Foldable Insulator Plates for Robust Resistance Heater Design
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Solution Overview
Problem
Existing electric resistance heaters face challenges in manufacturing complexity, limited flexibility in meeting heating requirements, and increased risk of wire contact and burnout due to the need for specialized wire shaping and mismatched insulator plate configurations.
Innovation Solution
The design employs folded insulator plates with angled configurations and fasteners to secure them, allowing for a more robust and flexible heater configuration with looped resistance wires that can vary in height and orientation, reducing manufacturing complexity and enhancing rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If insulator plates are spaced apart to allow wire looping, then wire flexibility is improved, but structural stability deteriorates
Solution Approach 1:
The insulator plates are nested together in a folded configuration where one plate is positioned within or adjacent to another, creating a compact multi-layered structure that maintains stability while accommodating wire loops
Solution Approach 2:
The insulator plates are arranged in a three-dimensional folded configuration rather than simple linear spacing, allowing the structure to maintain rigidity through spatial arrangement while providing pathways for flexible wire routing
2Stability of the object's composition
If specialized wire shaping with expanded portions is used to maintain plate spacing, then plate spacing stability is improved, but manufacturing complexity increases
Solution Approach 1:
The function of maintaining plate spacing is extracted from the wire itself and transferred to the folded insulator plate structure, eliminating the need for specialized wire shaping with expanded portions
Solution Approach 2:
The folded insulator plates serve as an intermediary structure that maintains spacing between wire sections, replacing the need for complex wire expansions while providing stable geometric support
3Adaptability or versatility
If mismatched insulator plate configurations are used to accommodate wire loops, then wire routing flexibility is improved, but manufacturing cost increases
Solution Approach 1:
The folded insulator plate configuration provides multiple functions: it maintains spacing, creates wire routing pathways, and provides structural support, all within a standardized plate design that can be manufactured uniformly
Solution Approach 2:
The insulator plate is divided into functional zones through folding, where different sections of the folded structure perform different functions (spacing maintenance, wire guidance, structural support) while using a single standardized plate component
4Ease of manufacture
If insulator plates are not fastened to allow movement, then ease of assembly is improved, but structural rigidity deteriorates
Solution Approach 1:
The insulator plates are pre-folded into their final configuration before assembly, so that when assembled they naturally maintain their relative positions and provide structural rigidity without requiring additional fastening operations
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
This design simplifies manufacturing, increases flexibility in meeting heating demands, reduces the risk of wire contact, and provides a more cost-effective and robust heater configuration compared to prior art designs.
Implementation Method 1
electrical resistance heater
Data Source
AI summary
A foldable electric resistance heater comprises at least a pair of insulator plates with a resistance wire threaded through openings in the insulator plates. In one mode, the insulator plates are folded with respect to each other and fastened together using one or more fasteners. In another mode, the plates can have other angled configurations with respect to each other. One or more insulators is positioned between the folded plates or adjacent the plates to isolate the resistance wire. The folded plate configuration and resistance wire provide significant advantages in manufacturing costs while forming a more robust heater configuration.