Elliptical Coil Support Reduces Heater Width
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Solution Overview
Problem
Conventional electric heater units for air handlers are large and costly due to the use of nickel chromium alloys and the need for discrete ceramic insulators, which are susceptible to market price fluctuations and heat deflection issues.
Innovation Solution
The design incorporates a coil support made of heat-resistant materials like mica, which can withstand high temperatures and supports the resistance wire in an elliptical configuration, reducing the width of the heater unit while using low-nickel or nickel-free resistance wire compositions, and a modular structure with staggered and offset coil arrangements for improved heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nickel chromium alloys are used for resistance wires to minimize coil deflection, then the durability and heat resistance are improved, but the cost increases due to market price fluctuations of nickel and chromium
Solution Approach 1:
The patent changes the material composition parameters of the resistance wire by reducing nickel content from conventional levels (typically 80% Ni) to lower nickel alloys (e.g., 40% Ni or less) or nickel-free compositions, thereby reducing material cost while maintaining functional performance through alternative alloy compositions
Solution Approach 2:
The patent employs composite material strategies by using low-nickel or nickel-free resistance wire alloys combined with mica coil supports to achieve the desired mechanical and thermal properties without relying on expensive nickel chromium compositions
2Reliability
If discrete ceramic insulators are used to support resistance wires, then the electrical insulation is improved, but the device size increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the support function and insulation function into a single integrated mica coil support structure, eliminating the need for separate ceramic insulators and reducing structural complexity while maintaining electrical insulation and mechanical support
Solution Approach 2:
The mica coil support performs multiple functions simultaneously: it provides mechanical support for the resistance wire, electrical insulation, and structural stability, replacing the need for multiple discrete components
3Power
If conventional circular coil configurations are used, then the heat output is maintained, but the width of the heater unit cannot be reduced
Solution Approach 1:
The patent transitions from symmetric circular coil configurations to asymmetric elliptical coil configurations, allowing the coils to be arranged in a more compact width while maintaining the necessary heat output through optimized elliptical geometry and spacing
Solution Approach 2:
The patent optimizes the spatial arrangement of coils by transitioning from circular to elliptical geometry, effectively utilizing space in different dimensional orientations to reduce the width dimension while maintaining heat generation capability
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 reduces the overall size and cost of electric heater units while maintaining heat output, allowing for a more compact and efficient heating solution with reduced nickel content and improved durability.
Implementation Method 1
heat generated when the wires are electrically energized from electrical current flowing therethrough
Implementation Method 2
The coil support may comprise a heat resistant material, which may withstand an operating temperature of at least approximately 1700° F
Data Source
AI summary
An electric heater apparatus for heating air is disclosed, comprising a heater coil assembly including a coil support comprising a panel around which lies a coil of an electrical resistance element from approximately one end of the panel to approximately an opposite end, the coil of the electrical resistance element comprising a pass of spaced apart loops, the coil support configured to support the spaced apart loops.