One-Piece Heater Rack with Attachment Nodes for Coil Support
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Solution Overview
Problem
Existing heater rack designs require multiple components, lead to material waste, and are not adaptable for both air flow over and through configurations, often resulting in short circuiting issues due to coil sagging and limited capacity for supporting multiple coils.
Innovation Solution
A one-piece heater rack with arrays of attachment nodes that allow secure positioning of ceramic supports from either side, minimizing the risk of short circuiting and accommodating various air flow configurations without additional components or assembly steps, using a single sheet of material for flexibility and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate parts are used to construct the heater assembly, then the heater can accommodate various components (thermostats, mounting brackets, ceramic supports), but the assembly complexity increases and more welding/fastening operations are required
Solution Approach 1:
The patent combines multiple separate components (heater rack, ceramic support mounts, terminal mounts, air flow control features) into a single integrated formed structure. This one-piece construction eliminates the need for multiple welding or fastening operations while maintaining the capacity to accommodate thermostats, mounting brackets, and ceramic supports through built-in features
Solution Approach 2:
The formed structure serves multiple functions simultaneously: it provides structural support for heating elements, incorporates mounting points for ceramic supports and terminals, includes air flow control features, and offers attachment points for additional heater components. This multi-functionality reduces the need for separate specialized parts
2Manufacturing precision
If material is removed from raw material stock to create the heater assembly, then the required features can be achieved, but material waste increases and cost increases
Solution Approach 1:
The patent transitions from a subtractive manufacturing approach (removing material) to a formative manufacturing approach (shaping material). The formed structure is created by molding or forming material into the desired configuration, which minimizes waste while achieving the required precision for mounting features and structural integrity
3Device complexity
If the heater rack structure is simplified to reduce parts, then assembly is simplified, but the ability to support multiple coils and accommodate components is reduced
Solution Approach 1:
The formed structure integrates multiple support functions into a single component, including ceramic support mounts, terminal mounts, and structural supports for multiple coils. This consolidation maintains the capacity to support multiple heating elements while eliminating the need for separate brackets and mounting hardware
4Device complexity
If the heater rack is designed for air flow parallel to the rack, then the structure can be simplified, but it cannot accommodate air flow through the rack configuration
Solution Approach 1:
The formed structure incorporates dual air flow capabilities by integrating both parallel and through-flow passages and openings into the single structure. This design allows the same heater assembly to accommodate different air flow configurations without requiring structural modifications, enhancing versatility while maintaining 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
The solution reduces material waste, simplifies assembly, enhances air flow control, and supports multiple coils without risking short circuiting, making it suitable for various heating applications with improved efficiency and reduced component complexity.
Implementation Method 1
open type coil electrical resistance heating elements
Data Source
AI summary
A one-piece heater rack includes a number of arrays of attachment nodes and a surrounding peripheral structure. The attachment nodes are configured to allow the attachment of ceramic supports, the ceramic supports designed to hold open type coil electrical resistance heating elements that make up of a heater assembly using the heater rack. The attachment nodes allow attachment of the ceramic supports from above and below the heater rack for ease of installation. The heater rack also includes other features that providing mounting support for other heater assembly elements like terminals, thermostats, temperature limit switches, and air flow control over and through the heater using the peripheral structure, the arrays of attachment nodes or combinations thereof.