Freely Coiled Heating Element Internal Structure
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Solution Overview
Problem
Existing electrical heating devices with tubular metal sheathings face limitations in spatial arrangement and resistance per unit length due to fixed coil forms or large spatial requirements, restricting the flexibility of electrical heating elements like heating wires or resistive wires.
Innovation Solution
An internal structure with a connection section, turnaround section, and spacer allows for freely coiled electrical heating elements, supported by connecting bars and optionally a connecting wire, enabling flexible spatial arrangement and mechanical stress adjustment within a tubular metal sheathing filled with insulating powder or granulate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a coil form is used to preconfigure the electrical heating element, then the heating element can be provided as a separate assembly, but the degrees of freedom for spatial arrangement are significantly reduced
Solution Approach 1:
The patent removes the coil form from the heating element assembly, extracting the constraint that limited spatial flexibility. The heating wire is now freely coiled without being bound to a rigid coil form, allowing it to be arranged in various spatial configurations while still being provided as a separate preconfigured assembly.
Solution Approach 2:
The heating element transitions from a static, rigid coil form structure to a dynamic, freely coiled configuration. The heating wire can now adapt its spatial arrangement based on the specific application requirements, enabling both straight and curved path configurations within the tubular metal sheathing.
2Adaptability or versatility
If a self-supporting electrical heating conductor is used, then spatial arrangement freedom is improved, but the minimum cross-section limits the resistance per unit length
Solution Approach 1:
The patent introduces an intermediary support structure consisting of the tubular metal sheathing and internal support elements that enable the use of thinner heating conductors. This intermediary structure provides the necessary mechanical support, allowing the heating wire to have a smaller cross-section while maintaining spatial freedom, thereby achieving higher resistance per unit length.
3Stability of the object's composition
If tubular heating bodies or coiled tube cartridges are used, then dimensional stability is achieved, but relatively large spatial requirements are produced
Solution Approach 1:
The patent replaces rigid tubular heating bodies with a flexible heating wire that is freely coiled. This flexible structure can be arranged in compact configurations within the tubular metal sheathing, significantly reducing the spatial requirements while still providing dimensional stability through the coiled structure and support elements.
4Adaptability or versatility
If the electrical heating element is freely coiled without support, then design freedom is maximized, but mechanical stability and positioning are compromised
Solution Approach 1:
The patent segments the heating element into a freely coiled heating wire that is supported at specific intervals by the tubular metal sheathing and internal support structures. This segmentation allows the heating wire to maintain mechanical stability at key points while preserving design freedom in the sections between supports, enabling flexible spatial arrangement.
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 internal structure provides increased design freedom, mechanical support, and efficient heat distribution, allowing for flexible heat output configurations and adaptation to various device lengths, while maintaining electrical insulation.
Implementation Method 1
an electrical heating element is arranged, which is typically fixed in its position after its arrangement in the interior of the tubular metal sheathing
Data Source
AI summary
An internal structure for an electrical heating device includes an electrical heating element. The internal structure includes a connection section for holding an end section of the electrical heating element or a connecting wire, with which one of the two end sections is connected. A turnaround section is positioned opposite the connection section. A spacer runs between the connection section and the turnaround section and is topped by the turnaround section in a radial direction relative to the profile of the spacer. The turnaround section has, for a turned-around electrical heating element or for a turned-around connecting wire in the area topping the spacer, a connecting bar by means of which the electrical heating element or the connecting wire is guided and thus turned around, with this connecting wire being connected to an end section.