Flat-Wire Dryer Heater Structure for Low Vibration Heating
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Solution Overview
Problem
Existing electric heaters for clothes dryers with coil-shaped heating wires are large, prone to vibration, collect fluff, and can cause noise and shorts, limiting their efficiency and reliability.
Innovation Solution
A compact electric heater design featuring a flat heating wire bent into loops, supported by a ring-shaped structure made of insulating material, which enhances heat transfer, reduces vibration, and prevents sagging and shorts, with optional zigzag or corrugated patterns for improved airflow and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If coil-shaped heating wires are used to provide sufficient heating power, then heating power is improved, but the heater size increases and vibration occurs
Solution Approach 1:
The heating wire is changed from a coil-shaped three-dimensional structure to a flat planar structure. This dimensional change allows the heating element to provide sufficient heating power through increased surface area contact with the air flow, while maintaining a compact overall heater size and eliminating the vibration problems associated with coil structures.
2Power
If coil-shaped heating wires are used, then heating power is achieved, but vibration and noise increase
Solution Approach 1:
By transforming the heating wire from a coil structure to a flat planar structure, the invention eliminates the vibration and noise problems inherent in coil-shaped heaters while maintaining effective heating power through increased surface area exposure to the air flow.
3Power
If coil-shaped heating wires are used, then heating function is provided, but fluff collection and sagging occur
Solution Approach 1:
The flat planar structure of the heating wire prevents fluff accumulation and sagging problems that occur with coil-shaped heaters, while maintaining effective heating function through increased surface area contact with the air flow.
4Power
If larger heaters are used to provide sufficient heating power, then heating power is improved, but device complexity increases
Solution Approach 1:
The flat planar heating wire structure provides sufficient heating power in a compact configuration, simplifying the overall heater design and reducing device complexity compared to traditional coil-shaped heaters that require larger sizes to achieve the same heating effect.
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 flat loop design allows for higher heating power, reduced noise, and increased mechanical stability, enabling efficient heat transfer and cost-effective manufacturing while minimizing vibration and fluff accumulation.
Implementation Method 1
A flat heating wire has a larger surface area than a coil-shaped heating wire of comparable dimensions and can therefore transfer heat more efficiently to a surrounding air flow
Implementation Method 2
an electric heater according to the present invention can stand higher electrical power, i.e. a higher current, without overheating
Data Source
AI summary
The invention refers to an electric heater for a clothes dryer, said heater comprising at least one heating wire, a ring shaped support structure carrying the at least one heating wire. The at least one heating wire is a flat wire bent into loops.