FeCrAl Heating Element Structure for High-Temperature Gas Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric heaters for heating gases suffer from inefficiencies in thermal energy transfer, mechanical stability, and susceptibility to shorting due to the use of thin heating wires and ceramic structures, limiting maximum achievable temperatures and operational flexibility.
Innovation Solution
A heating element formed from an electrically conducting material, such as an iron-chromium-aluminium alloy, which serves as both the structural framework and heating source, eliminating the need for internal wires and enhancing mechanical stability and thermal efficiency through high surface area per volume ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thin heating wires and ceramic structures are used in conventional electric heaters, then the device can heat gases to high temperatures, but the mechanical stability and resistance to vibrations are insufficient
Solution Approach 1:
The patent merges the heating function and structural support function into a single integrated heating element made of high-temperature resistant alloy. This eliminates the need for separate thin heating wires and ceramic structures, combining thermal generation with mechanical stability in one component that can withstand vibrations and high temperatures simultaneously.
Solution Approach 2:
The invention uses high-temperature resistant alloys with specific compositional ranges (including elements like Cr, Al, Ti, Nb, Ta, W, Mo, Hf, Zr, B, Si, Mn, Fe, Ni, Co, Cu, and rare earth elements) to create a composite material structure that provides both the necessary thermal resistance for high-temperature operation and the mechanical strength to resist vibrations and mechanical stresses.
2Productivity
If thin heating wires are used to increase heating surface area, then thermal energy transfer efficiency improves, but the structure becomes susceptible to mechanical stress and vibrations
Solution Approach 1:
The patent changes the physical parameters of the heating element by using a solid rod structure with controlled dimensions (diameter 2-20mm, length 10-100mm) instead of thin wires. The high-temperature resistant alloy provides sufficient surface area for thermal energy transfer while the increased structural dimensions and material properties ensure resistance to mechanical stress and vibrations.
3Area of stationary object
If ceramic block structures with internal bores are used, then heating surface area is increased, but the device complexity and susceptibility to shorting increase
Solution Approach 1:
The patent extracts the heating function from the structural component by making the heating element itself the structural support. This eliminates the need for separate ceramic blocks with internal bores, removing the complex multi-component structure while maintaining adequate heating surface area through the rod's external surface and simplified internal geometry.
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 achieves high heating temperatures up to 1300°C with a low surface load, improved mechanical strength, and resistance to vibrations, while allowing for complex geometric designs and efficient thermal energy transfer.
Implementation Method 1
The effectiveness and efficiency of the conversion of the electrical energy into heat (via the heating wire)
Implementation Method 2
heating element defining an axially elongate heating block... adapted via internal bores or channels for the through-flow and direct/active heating of the fluid
Data Source
AI summary
A heating element and heating assembly to heat a fluid as part of a heating device. The heating element is formed from a high electrical resistance material such as an FeCrAl based material. The heating device comprises a heating block having a high heating-surface area to volume ratio (HTVR) to achieve a high heating density with a low surface load.