Modular Heat Trace System With Fins For Uniform Conduit Heating

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Solution Overview

Problem

Existing electric heat trace systems for conduits, such as those in semiconductor processing systems, are cumbersome to install and replace due to the need for custom-made prefabricated heat-traced pipes, leading to increased inventory and maintenance costs, and they provide non-uniform heating profiles due to limited area coverage and crude securing methods.

Innovation Solution

A modular heater system comprising heat trace sections with fins and a dielectric cover, along with a connector assembly that includes a shell with cavities and a fitting heater assembly, allowing for quick engagement and disengagement, and featuring a semiconductive polymer core and insulation jacket for improved heat transfer and reduced heat loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If custom-made prefabricated heat-traced pipes are used, then heating performance is improved, but inventory costs and manufacturing costs increase

Engineering Contradiction:

Improveheating performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heat trace system is divided into separate modular components: heat trace cables, insulation jackets, and pre-fabricated pipe sections with integrated connectors. This segmentation allows standard components to be manufactured independently and assembled as needed, eliminating the need for custom-made prefabricated pipes while maintaining heating performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Standard heat trace cables and insulation jackets are designed to be universally applicable to multiple pipe sizes and configurations. The modular connector enables these universal components to be quickly assembled onto different pipe sections, providing the same reliable heating performance as custom-made solutions without requiring custom manufacturing for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If heat trace cables are fastened with bands and retaining straps, then the cables are secured to pipes, but installation time increases

Engineering Contradiction:

Improvecable securingVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The insulation jacket is pre-fabricated with integrated retaining straps and mounting features built in during manufacturing. When installed, the entire assembly (pipe, heat trace cable, and insulation jacket with integrated straps) is installed as a unified system, eliminating the separate step of fastening cables with bands and retaining straps, thus reducing installation time while maintaining secure cable attachment.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If conventional heat trace cables are used, then simplicity and low cost are achieved, but heating uniformity deteriorates

Engineering Contradiction:

Improvesystem simplicityVSAvoidheating uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The insulation jacket is designed with varying thickness or thermal conductivity in different regions to compensate for heat loss patterns. Thicker insulation or enhanced thermal barriers are placed in areas where heat loss is higher, creating localized quality variations that ensure uniform heat distribution along the pipe, maintaining heating uniformity while keeping the overall system simple and cost-effective.

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

The modular system facilitates easier installation and replacement, provides a more uniform heating profile, reduces heat loss, and is cost-effective by allowing preformed heat trace sections to be cut to length and adapted to different conduit sizes, enhancing operational efficiency and reducing maintenance costs.

Implementation Method 1

a heat trace section disposed around the fitting adapter

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a heat trace section defining a plurality of fins

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

an insulation jacket surrounding the heat trace section

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS7964826B2Modular heater systems

Publication Date: 2011.06.21 WATLOW ELECTRIC MANUFACTURING CO

AI summary

A modular heater system is provided that includes a heat trace assembly and a connector assembly. The heat trace assembly has a heat trace section that defines a plurality of fins, an insulation jacket surrounding the heat trace section, and at least one terminating member disposed at an end of the heat trace section. The connector assembly has a shell, including a plurality of outer walls and inner walls defining cavities therebetween, and a fitting heater assembly that includes a fitting adapter, a heat trace section disposed around the fitting adapter, and an outer casing disposed around the fitting adapter.