Gas Heating System with Interposed Heat Shield
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Solution Overview
Problem
Current gas heating systems for preventing icing and pressure issues in gas regulators are inefficient due to high risks of hot spots, suboptimal regulation, and potential for overheating, which can lead to leaks and explosions, especially when using high-power electric resistors.
Innovation Solution
A system with a heat shield interposed between the electric heating source and the gas circulation duct, featuring a serpentine-shaped duct wound in a spiral and metal plates for enhanced heat exchange, along with a regulation thermostat and thermal fuse for safety, to improve heat diffusion and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If high-power electric resistors (100W to 1000W) are used to heat the gas, then the heating efficiency is improved, but the risk of hot spots and overheating increases
Solution Approach 1:
The heating resistor is segmented into multiple sections along the gas flow path, with each section having its own thermal fuse and regulation means. This segmentation allows distributed heat management, preventing concentrated hot spots while maintaining overall heating efficiency through multiple lower-power heating zones instead of a single high-power resistor.
Solution Approach 2:
A heat shield is introduced as an intermediary component between the heating resistor and the gas circulation duct. The heat shield distributes thermal energy more uniformly, acting as a thermal mediator that prevents direct contact between the high-power resistor and the gas stream, thereby reducing hot spots while maintaining heating effectiveness.
2Use of energy by moving object
If the heating resistor is in direct contact with the gas circuit, then heat transfer efficiency is improved, but the risk of overheating and device explosion increases
Solution Approach 1:
The heat shield serves as a protective intermediary layer between the heating resistor and the gas circuit. It maintains thermal coupling for efficient heat transfer while preventing direct exposure of the gas to excessive temperatures, thus reducing the risk of overheating and explosion hazards.
Solution Approach 2:
Thermal fuses are positioned beforehand at critical locations along the gas flow path to provide premature protection. These thermal fuses act as safety cushions that will melt and disconnect the circuit before dangerous overheating conditions can develop, preventing device explosion.
3Device complexity
If regulation means and thermal fuse are positioned at the ends of the heating resistor, then the assembly is simplified, but the heating stability and uniformity deteriorate
Solution Approach 1:
The regulation means and thermal fuse are segmented and distributed at multiple positions along the gas flow path rather than concentrated at the ends. This distributed arrangement provides more uniform heating control and stability throughout the gas stream while maintaining relatively simple assembly procedures for each modular section.
4Area of stationary object
If the gas circulation duct is wound in a serpentine shape, then the heat exchange surface area is increased, but the device complexity increases
Solution Approach 1:
The gas circulation duct is configured in a serpentine (snake-like) curved path rather than a straight line. This curved configuration maximizes the heat exchange surface area between the heating resistor and the gas flow while maintaining a compact overall device footprint, balancing increased surface area with acceptable structural complexity.
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 system provides a larger heat exchange surface, reducing the risk of overheating and improving gas flow rate and safety by maintaining controlled temperatures, adaptable to various gases and environments.
Implementation Method 1
The heating source comprises at least one electric resistor
Implementation Method 2
at least one heat shield is interposed between the heating source and at least part of the gas circulation duct
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a heating system (1) for heating at least one gas or gas mixture flowing in a duct (2) having one end (3) connected to at least one pressurised or liquid gas source, which comprises at least one electric heating source (4) adjacent to a portion of the duct (2), characterised in that at least one thermal screen (6, 7) is provided between the heating source (4) and at least a portion of the duct (2) in which the gas to be heated flows.