Flow-Through Heater With Anfractuous Path for Turbulent Heat Transfer
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Solution Overview
Problem
Conventional flow-through heater assemblies face maintenance challenges and inefficient thermal transfer due to the design of external heaters and internal baffles, which complicate cleaning and service, and result in suboptimal heat transfer efficiency.
Innovation Solution
A flow-through heater assembly with an internal heater defining an anfractuous path within a two-piece housing, featuring o-rings and mechanical fasteners for sealing, and optionally formed via additive manufacturing, which enhances turbulence and thermal efficiency by integrating the heater and baffle functions into a single component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external heater is installed onto the outside of the tubular flow body, then electrical integration and chemical compatibility are improved, but thermal transfer efficiency deteriorates
Solution Approach 1:
The heater element is integrated within the tubular flow body structure itself, merging the heating function with the flow conduit. This eliminates the thermal barrier of the tubular wall that exists with external heaters, allowing direct thermal transfer from the heater to the fluid while maintaining electrical integration and chemical compatibility through material selection.
Solution Approach 2:
The tubular flow body wall acts as an intermediary thermal path. By placing the heater internally, the thermal path becomes shorter and more direct, with the tubular wall serving as a thinner thermal barrier compared to external heater configurations, thereby improving thermal transfer efficiency.
2Loss of energy
If a baffle is located within the flow path to increase turbulence, then heat transfer efficiency is improved, but maintenance difficulty increases
Solution Approach 1:
The heater element is designed with an anfractuous (turbulent) path that combines the heating function with the flow disruption function previously performed by separate baffles. This integration eliminates the need for separate baffle components that would obstruct maintenance access, while still achieving the desired turbulence for enhanced heat transfer.
Solution Approach 2:
The heater element serves multiple functions: it provides thermal heating through resistive heating and simultaneously creates turbulence in the fluid flow through its anfractuous path configuration. This multi-functionality replaces the need for separate baffle components, simplifying the overall structure and improving maintainability.
3Loss of energy
If the heater defines an anfractuous path, then fluid turbulence and heat transfer efficiency are improved, but device complexity increases
Solution Approach 1:
The complex anfractuous path geometry is integrated directly into the heater element construction rather than requiring separate turbulence-inducing components. This merging of the turbulent flow path with the heating element reduces overall device complexity while maintaining the turbulence necessary for efficient heat transfer.
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 anfractuous path design increases fluid turbulence, improving heat transfer efficiency and reducing thermal time constants, allowing faster and more uniform heating of fluids with reduced power consumption.
Implementation Method 1
Heat is transferred from the external heater 14 through the tubular flow body 12 and into a fluid 18 flowing therein
Implementation Method 2
The anfractuous path design increases fluid turbulence, improving heat transfer efficiency
Implementation Method 3
A heater is disposed within the housing and extends between the inlet and the outlet
Data Source
Figure 1
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Figure 3
AI summary
A flow-through heater assembly includes a housing and a heater. The housing includes an inlet, an outlet, and a bore extending between the inlet and the outlet. The heater is disposed within the housing and extends between the inlet and the outlet. The heater includes at least one opening proximate the inlet and at least one opening proximate the outlet. The heater defines an anfractuous path from the inlet to the outlet, and the openings in the heater are in fluid communication with the bore of the housing.