Heating element with open-cell structure

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Solution Overview

Problem

Conventional heating elements have limited energy transfer efficiency due to a small area-to-volume ratio, are structurally weak, and struggle with uniform heating of irregular objects, especially under high temperature and pressure conditions.

Innovation Solution

A three-dimensional latticework matrix heating element with an open structure, providing a high surface area-to-volume ratio, enhanced mechanical strength, and adaptability for various configurations, manufactured via 3D printing, which supports structural integrity and efficient thermal energy transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional thin wires or strips are used as heating elements, then the device complexity is low, but the energy transfer efficiency is limited due to small area-to-volume ratio

Engineering Contradiction:

Improveenergy transfer efficiencyVSAvoidstructural complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The heating element transitions from conventional two-dimensional thin wires or strips to a three-dimensional latticework structure. This dimensional change dramatically increases the surface area-to-volume ratio, enabling significantly improved energy transfer efficiency while maintaining reasonable structural complexity through the use of repeating unit cells.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The heating element employs a porous latticework structure with open cells that provide high surface area for heat transfer. The porous nature of the structure allows fluid to flow through while maximizing the heating surface area, resolving the contradiction between energy transfer efficiency and structural complexity.

Inventive Principle:

Principle #31Porous materials

2Productivity

If larger heating elements are used to increase heating area, then the energy transfer efficiency improves, but the structural strength decreases causing deformation and sagging

Engineering Contradiction:

Improveheating areaVSAvoidstructural strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The heating element is segmented into a latticework structure composed of multiple repeating unit cells. This segmentation allows the heating area to be expanded while maintaining structural strength through the distributed framework of the lattice, preventing deformation and sagging that would occur in solid larger elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating element combines the heating function with a structurally strong latticework framework. This composite approach integrates both thermal performance and mechanical strength into a single structure, eliminating the need for separate support structures and preventing deformation under thermal and gravitational loads.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If conventional heating elements are used, then the manufacturing process is simple, but the adaptability to irregular objects and voltage sources is limited

Engineering Contradiction:

Improveadaptability to irregular objectsVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The heating element's latticework structure allows for parameter changes in geometry, scale, and configuration to adapt to irregular objects and different voltage sources. The repeating unit cell design enables flexible scaling and shaping while maintaining manufacturing simplicity through standardized fabrication processes.

Inventive Principle:

Principle #35Parameter changes

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 latticework matrix heating element achieves improved thermal energy transfer efficiency, structural stability, and adaptability for diverse applications, including uniform heating of irregular objects, while withstanding high temperature and pressure demands.

Implementation Method 1

enhanced thermal energy transfer from a body of the heating element to a receiving phase such as a fluid flowing in contact with the heating element or to a solid body to be heated by radiation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

to a solid body to be heated by radiation

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 3

resistant to deformation, sagging and creep following repeated high temperature operations

Methodology Applied

Scientific EffectCreep resistance: Creep

Implementation Method 4

Electric heaters typically include an electrical resistance heating element to heat a fluid or a solid object. Conventionally, relatively thin wires, strips or tubes of metal alloy are used as the heating elements with the heating effect achieved by the passage of current and the wire's, or tube's, electrical resistance

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20220400537A1Heating element with open-cell structure

Publication Date: 2022.12.15 KANTHAL LTD

AI summary

A heating element comprises a main body having a three-dimensional matrix with an open structure including openings and internal voids, cavities and/or pores extending throughout the main body. The three-dimensional matrix is provided as a lattice having a repeating unit cell extending in three directions. The present heating element is adapted for maximised surface area so as to provide an effective and efficient thermal energy transfer medium.