Heating structure for hot air distributors
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Solution Overview
Problem
Existing heating structures for hot air distributors are inefficient in heat transfer and reliability, leading to prolonged heating times and increased dimensions, while also being costly and complex to manufacture.
Innovation Solution
A coaxial heating structure with ceramic tubular elements and conductive layers that facilitate rapid and uniform heat exchange through a winding circuit, reducing the risk of overheating and mechanical stress, and incorporating a conductive ceramic layer for enhanced heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional heating elements with spiral-shaped electrical conductors are used, then the structure is simple to manufacture, but the heat transfer efficiency is poor and heating time is prolonged
Solution Approach 1:
The heating element is segmented into multiple independent heating zones along the tubular element, with each zone having its own electrical conductor section. This segmentation allows for distributed heat generation along the air flow path, improving overall heating efficiency while maintaining manufacturing simplicity through modular construction
Solution Approach 2:
The patent transitions from a two-dimensional spiral conductor layout to a three-dimensional coaxial tubular structure with conductors arranged along the length of the tube. This dimensional change increases the surface area for heat transfer and improves heat distribution across the air flow cross-section, significantly enhancing heat transfer efficiency
2Temperature
If ceramic material is used for the tubular element, then heat resistance is improved, but heat conduction to the air flow is reduced
Solution Approach 1:
The tubular element is constructed as a composite structure combining ceramic material for heat resistance with embedded electrical conductors that generate heat directly within the tube walls. This composite approach allows the ceramic to provide structural integrity and heat resistance while the embedded conductors ensure efficient heat generation and transfer to the passing air flow
Solution Approach 2:
The electrical conductors embedded in the ceramic tubular element act as intermediaries that convert electrical energy to thermal energy directly within the heat-resistant structure. This intermediary mechanism allows the ceramic to maintain its heat resistance properties while the conductors facilitate efficient heat transfer to the air flow, overcoming the limitation of pure ceramic materials
3Ease of operation
If the heating element is placed at the air inlet, then the support element is easily positioned, but the air flow does not receive sufficient heating before outlet
Solution Approach 1:
The heating element is divided into multiple heating zones distributed along the tubular element's length, with conductors positioned at different locations. This segmentation ensures that air flow receives progressive heating as it moves through the device, improving overall heating effectiveness while maintaining easy installation through the modular tubular design
Solution Approach 2:
The heating zones are positioned to provide preliminary heating early in the air flow path, with additional heating zones further along the tube. This preliminary action ensures that air receives heat incrementally throughout its passage, achieving thorough heating before outlet while maintaining the simple installation of positioning the entire tubular element at the inlet
4Volume of moving object
If the tubular element walls are made thin, then the device dimensions are reduced, but the structural strength and heat transfer capability are compromised
Solution Approach 1:
The tubular element uses composite construction with thin ceramic walls providing structural integrity and heat resistance, combined with embedded electrical conductors that generate heat directly within the wall structure. This composite approach allows reduced wall thickness while maintaining both strength and heat transfer capability through the distributed heating zones
Solution Approach 2:
The patent moves from thick-walled simple tubes to thin-walled tubes with three-dimensional embedded conductor structures. This dimensional change allows the conductors to be positioned within the wall thickness itself, providing heat generation capability within the reduced wall structure, thereby maintaining heat transfer efficiency with thinner walls
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 achieves immediate and homogeneous air heating with reduced fluid and time consumption, enhancing efficiency and reliability while minimizing production costs and complexity.
Implementation Method 1
at least one conductor element, which is coupled with a support element made of a stable thermally material, converts electrical energy into heat
Implementation Method 2
internal and external surfaces of said tubular elements have a conductive ceramic layer which behaves as a heat conductor
Data Source
Figure 1
Figure 2
AI summary
A heating structure for hot air distributors, comprising a tubular element (10) inserted inside a casing (11) of a hot air distributor, wherein said tubular element (10) is engaged in correspondence with a tapered end (12) of said distributor from which a flow of hot air (7) outcomes and said tubular element (10) includes at least one resistor (13) attached to a thermally conductive layer (14), while, at one end opposite to said tapered end (12), an inlet opening (1) is provided where a flow of supply air (F) flows; said flow of supply air (F) is divided, by means of a transverse barrier (2), into two air flows (F1), which flow inside respective cavities (3) and follow a winding path, so that the air flow (F3) conveyed towards the output, by flowing along said resistor (13), is constantly and efficiently heated.