Heating Cartridge with Segmented Windings for Uniform Heat Distribution
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Solution Overview
Problem
Existing electric heating cartridges with multiple windings lack even heat distribution along their length, as individual windings are not fully galvanically isolated, leading to uneven heating when different windings are switched on and off, which is undesirable for applications like heating medical liquids.
Innovation Solution
The heating cartridge features multiple heating wire windings that are completely galvanically isolated from each other and can be switched on and off separately, with each winding end and connecting wires inserted into axial bores, ensuring even heat distribution by arranging windings on a common ceramic support with specific pitch and spacing to maintain consistent power delivery across the cartridge's length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple heating wire windings are arranged axially offset on a common winding support, then different heating outputs can be achieved by switching individual windings, but uneven heat distribution occurs along the cartridge length
Solution Approach 1:
The heating cartridge is divided into multiple axially offset heating sections, each with its own heating winding. This segmentation allows independent control of different heating zones while ensuring that each zone contributes to overall uniform heat distribution along the cartridge length, preventing localized overheating or cold spots.
Solution Approach 2:
Each heating winding is positioned in a specific axial region of the cartridge, creating localized heating zones with tailored thermal characteristics. The offset arrangement ensures that each local heating zone complements the others to achieve global thermal uniformity throughout the liquid heating volume.
2Adaptability or versatility
If heating wire windings are electrically connected in parallel for switching, then different heating powers can be achieved, but complete galvanic isolation between windings cannot be ensured
Solution Approach 1:
A ceramic winding support serves as an electrical intermediary between the heating windings and the cartridge housing. This insulating medium provides complete galvanic isolation between separately switchable heating zones while allowing thermal energy to pass through, enabling independent control of each heating section without electrical interference.
Solution Approach 2:
The winding support is made of ceramic material that combines electrical insulation properties with thermal conduction capabilities. This composite functionality allows the support structure to simultaneously provide electrical isolation between windings and thermal coupling to the cartridge housing, ensuring both safety and heating efficiency.
3Device complexity
If a single heating wire winding is used, then simple construction is achieved, but different heating outputs cannot be switched
Solution Approach 1:
The single heating element is segmented into multiple axially offset heating windings, each capable of independent switching. This segmentation provides variable heating outputs and localized temperature control while maintaining a relatively simple overall cartridge structure with a single ceramic support and unified housing.
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 design ensures even heat distribution across the entire length of the heating cartridge, regardless of which windings are active, enhancing safety through complete electrical isolation and allowing for precise control of heating outputs.
Implementation Method 1
electric heating cartridge with at least two heating wire windings that can be switched on and off separately
Data Source
Figure 1~5
Figure 6~8
Figure 9
AI summary
The cartridge has heating wire coils (W1, W2), which are arranged on a circumference of a coil carrier such that a winding of the coil (W2) is placed between two successive windings of the coil (W1). The coil carrier is made of an insulating material and is provided with axial holes. Coil ends and connecting wires are introduced into the holes, where the connecting wires (15, 16, 18) are connected with the ends.