Gas Heater Heating Element Embedded-Wire Monolith Manufacturing
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Solution Overview
Problem
The production of gas heater heating elements is time- and cost-intensive, and the installation is technically complicated, making it impractical for both small and large, powerful gas heaters.
Innovation Solution
A method for manufacturing gas heater heating elements involves shaping an electric heating element, coating it, and then introducing it into a mold to form a monolith with a support and channel structure, where the coating is removed to create channels, allowing for cost-effective production of both small and large elements with reduced manufacturing effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heating elements are produced from bent heating wire and extruded ceramic rods, then the heating element structure is achieved, but the manufacturing effort and costs increase significantly
Solution Approach 1:
The patent combines the heating wire and ceramic support structure into a single integrated component. The heating wire is embedded directly into the ceramic body during one manufacturing process, eliminating the need to separately produce and assemble ceramic rods and heating wire components. This merging of previously separate components into a unified structure reduces manufacturing steps and complexity.
Solution Approach 2:
The ceramic body serves multiple functions simultaneously: it provides structural support, creates the necessary channel geometry for gas flow, and houses the heating wire element. This multi-functionality eliminates the need for separate structural components and simplifies the overall manufacturing process by consolidating multiple functions into a single component.
2Reliability
If detailed structure with minimal space between ceramic rods is used, then bypass flow is prevented, but manufacturing complexity and costs increase
Solution Approach 1:
The ceramic body is designed with integrated channel segments that are formed directly during manufacturing. The channels are segmented into distinct flow paths with defined geometry, ensuring gas flows through the intended heating zones rather than bypassing them. This segmentation approach achieves reliable flow control without requiring complex post-manufacturing assembly of multiple ceramic rods.
3Power
If vertical installation and vertical gas through-flow are implemented, then heating performance is achieved, but production becomes technically complicated and cost-intensive
Solution Approach 1:
The vertical channel geometry and heating wire orientation are built into the ceramic body during the initial manufacturing process. The heating wire is pre-positioned and embedded in the vertical channels before the ceramic body is finalized, ensuring the correct vertical configuration for optimal heating performance without requiring complex post-assembly steps or specialized installation procedures.
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 method significantly reduces production costs and time, enabling the economical realization of gas heater heating elements by combining the electric heating element with the support and channel structure into a single, self-supporting component, facilitating easier integration and reducing the number of parts needed.
Implementation Method 1
heat within the channels can be transferred by the heating element to a gas flowing through the channels to heat the gas and/or to achieve high gas temperatures
Implementation Method 2
The coating material of the electric heating element is removed
Implementation Method 3
The coating material of the electric heating element is removed
Data Source
AI summary
A method of manufacturing a gas heater heating element including a support and channel structure with a plurality of channels formed in the monolith includes shaping an electric heating element and at least partially coating the electric heating element with at least one coating material. The at least partially coated electric heating element is positioned in a mold for producing the monolith. The monolith is produced and surrounds the at least partially coated electric heating element. The coating material of the at least partially coated electric heating element is removed. The gas heater heating element includes at least one electric heating element in the monolith and the electric heating element is guided in the plurality of channels of the support. Heat within the plurality of channels is configured to be transferred by the electric heating element to a gas flowing through the plurality of channels to heat the gas.