Electric Heater with Segmented Heating Unit and Non-Heating Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric heaters suffer from thermal stress concentration, cracking, and dielectric breakdown due to curved heating unit designs and eccentric utensil placement, limiting their service life and output.
Innovation Solution
The electric heater features a base with unit heating elements and non-heating connection portions, arranged in radial or linear shapes, with separate power connections to manage thermal stress and prevent damage, using materials with low electrical resistance for non-heating connections to reduce heating value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If curved portions with small curvature are formed in the heating unit, then the heating unit can be connected to power connection unit, but thermal stress concentration occurs leading to cracking and dielectric breakdown
Solution Approach 1:
The heating unit is divided into multiple heating wire segments that are separately supported on the inner wall of the stainless tube. Each segment can be independently positioned and connected, avoiding the need for continuous curved portions with small curvature. The segmentation allows for smoother transitions and reduced thermal stress concentration at connection points.
Solution Approach 2:
A support structure consisting of the stainless tube and internal support elements is introduced as an intermediary between the heating wires and the external environment. This support structure provides mechanical strength and distributes thermal stress, preventing direct stress concentration on the heating wires at curved portions.
2Device complexity
If heating wires are used in the electric heater, then the heater can be manufactured with simple structure, but oxidation occurs and structural support problems arise
Solution Approach 1:
The heating wires are enclosed within a stainless tube that creates a protective environment. The tube prevents direct contact between the heating wires and oxidizing air, effectively creating an inert atmosphere that protects the heating elements from oxidation while maintaining structural integrity.
Solution Approach 2:
The heater employs a composite structure combining heating wires (for heat generation) with a stainless tube enclosure (for protection and structural support). This composite design allows the heating wires to function without direct exposure to oxidizing conditions while the stainless tube provides mechanical strength and environmental protection.
3Productivity
If plane heater with thin substrate is used, then space utilization is improved and instantaneous heating is achieved, but thermal stress concentration occurs at curved portions
Solution Approach 1:
The heating element is segmented into discrete heating wire sections rather than a continuous thin substrate. This segmentation allows each segment to be independently supported on the stainless tube wall, distributing thermal stress and preventing concentration at curved portions while maintaining the thin-profile advantage for rapid heating.
Solution Approach 2:
The stainless tube acts as a flexible yet strong shell that can accommodate the heating wire segments. The tube's flexibility allows it to conform to various shapes including curves, while its structural integrity prevents stress concentration and cracking, enabling both rapid heating and crack resistance.
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 design stabilizes operation at high power levels, prevents cracking and dielectric breakdown, and enhances output by uniformly heating and reducing thermal stress, even with eccentric utensil placement.
Implementation Method 1
a heating unit having a plurality of unit heating elements disposed on a plate surface of the base, and at least one of heating connection portions configured to heat and conductively connecting the unit heating elements to each other
Implementation Method 2
non-heating connection portions configured not to heat and conductively connecting the unit heating elements to each other
Data Source
AI summary
Disclosed is the electric heater including a base, and a heating unit having a plurality of unit heating elements disposed on a plate surface of the base and at least one of heating connection portions configured to heat and conductively connecting the unit heating elements to each other and non-heating connection portions configured not to heat and conductively connecting the unit heating elements to each other, thereby preventing a thermal stress concentration, thus to prevent damage to the heating unit and to enhance its output.