Encapsulated Bus Circuit for Medium-Voltage Fluid Heating Systems
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Solution Overview
Problem
Industrial electric heaters require high electrical current and large, expensive power components due to low voltage operation, necessitating complex grounding strategies and transformer usage, especially in medium voltage heat exchanger applications.
Innovation Solution
A termination assembly with electrically nonconductive members and embedded electrical circuits, featuring apertures for power pins, connectors, and dielectric encapsulation, allowing for efficient connection and insulation of resistive heaters to a power supply, reducing the need for large components and complex grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If low voltage electric heaters are used to heat materials, then the heating function is achieved, but large electrical current and large, expensive power components are required
Solution Approach 1:
The patent changes the voltage parameter from low voltage to medium voltage operation. The resistive heating elements operate at medium voltage (e.g., 2.4kV to 15kV), which reduces the electrical current required for the same power output. This parameter change eliminates the need for large power components and complex grounding strategies while maintaining the heating function.
Solution Approach 2:
The patent replaces the traditional low-voltage high-current electrical system with a medium-voltage low-current system. This substitution fundamentally changes the electrical characteristics, allowing direct connection to medium voltage power sources without requiring large transformers, heavy gauge cables, or extensive grounding infrastructure.
2Power
If low voltage electric heaters operate at high current, then the required power is achieved, but large and expensive power components and cables are needed
Solution Approach 1:
The patent changes the operating voltage parameter to medium voltage, which inversely reduces the current for the same power level. This parameter change directly reduces the size and weight of power components and cables, as they are designed for lower current ratings.
3Power
If step-down transformers are used to supply low voltage, then the power supply requirement is met, but the system complexity and cost increase
Solution Approach 1:
The patent changes the voltage parameter to match available medium voltage power sources directly, eliminating the need for step-down transformers. The resistive heating elements are designed to operate at medium voltage, allowing direct connection to utility power sources without additional transformation equipment.
Solution Approach 2:
The patent extracts and removes the transformer component from the power supply system. By designing the heating elements to operate directly at medium voltage, the transformer is completely eliminated from the system, reducing both complexity and cost.
4Power
If high current is used to achieve required power, then the heating capability is sufficient, but expensive power components and grounding strategies are required
Solution Approach 1:
The patent changes the current parameter by increasing the voltage to medium levels. This reduces the current required for the same power output, which simplifies grounding requirements. Medium voltage systems have well-established grounding practices that are less complex than high-current low-voltage systems.
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 enables efficient power distribution among resistive heaters with reduced installation labor and improved serviceability, using dielectric materials to insulate and support the circuit, allowing for custom designs without dedicated tooling and minimizing installation forces.
Implementation Method 1
a dielectric encapsulant surrounding at least one of the power pins within at least one aperture
Implementation Method 2
resistance heaters that convert electrical power to heat
Data Source
AI summary
A termination assembly for a heater assembly includes a plurality of resistive heaters arranged in discrete power phases, each resistive heater comprising a resistive heating element surrounded by dielectric material and a sheath. The termination assembly includes a plurality of electrically nonconductive members. Each electrically nonconductive member includes a plurality of apertures configured to receive power pins of the plurality of resistive heaters. The termination assembly includes a plurality of connectors configured to connect the power pins to the electrically nonconductive members. The termination assembly includes an electrical circuit embedded in or disposed on at least one of the plurality of electrically nonconductive members.