Offset Insulator Sinusoidal Coil Heater Vibration
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Solution Overview
Problem
Open coil electric resistance heaters face issues with noise due to insulator vibration, coil shadowing, and reduced heat transfer efficiency due to straight coil configurations, which lead to undesirable operational conditions such as increased noise and reduced heating effectiveness.
Innovation Solution
The use of offset insulators to create a sinusoidal shape for the resistance wire coil, which reduces vibration, minimizes shadowing, and maximizes heat transfer by ensuring more of the duct cross-section is filled with heating elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If straight coil configurations are used, then manufacturing is simple, but heat transfer efficiency is reduced due to coil shadowing
Solution Approach 1:
The patent applies curvature by configuring the resistance wire coil in a sinusoidal pattern rather than a straight linear arrangement. This curved configuration allows air to flow through and around multiple coils without being blocked by upstream coils, eliminating the shadowing effect while maintaining manufacturing simplicity through standard coiling processes.
2Reliability
If insulators are positioned along the coil path, then coil support is provided, but insulator vibration causes noise
Solution Approach 1:
The patent positions insulators at asymmetric offset locations rather than directly along the coil path. This asymmetric arrangement provides adequate coil support while reducing the vibration transmission to the insulators, thereby minimizing operational noise without compromising support stability.
3Loss of energy
If more of the duct cross-section is filled with heating elements, then heat transfer efficiency is improved, but device complexity increases
Solution Approach 1:
The sinusoidal coil configuration naturally fills more of the duct cross-sectional area compared to straight coils, maximizing heat transfer surface area exposure to air flow. The curved pattern achieves this enhanced heat transfer efficiency without requiring complex multi-element assemblies, maintaining relative manufacturing simplicity.
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 configuration reduces noise, prevents vibration resonance, and enhances heat transfer efficiency by exposing more of the coil to the air stream, leading to improved heater performance and longer operational life.
Implementation Method 1
The heater elements 10a, 10b are supplied with electricity via terminals 12 extending from the terminal block 28
Data Source
AI summary
An open coil electrical resistance heater uses a number of offset insulators to support the coil of the heater. The offset insulators configure the run of coil in a sinusoidal shape to hold the insulators in a more secure manner and reduce vibration and noise generation during heat operation. The sinusoidal configuration of the coil also reduces the problem of shadowing of portions of the resistance wire coil.