MoSi2 Heating Element Plate Geometry and Bent Part Stability
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Solution Overview
Problem
Conventional MoSi2 heating elements face challenges in achieving energy savings and uniform isothermal properties due to difficulties in maintaining shape stability, welding instability, and temperature variations when transitioning from a rod-shaped to a plate-shaped heat generating part, which affects the heater's lifespan and efficiency.
Innovation Solution
A U-shaped MoSi2 heating element is produced by bending a columnar MoSi2 wire into a U shape and only the straight part is ground to form a plate-shaped heat generating part, while the bent part is left unground, maintaining its original shape to reduce heat generation and temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the heat generating part is changed from rod-shaped to plate-shaped to increase the view factor and transmitted thermal energy, then energy saving is achieved, but shape stability becomes extremely difficult to maintain
Solution Approach 1:
The heating element is divided into three distinct parts: columnar terminal parts, a bent part, and a plate-shaped heat generating part. This segmentation allows each part to have optimized geometry for its specific function while maintaining overall shape stability through the columnar terminals and bent connections
Solution Approach 2:
Different parts of the heating element have different geometries and properties: the terminal parts maintain columnar shape for stability, the bent part connects the sections, and only the heat generating part is plate-shaped to maximize radiative heat transfer. This local differentiation resolves the contradiction by applying plate geometry only where energy efficiency is prioritized
2Loss of energy
If the heat generating part is changed to plate-shaped to improve heat transfer efficiency, then transmitted thermal energy increases, but welding stability deteriorates
Solution Approach 1:
The heating element is divided into distinct columnar terminal parts and a plate-shaped heat generating part, with the terminal parts serving as stable welding zones. This segmentation isolates the welding operations to the columnar sections which maintain shape stability, while the plate-shaped heat generating part can be optimally designed for heat transfer without compromising welding reliability
Solution Approach 2:
The columnar terminal parts are specifically designed with geometry suitable for stable welding and electrical connection, while the plate-shaped heat generating part is optimized for radiative heat transfer. This local differentiation allows welding stability to be maintained in the terminal regions while achieving superior heat transfer efficiency in the heat generating region
3Loss of energy
If the entire element is made plate-shaped to maximize the heat generating area, then the view factor increases and energy saving is achieved, but temperature uniformity deteriorates due to bending and grinding processes
Solution Approach 1:
The heating element is segmented into columnar terminal parts and a plate-shaped heat generating part. The columnar terminals maintain dimensional stability and serve as stable reference points, while the plate-shaped heat generating part is positioned between them. This segmentation prevents the temperature variations and deformation issues that would occur if the entire element were plate-shaped
Solution Approach 2:
Only the heat generating part is made plate-shaped to maximize radiative heat transfer surface area, while the terminal parts remain columnar to maintain shape stability and serve as stable anchoring points. This local differentiation ensures temperature uniformity in the heat generating region without the degradation issues associated with bending and grinding entire plate-shaped elements
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 approach enhances the heater's efficiency, reduces degradation, and ensures uniform heat distribution without temperature variations, allowing for high-temperature heating with lower energy consumption.
Implementation Method 1
the heat generating part (normally, the 'heat generating part' means the part (other than the terminal part) having a narrow diameter which generates heat when applying current)
Implementation Method 2
it is said that the ratio of heat radiation from the heater is high in the heat transfer to the object to be heat-treated in a resistance heating furnace. The transmitted thermal energy Q of radiant energy is expressed with the formula of Q = σ(T1^4 - T2^4) × F
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The present invention provides a U-shaped MoSi2 heating element comprising a columnar terminal part at each end, a bent part, and a plate-shaped heat generating part which connects the columnar terminal parts and the bent part, wherein a cross-sectional area of the bent part is greater than a cross-sectional area of the plate-shaped heat generating part. The present invention additionally provides a method of producing a U-shaped MoSi2 heating element, wherein a columnar MoSi2 raw material is bent into a U shape, and an area to become a heat generating part is thereafter ground, with a bent part left unground, to have a plate shape. The heat generating part having a flat surface has a large area that is greater than a conventional rod shape, and it is possible to yield the effects of improving the heat-transfer efficiency of radiant energy, and realizing energy saving and increasing isothermal properties in comparison to a conventional rod-shaped heater. Furthermore, as a result of not grinding the bent part, it is possible to reduce the degradation of the U-shaped part and suppress heat generation therefrom, and eliminate temperature variation, whereby provided is an efficient heating element having MoSi2 as its main component.