Heating unit with LEDs and venting

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Solution Overview

Problem

Traditional heating units for maintaining food products at a desired temperature often expose light sources, such as LEDs, to direct heat, which can reduce their efficiency and lifespan due to high temperatures.

Innovation Solution

A heating unit design featuring a reflector assembly with air gaps and vents that thermally isolates LEDs from the heating element, directing heat towards the food zone while maintaining the LEDs within a suitable operating temperature range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If LEDs are positioned close to the heating element for compact design, then device complexity is reduced, but the LEDs are exposed to direct heat which reduces their efficiency and lifespan

Engineering Contradiction:

Improvestructural simplicityVSAvoidLED lifespan

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The heating unit is divided into distinct thermal zones: a hot zone containing the heating element and a cool zone containing the LEDs. The reflector assembly with air gaps creates physical separation between these zones, allowing each component to operate in its optimal temperature environment without direct thermal exposure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reflector assembly acts as an intermediary structure between the heating element and LEDs. It includes a first reflector coupled to the housing interior surface and a second reflector coupled to the first reflector, with air gaps between them. This intermediary structure redirects heat away from the LEDs while maintaining overall device compactness.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If LEDs are thermally isolated from the heating element using reflector assembly with air gaps, then LED operating temperature is maintained, but device complexity increases

Engineering Contradiction:

ImproveLED operating temperatureVSAvoidreflector assembly structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The reflector assembly serves multiple functions simultaneously: it provides thermal isolation for the LEDs, directs heat toward the food heating zone, and maintains structural support for the lighting elements. The housing structure itself is designed to accommodate the reflector assembly, integrating support and thermal management functions into a unified structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The reflector assembly is nested within the housing structure, with the first reflector coupled to the housing interior surface and the second reflector coupled to the first reflector. This nested arrangement allows thermal management components to be integrated within the existing housing boundaries without requiring additional external space.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Productivity

If vents are positioned between the LEDs and heating element, then heat is directed towards food zone, but illumination intensity may be reduced

Engineering Contradiction:

Improveheating efficiencyVSAvoidlight output

Core Design Contradiction:

ProductivityVSIllumination intensity

Solution Approach 1:

Different regions of the heating unit are assigned different functional qualities: the central region contains the heating element for thermal processing, while the peripheral regions contain the LEDs for illumination. The vents are strategically positioned to channel heat from the central hot zone toward the food heating area, while the LEDs in the cooler peripheral zones provide illumination without interfering with the heating function.

Inventive Principle:

Principle #3Local quality

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 enhances the light output and extends the lifespan of LEDs by preventing direct heat exposure, ensuring efficient heating and illumination while maintaining the LEDs within a suitable operating temperature.

Implementation Method 1

The reflector assembly includes a first reflector coupled to an interior surface of the housing and a second reflector coupled to the first reflector. The first reflector is spaced from the interior surface forming a first air gap therebetween and the second reflector is spaced from the first reflector forming a second air gap therebetween.

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

a first spacer positioned between the first reflector and the interior surface forming a first air gap therebetween, a second reflector coupled to the first reflector, and a second spacer positioned between the first reflector and the second reflector forming as second air gap therebetween

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Implementation Method 3

a heating element disposed within the thermal cavity

Methodology Applied

Scientific EffectJoule Heating: Joule Heating

Data Source

PatentUS10900655B2Heating unit with LEDs and venting

Publication Date: 2021.01.26 HATCO CORP

AI summary

A heating unit includes a housing defining a thermal cavity, a reflector assembly disposed within the thermal cavity, and a heating element disposed within the thermal cavity. The reflector assembly includes a first reflector coupled to an interior surface of the housing and a second reflector coupled to the first reflector. The first reflector is spaced from the interior surface forming a first air gap therebetween and the second reflector is spaced from the first reflector forming a second air gap therebetween. The heating element is at least partially surrounded by the reflector assembly.