Heating elements of large sizes and of metallic tubular designs
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Solution Overview
Problem
Current radiant heating technologies face challenges in achieving high radiant heat efficiency, durability, and safety for indoor spaces with low ceilings, as well as high ceiling and outdoor applications, due to issues with fragility, low efficiency, and safety standards. Existing heating elements either emit intense light, have short lifespans, or provide low radiant heat efficiency, limiting their effectiveness and adaptability.
Innovation Solution
The development of larger diameter or cross-sectional metallic tubular heating elements with high emissivity coatings and innovative designs that allow for lower surface temperatures, increased durability, and improved radiant heat efficiency, enabling efficient radiant heating in various applications while meeting safety standards and aesthetic requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional radiant heating elements (quartz lamps, ceramic tubes) are used to achieve high radiant heat efficiency, then radiant heat efficiency is improved (80-93%), but durability and lifespan are worsened (5000-10000 hours) due to fragility
Solution Approach 1:
The heating element combines a metallic tube (providing mechanical strength and durability) with a ceramic coating layer (providing high emissivity for radiant heat efficiency). This composite structure integrates the advantages of both materials: the metal ensures long lifespan and resistance to thermal shock, while the ceramic coating achieves 80-93% emissivity for high radiant heat efficiency without the fragility of pure ceramic tubes.
Solution Approach 2:
The invention changes the material parameters by transitioning from fragile ceramic or quartz materials to a metallic base with ceramic coating. This parameter change in material composition maintains high emissivity while dramatically improving mechanical strength and lifespan to 25000-50000 hours, resolving the contradiction between efficiency and durability.
2Power
If high temperature operation is used to increase radiant power output, then radiant heat efficiency is improved, but safety and user comfort are worsened due to intense heat and light emission
Solution Approach 1:
The ceramic coating on the metallic tube enables high emissivity operation at moderate temperatures (below 500°C). This parameter change in operating temperature, enabled by the high emissivity coating, maintains high radiant power output while avoiding the intense light and excessive heat that occur with conventional high-temperature quartz lamps, thus improving safety and user comfort.
Solution Approach 2:
The ceramic coating can be applied in various colors (white, almond, black, grey) that affect the emissivity and visual appearance. This allows optimization of the surface properties for radiant heat emission while controlling the visual intensity and heat perception, reducing the harmful effects of intense light and heat emission.
3Reliability
If metallic tubular heating elements are used to improve durability, then reliability is improved (25000-50000 hours lifespan), but radiant heat efficiency is worsened (50-75%) compared to ceramic or quartz elements
Solution Approach 1:
The invention applies a ceramic coating to the metallic tube, creating a composite structure where the metal provides durability and the ceramic coating provides high emissivity (80-93%). This composite approach resolves the contradiction by combining the advantages of both materials: the metallic base ensures 25000-50000 hour lifespan, while the ceramic coating achieves radiant heat efficiency comparable to pure ceramic elements.
Solution Approach 2:
The ceramic coating is applied locally on the surface of the metallic tube, providing high emissivity properties only where needed for radiant heat emission. This local application of different material properties allows the bulk metal to provide structural integrity and longevity, while the surface coating optimizes thermal radiation efficiency.
4Object-affected harmful factors
If larger diameter heating elements are used to reduce surface temperature and meet safety standards, then safety is improved, but device size and area are increased
Solution Approach 1:
The high emissivity ceramic coating changes the thermal radiation parameters, allowing the heating element to operate at lower surface temperatures (below 500°C) while maintaining high radiant heat efficiency. This parameter change in operating temperature enables safety compliance without requiring excessive increases in element size, as the high emissivity compensates for the reduced temperature differential.
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 new heating elements achieve radiant heat efficiencies of up to 90% for high ceiling spaces and 72% for low ceiling spaces, with longer lifespans and the ability to operate at lower surface temperatures, enhancing energy savings and user comfort while meeting safety and design standards.
Implementation Method 1
a coiled resistive conductor, which is electrically insulated from the metallic tube using an electrically insulating material having a relatively high thermal conductivity
Implementation Method 2
The outer surface of the metallic tube is treated or coated with a high emissivity coating that is resistant to the operating temperatures
Implementation Method 3
an electrically insulating material having a relatively high thermal conductivity to properly conduct the heat to the metallic tube
Data Source
AI summary
A series of metallic heating elements of large sizes are presented. A conventional metallic tubular heating element is positioned into a hollow metallic profile, wherein additional high temperature resistant components are used in different assemblies, as required. A coiled resistance conductor is positioned within the interstice of two metallic tubes fitted into one another, wherein an electrically insulating powder or grit is used within the interstice, and to embed the coiled resistance conductor, and wherein additional high temperature resistant components are used in different assemblies, as required. The assemblies provide methods to reduce the use of electrically insulating powders and/or thermally conductive powders for large size heating elements, and more particularly for radiant purposes; and components are also presented to improve the emissivity of the outer surface of the radiant heating elements with a colorful look, for surface temperatures operating around and up to 500° C. to 600° C.