Forced Air Heater

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Solution Overview

Problem

Conventional forced air heaters suffer from inadequate heat distribution, non-uniform heating, and reduced reliability due to limitations in airflow dynamics and thermostat cycling, leading to inefficient heat generation and potential thermostat failure.

Innovation Solution

The implementation of a forced air heater with impingement airflow technology, utilizing multiple air movers to direct air at an acute angle towards a heat source with extended surfaces, and a thermally coupled temperature sensing device to improve heat transfer and reduce thermostat cycling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional heaters blow air parallel to the base and extended surfaces of the heat source, then the heater structure is simple, but heat distribution is insufficient and temperature gradients are large

Engineering Contradiction:

Improveheat distribution uniformityVSAvoidairflow control structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent inverts the conventional parallel airflow approach by directing air perpendicular to the heat source surfaces (impingement airflow). This reversal of airflow direction creates forced convection that significantly enhances heat transfer coefficients and eliminates temperature gradients, achieving uniform heat distribution across all surfaces including bases and extended surfaces.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent employs pneumatic principles by using controlled airflow (forced convection) to enhance heat transfer. The directed air stream acts as a fluid medium that efficiently carries thermal energy from the heat source to the surrounding environment, replacing reliance on natural convection and radiation alone.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If conventional heaters use a thermostat with low thermal mass electrical contacts, then the thermostat responds quickly to temperature changes, but unnecessary cycling occurs and thermostat life is shortened

Engineering Contradiction:

Improvethermostat service lifeVSAvoidthermostat response speed

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

The patent applies beforehand cushioning by pre-heating the thermostat housing and electrical contacts during the heater startup phase. This prior heating creates a thermal buffer that prevents rapid temperature fluctuations from causing excessive cycling, thereby cushioning the thermostat contacts from thermal shock and extending their service life while maintaining adequate response capability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Productivity

If conventional heaters have large physical size, then heat source capacity can be increased, but heat distribution effectiveness is reduced

Engineering Contradiction:

Improveheat extraction efficiencyVSAvoidheater physical size

Core Design Contradiction:

ProductivityVSVolume of moving object

Solution Approach 1:

The patent utilizes another dimension by directing airflow perpendicular to the heat source surfaces rather than parallel. This dimensional change in airflow direction maximizes the surface area exposed to forced convection, dramatically increasing heat extraction efficiency without requiring an increase in heater volume. The impingement airflow penetrates and contacts all surfaces including bases and extended surfaces simultaneously.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 configuration enhances heat transfer coefficients, achieves more uniform heating, increases heat extraction from PTC heat sources, and prolongs thermostat life by reducing unnecessary cycling, resulting in improved reliability and efficiency.

Implementation Method 1

an air mover directing air towards the heating element such that the directed air provides impinged airflow in relation to the heating element

Methodology Applied

Scientific EffectForced Convection: Forced Convection

Implementation Method 2

Conventional heaters typically generate and disseminate (distribute) heat by forced convection, that is, by blowing air over a heat source

Methodology Applied

Scientific EffectHeat transfer: Convection

Implementation Method 3

the heat source is a positive temperature coefficient (PTC) heat source

Methodology Applied

Scientific EffectJoule Heating: Joule Heating

Data Source

PatentUS20230375226A1Forced Air Heater

Publication Date: 2023.11.23 CAFRAMO

AI summary

A forced air heater that includes a temperature sensing device, the temperature sensing device includes: a sensing plate mounted on a metallic component in the environment to be heated; and an electrical contact connected to the sensing plate, wherein the electrical contact is thermally coupled with the metallic component via the sensing plate. There is further provided a method of controlling a heater that includes a temperature sensing device that it is thermally connected to a solid component in the environment to be heated.