Compact Heater Assembly with Integrated Mica Insulation
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Solution Overview
Problem
Existing electrical resistance heater assemblies for clothes dryers are large and flimsy due to their design, which poses challenges in size and structural integrity, necessitating an improved solution for heating applications.
Innovation Solution
The improved heater assembly features annular insulators with spaced openings for heater ribbons, a metal connecting plate with tabs to secure the insulators, and a terminal assembly for power connection, eliminating the need for traditional fasteners and providing anti-rotation features through notches and flanges for enhanced stability and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional heater assemblies use mica boards and fasteners to secure heater ribbons, then electrical isolation is achieved, but the assembly becomes large and flimsy
Solution Approach 1:
The patent combines the mica board and fastener components into a single integrated heater assembly structure. The heater ribbon is secured directly to the housing without requiring separate mica boards and fasteners, eliminating the need for multiple components and reducing overall assembly size while maintaining electrical isolation functionality.
Solution Approach 2:
The patent removes the separate mica board and fastener components from the traditional heater assembly design. By extracting these unnecessary components, the design achieves the same electrical isolation function with a simpler, more compact structure that eliminates the flimsy nature of the original assembly.
2Ease of manufacture
If traditional heater assemblies use separate fasteners to secure components, then assembly is possible, but structural integrity is reduced
Solution Approach 1:
The patent integrates the securing function directly into the heater assembly structure itself, eliminating the need for separate fasteners. The heater ribbon is mechanically secured to the housing through the integrated design, which provides superior structural integrity while maintaining ease of manufacture through a simpler assembly process.
3Volume of moving object
If heater assemblies are made compact, then space is reduced, but thermal performance may be compromised
Solution Approach 1:
The patent applies local quality by concentrating the heating element and insulation components in a compact arrangement where the heater ribbon is positioned to maximize thermal contact with the housing. This localized optimization ensures efficient heat transfer in the reduced space, maintaining thermal performance despite the compact size.
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 solution results in a more compact, rigid, and stable heater assembly with reduced risk of short circuits and improved thermal performance, allowing for efficient heating of fluids while accommodating thermal expansion without the need for additional mounting components.
Implementation Method 1
electrical resistance heater assembly... heater ribbon... heating of fluids
Implementation Method 2
mica boards that provide electrical isolation of the heater ribbon
Data Source
AI summary
An electrical resistance heating assembly comprises a heater ribbon woven through a first mica board. The heater ribbon extends upwardly from a top surface of the first mica board to provide heat to a fluid passing over the upwardly extending heater ribbon. The heat ribbon on an underside of the first mica board is electrically isolated by a second mica board positioned adjacent the first mica board. The first and second mica boards are held together with by a clamp-containing metal place positioned adjacent the second mica board with the clamps bent over the first mica board to keep the mica boards together.