but the heater cannot provide distributed wattage or independent heat zones

Engineering Contradiction:

Improvedistributed wattage and independent heat zonesVSAvoidheater construction complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The heater is divided into multiple independent heating zones along the longitudinal axis, each zone controlled by separate heating elements that can be independently adjusted. This segmentation allows optimization of heat transfer in different zones while maintaining manufacturing feasibility through modular assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heater incorporates adjustable and reconfigurable heating zones that can be dynamically controlled to provide distributed wattage across different sections. This dynamic capability allows the heater to adapt to varying process requirements while maintaining a relatively simple base construction

Inventive Principle:

Principle #15Dynamics

3Temperature

If conventional heater materials are used, then the construction is simple, but the heater cannot operate at high temperatures with superior dielectric properties

Engineering Contradiction:

Improvehigh temperature operation capabilityVSAvoiddielectric properties

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The heater employs composite construction combining stainless steel sheath, ceramic insulation material, and heating elements. This composite structure provides superior heat transfer properties through the stainless steel, excellent dielectric properties through the ceramic insulation, while maintaining manufacturability through standardized material combinations

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 results in more durable heaters with superior thermal and electrical properties, capable of operating at high temperatures, providing uniform heat distribution, and accommodating various industrial processes with customizable configurations.

Implementation Method 1

winding of electric heating wire

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

magnesium oxide insulation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10182471B2Electric heater crushable cores and compacted unitary heater device and method of making such devices

Publication Date: 2019.01.15 CRANDELL WALTER

AI summary

A crushable ceramic heater core for an electric heater device which has a cylinder-like body of crushable ceramic material and grooves along the periphery of the body, the grooves being key shaped and adapted to receive a conductive pin in a groove. The invention also includes an electric heater device where such a core has been wound with heater wire and the conductive pin has been inserted in a core groove in contact with the wire, and the wire wound core has been installed in a sheath which has been filed with electrical insulting material. The sheath and its contents are swaged to create a compacted unitary heater assembly. The invention also includes the process for making the wire wound\grooved core having a conductive pin therein in contact with the wire winding, and a method for making a heating device having such a core and which has been compacted to a theoretical density. The heater assembly and the method may also include installation of temperature sensing devices.