Inline heater
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Solution Overview
Problem
Existing inline heaters lack superior performance in heating efficiency, explosion resistance, flow-through rate, and design improvements, particularly in inlet and outlet fittings, which are essential for certain applications.
Innovation Solution
An inline heater design featuring a tubular heat spreader assembly with a helical conduit system and an electrically operated heating element, integrated with a purge manifold for enhanced heat transfer and explosion resistance, and improved fluid flow and fitting connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a conventional inline heater design is used, then the basic heating function is provided, but the heating efficiency is insufficient
Solution Approach 1:
The patent employs a helical conduit configuration that wraps around the central heating element in a spiral pattern. This curved arrangement increases the surface area of the conduit in contact with the heated zone, improving heat transfer efficiency from the heating element to the fluid while maintaining a compact overall structure.
Solution Approach 2:
The helical conduit introduces a third dimensional aspect to the heat transfer path by wrapping around the heating element axially. This transforms a simple linear or radial heat transfer into a multi-dimensional thermal field, allowing more comprehensive heating of the fluid as it flows through the spiral pathway.
2Reliability
If a conventional inline heater design is used, then the basic structure is simple, but the explosion resistance is insufficient
Solution Approach 1:
The patent incorporates a purge manifold system that introduces an inert purge gas (such as nitrogen) into the heater assembly. This creates an inert atmosphere within the housing and around the heating element, preventing explosive mixtures from forming and significantly improving explosion resistance without requiring complex pressure relief or containment systems.
3Productivity
If a conventional inline heater design is used, then the basic fluid flow is provided, but the flow-through rate is insufficient
Solution Approach 1:
The heating system is divided into multiple heating zones along the length of the helical conduit, with the conduit making multiple turns around the heating element. This segmentation allows different sections of the fluid to be heated at different stages, improving overall heat transfer efficiency and enabling higher flow rates without excessive energy loss.
4Ease of operation
If a conventional inline heater design is used, then the basic inlet and outlet fittings are provided, but the design optimization is insufficient
Solution Approach 1:
The purge manifold serves multiple functions: it distributes purge gas throughout the heater assembly for explosion protection, provides structural support for the conduit arrangement, and integrates the inlet and outlet fitting connections. This multi-functionality improves ease of operation and installation while avoiding excessive complexity by combining several functions into a single integrated component.
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 provides improved heating efficiency, enhanced explosion resistance, increased flow-through rate, and optimized design for inlet and outlet fittings, addressing the limitations of existing inline heaters.
Implementation Method 1
An electrically operated heating element is provided for heating the heat spreader
Implementation Method 2
at least one conduit extends helically about the longitudinal axis of the tubular heat spreader between the fluid inlet and the fluid outlet to define a fluid heating flow path
Data Source
AI summary
An inline heater includes a heater core that includes a heat spreader assembly comprising a tubular heat spreader that extends axially along a longitudinal axis and that comprises an external surface. The heat spreader assembly includes a fluid inlet and a fluid outlet. At least one conduit extends helically about the longitudinal axis of the heat spreader between the fluid inlet and the fluid outlet to define a fluid heating flow path that fluidically connects the fluid inlet and the fluid outlet. The heat spreader assembly further comprising an electrically operated heating element for heating the heat spreader.