Insulator for Open Coil Resistance Heaters
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Solution Overview
Problem
Existing insulators for open coil electrical resistance heaters are ineffective in supporting coils with small diameters, small wire diameters, and small coil pitches, leading to distortion and inadequate airflow due to their design.
Innovation Solution
A unique insulator configuration featuring angled slot segments and I-shaped coil convolution catches that securely engage and support coils without distorting them, allowing for effective electrical isolation and airflow, even with small dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional point suspension insulators are used to support heater coils, then electrical isolation is provided, but coils with small diameters, small wire diameters, and small coil pitches cannot be properly supported without distortion
Solution Approach 1:
The insulator features a slot with specifically designed geometry including angled sides and a slot end face configured to locally engage and support small diameter coil convolutions. This localized adaptation allows the insulator to properly support small pitch coils without causing distortion, while the rest of the insulator structure maintains its electrical isolation function.
2Adaptability or versatility
If string thru bushings are used to surround and capture the coil, then small diameter coils can be supported, but the insulator thickness covers part of the coil and reduces airflow exposure
Solution Approach 1:
The invention extracts the coil support function from a surrounding bushing structure and implements it through a slot-based engagement system. The slot engages the coil convolutions at specific points rather than surrounding the entire coil, thereby removing the insulator material from the airflow path while maintaining support capability for small diameter coils.
3Reliability
If insulators with larger dimensions are used to ensure proper engagement, then engagement stability is improved, but the footprint and mounting space requirements increase
Solution Approach 1:
The insulator design segments the coil engagement function into a focused slot structure that concentrates the engagement area. The slot with its angled sides and end face provides stable engagement for small pitch coils within a compact footprint, eliminating the need for larger dimensional insulators while maintaining engagement reliability.
Data Source
AI summary
An open coil electrical resistance heater employs an insulator having a coil convolution engaging portion that is adapted to engage heater coils with small diameters, small wire diameters, and/or small pitches without distorting the coil and compromising heater performance.