Pressurized Heating Cartridge Insulating Plate Support
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Solution Overview
Problem
Existing compressed heating cartridges face challenges in production due to the lack of support elements for the heating coil, leading to difficulties in filling insulating granulate and increased production costs, as the coils must be carefully kept away from the tube wall to prevent contact.
Innovation Solution
The use of flat insulating material plates as supports for the heating wire coils, with a connecting coil section that guides around a deflection edge, allows for easier placement and filling of insulating granulate, reducing the risk of coil contact with the tube wall and stabilizing the coils within the tubular body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If no support elements are provided for the heating coil, then the device structure is simpler, but the filling of insulating granulate becomes difficult and production costs increase
Solution Approach 1:
An insulating plate is introduced as an intermediary component between the heating coil and the insulating granulate. The plate provides a support surface for the heating coil, preventing it from contacting the tube wall during filling, while also serving as a barrier between the heating coil and the granulate material.
Solution Approach 2:
The interior space of the tubular body is segmented into distinct zones: a first region above the insulating plate containing the heating coil, and a second region below the plate containing the insulating granulate. This segmentation allows independent arrangement and filling of each zone without interference.
2Reliability
If care is taken to keep heating coils away from the tube wall during filling, then coil contact is prevented, but production time increases and costs rise
Solution Approach 1:
The heating coil is pre-positioned on the insulating plate before the insulating granulate is introduced. This preliminary arrangement ensures the coil is already supported and protected from wall contact, allowing the granulate filling to proceed quickly without requiring careful manual positioning during the filling process.
3Loss of substance
If the heating coil is freely arranged without support, then material expenditure is reduced, but the coil may contact the tube wall causing defects
Solution Approach 1:
The insulating plate serves as a mediator that provides mechanical support for the heating coil, ensuring accurate positioning and preventing contact with the tube wall. The plate is made of insulating material, maintaining electrical isolation while providing structural support.
4Ease of manufacture
If flat insulating material plates are provided as support, then coil placement is simplified and filling is faster, but device complexity increases
Solution Approach 1:
The insulating plate performs multiple functions simultaneously: it provides mechanical support for the heating coil, acts as an electrical insulator, serves as a physical barrier during granulate filling, and defines the boundary between the coil region and granulate region. This multi-functionality justifies the addition of the component.
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 simplifies the assembly and filling process, reducing production costs and ensuring stable coil placement, thereby enhancing the efficiency and cost-effectiveness of the heating cartridge production.
Implementation Method 1
an electric tubular heating element with an integrated temperature sensor, in which the heating conductor coil is laid out in the shape of a hairpin
Implementation Method 2
the heating wire coils running along the two flat sides of the insulating material plate
Data Source
Figure 1~7a
Figure 4~9
Figure 10~15
AI summary
The tubular housing (2) has a sealed end (3) and one or more resistance heating wire spirals (8,9) separated by an insulated plate (10) having separated semi-circular spacers (14) by which the granulated filling is distributed. Terminals (7) pass through a closing cap (5).