Multi-Passage Ceramic Heater for Cold Spray Gun Safety

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Solution Overview

Problem

Existing cold spray guns are heavy, pose safety risks due to high operating temperatures, and are difficult to package in a portable and durable form, making commercialization challenging.

Innovation Solution

A multi-passage ceramic heater assembly with a stainless steel heater housing and insulating cone, secured within a polymer gun housing, which includes a biasing member to maintain the heater core's orientation and prevent overheating, along with a shroud to protect users from hot components and prevent damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a heater assembly is used to heat carrier gas to high temperatures (400-650°C), then the carrier gas density is reduced for effective cold spray operation, but the user is exposed to safety risks due to high operating temperatures

Engineering Contradiction:

Improvecarrier gas temperatureVSAvoiduser exposure to high temperature

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The heater core is nested within the heater housing, which is in turn nested within the gun housing. The insulating cone is positioned between the heater core and the gun housing, creating nested layers of protection that contain heat and protect the user from high temperatures while maintaining effective heating of the carrier gas

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The insulating cone acts as an intermediary between the high-temperature heater core and the gun housing, thermally isolating the user-exposed surfaces from the heat source while allowing the heating function to proceed effectively

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If traditional heater assemblies are used in cold spray guns, then heating function is achieved, but the heater assembly is susceptible to breakage and electrical shorts due to rough handling

Engineering Contradiction:

Improveheater assembly durabilityVSAvoidbreakage and electrical shorts

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The heater assembly is segmented into distinct components: the heater core, heater housing, insulating cone, and biasing member. This segmentation allows each component to be optimized for its specific function and makes the overall assembly more robust against rough handling, as individual components can withstand stress better than a monolithic structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The biasing member introduces a dynamic element that allows the heater core to maintain optimal positioning while accommodating movements and vibrations during handling. This dynamic adjustment capability prevents breakage and maintains electrical connections despite rough handling

Inventive Principle:

Principle #15Dynamics

3Power

If heavy heater assemblies are used to generate heat, then sufficient heating capability is achieved, but the spray gun becomes heavy and difficult to package in a portable size

Engineering Contradiction:

Improveheating capabilityVSAvoidspray gun weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The heater housing and insulating cone are designed with optimized local qualities - using materials and geometries that provide necessary thermal insulation and structural support only where required, rather than throughout the entire assembly. This reduces unnecessary weight while maintaining heating capability

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The heater assembly uses composite construction with the heater core, heater housing, and insulating cone made from different materials optimized for their specific functions. This composite approach achieves sufficient heating capability with reduced overall weight compared to homogeneous heavy-duty designs

Inventive Principle:

Principle #40Composite materials

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 a safer, more durable, and portable gas dynamic spray unit that effectively heats the carrier gas while protecting users from high temperatures and preventing damage, facilitating the commercialization of portable cold spray units.

Implementation Method 1

The heating element has a helical configuration and is positioned within a ceramic heater core such that the heating element heats the carrier gas to a high temperature

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

A biasing member biases the ceramic heater core toward a tapered outlet

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

The heated gas then flows through a venturi throat and is accelerated

Methodology Applied

Scientific EffectVenturi effect: Venturi Effect

Data Source

PatentUS10159995B2Multi-passage heater assembly

Publication Date: 2018.12.25 DOBEN LTD

AI summary

A gas dynamic spray unit is provided that includes gun housing halves secured about a heater assembly. The heater assembly includes a one-piece, multi-passage ceramic heater core. The heater assembly is retained within the gun housing using locating features provided on the heater assembly and the gun housing. The heater assembly includes a heater housing at least partially surrounding the heater core. A biasing member biases the ceramic heater core toward a tapered outlet, which is provided by a deflecting cone surrounded by an insulating cone.