Fluid Flow Heater Support Member for High-Temperature Element Stability
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Solution Overview
Problem
Conventional electric fluid flow heaters face issues with high temperature limitations and mechanical stress leading to fracture and failure of heating elements due to vibration and movement, especially when oriented vertically, which reduces their service lifetime.
Innovation Solution
An electric fluid flow heater design featuring a support member that contacts the bent axial end sections of the heating element to inhibit axial and lateral movement relative to the jacket block, thereby stabilizing the heating element and minimizing physical stress, while maintaining efficient thermal energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heating elements are used in conventional electric fluid flow heaters to achieve high temperatures, then heating effectiveness is improved, but mechanical stress and vibration cause fracture and failure of the heating elements
Solution Approach 1:
The heating element is divided into multiple sections with bent axial end sections that can be independently supported. This segmentation allows the heating element to be stabilized at multiple points along its length, reducing mechanical stress and vibration on any single section while maintaining high temperature heating capability.
Solution Approach 2:
Support members are introduced as intermediary components between the heating element and the jacket block. These support members contact the bent axial end sections of the heating element to inhibit axial and lateral movement, thereby reducing mechanical stress and vibration without interfering with the heating function.
2Use of energy by moving object
If heating elements are positioned within jacket blocks for thermal efficiency, then heat transfer is improved, but vibration and movement cause mechanical impacts and stress on the heating elements
Solution Approach 1:
Support members serve as intermediary components between the heating element and the jacket block. These support members contact the bent axial end sections to provide mechanical stabilization while allowing the heating element to remain positioned within the jacket block for efficient thermal energy transfer.
Solution Approach 2:
The support members are pre-positioned within the jacket block to contact and stabilize the bent axial end sections of the heating element before operation begins. This beforehand cushioning prevents mechanical impacts and excessive stress during operation by maintaining proper positioning and reducing movement.
3Temperature
If heating elements are allowed to move freely for thermal expansion, then thermal management is improved, but axial and lateral movement causes vibration and mechanical stress
Solution Approach 1:
The heating element is segmented into sections with bent axial end sections that are specifically targeted for support. This segmentation allows controlled thermal expansion of the heating element while the support members inhibit excessive axial and lateral movement that would cause vibration and mechanical stress.
Solution Approach 2:
The support members are designed to contact specifically the bent axial end sections of the heating element. This selective support changes the mechanical parameters of the system by providing stabilization at critical locations while allowing other portions to accommodate thermal expansion, thereby reducing vibration frequency and mechanical stress.
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 the heater to achieve high temperatures (up to 1200°C) with reduced fatigue and damage to the heating element, enhancing the service lifetime and maintaining efficient thermal energy transfer by stabilizing the heating element within the jacket block.
Implementation Method 1
an electric heater to heat a flow of a fluid... an electrical heating element positioned within the tube to transfer heat to the gas as it flows
Implementation Method 2
at least one support member connected to or projecting from the casing to contact at least some of the bent axial end sections and inhibit axial and/or lateral movement of the heating element
Data Source
AI summary
An electric heater to heat a flow of a fluid having a jacket block comprising a plurality of longitudinal bores to allow the through-flow of a gas phase medium. An elongate heating element extends through each of the bores and is positionally stabilised relative to the jacket block via at least one support member, optionally in the form or an elongate rod to inhibit undesirable independent axial and/or lateral movement of the heating element relative to the jacket block.