Holder for insulators, insulator holder of an air heater, air heater and machine comprising the same
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Solution Overview
Problem
Existing electric air heaters for diesel machines face issues with maintaining serpentine shaped resistor ribbons under vibration and air flow, leading to preferential wear and reduced heating efficiency due to inadequate insulation and mechanical stress.
Innovation Solution
A monolithic holder made from suitable materials like metals or polymers, designed with a U-shaped section and partitions to securely accommodate and separate insulators, ensuring independent compression and thermal expansion of serpentine shaped air heating elements, thereby enhancing mechanical resistance and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If opposite holders with leaf springs are used to maintain insulators, then the insulators are held in position, but the serpentine ribbons are not independently maintained and one ribbon is not effectively maintained in compression, leading to preferential wear
Solution Approach 1:
The holder is divided into two independent compartments by a partition wall, with each compartment containing its own insulator and leaf spring assembly. This segmentation allows each serpentine ribbon to be independently maintained in compression without interference from the other ribbon, resolving the preferential wear problem while keeping the overall structure integrated and manageable.
Solution Approach 2:
Each compartment of the holder is designed with localized properties - each has its own insulator positioned to contact only one serpentine ribbon and its own leaf spring providing independent compression force. This local quality ensures that each ribbon receives appropriate mechanical support tailored to its specific position and requirements.
2Reliability
If a monolithic holder with partitions is used to accommodate insulators, then independent compression of ribbons is achieved, but the device complexity increases
Solution Approach 1:
The holder structure combines multiple functions into a single monolithic component: it provides structural support, creates separate compartments for insulators, incorporates partition walls for isolation, and integrates mounting features. This merging reduces the total number of separate parts while achieving independent compression maintenance for each ribbon.
3Ease of manufacture
If insulators are not properly maintained under vibration, then assembly is simpler, but preferential wear occurs and heating efficiency is reduced
Solution Approach 1:
The leaf springs are designed to automatically maintain compression force on the insulators and serpentine ribbons throughout operation. As the heater experiences vibration or thermal expansion, the leaf springs self-adjust to maintain constant contact and compression, eliminating the need for external adjustment mechanisms and ensuring continuous reliable maintenance of heating element position.
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 effectively maintains serpentine shaped air heating elements in compression, reducing wear and maintaining heating efficiency under engine vibrations and thermal stress, resulting in a robust and durable air heater with reduced assembly time and cost.
Implementation Method 1
one leaf spring extending between the bottom wall of the holder and a main face of the insulator and cooperating with the holder by urging said insulator away from the bottom wall
Implementation Method 2
Holder for insulators, insulator holder of an electric air heater comprising said holder for insulators
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a holder (1) for accommodating at least two solid pieces (21) in an insulating material, the at least two solid pieces (21) being adapted for maintaining serpentine shaped air heating elements (31) of an air heater (30), in a debit of air flowing through the air heater (30) and for maintaining said serpentine shaped air heating elements (31) at distance from each other in the air heater (30); said holder (1) presenting a bottom (2) and two lateral walls (3) extending from longitudinal sides of the bottom (2) in two planes parallel to each other and orthogonal to the plane of the bottom (2), and defining a U-shaped transversal section of the holder (1), characterized in that said holder (1) is made of a unique piece and presents at least one partition extending from the bottom (2) in a plane parallel to the planes of the lateral walls (3) and delimiting with the bottom (2) and the lateral walls (3), at least two compartments (5) of the holder (1), each compartment (5) being designed to accommodate and secure one solid pieces (21).