Open Coil Heater Layout for Balanced Multistage Heat Distribution

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Solution Overview

Problem

Existing open coil electric heaters with multiple stages face challenges in achieving balanced and efficient heat distribution across both sides of a support plate, often requiring expensive ceramic insulators and labor-intensive terminal connections, which can be cumbersome and prone to deterioration due to high temperatures.

Innovation Solution

A multistage open coil electric resistance heater design where the coils are arranged to provide even power distribution across the top and bottom and right to left sides of the support plate, with all coil ends located at one end for simplified routing and secure lightweight terminal connections, eliminating the need for special ceramic insulators and reducing the risk of overheating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If heater coils are arranged with one coil completely on one side of the plate and the second coil on the opposite side, then the heater structure is simple to manufacture, but heat distribution becomes unbalanced with only one side heated during first stage

Engineering Contradiction:

Improveheater structure simplicityVSAvoidheat distribution balance

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The heater coils are segmented into multiple runs that are distributed across both sides of the support plate. Each coil is divided into several runs that alternate sides, ensuring balanced heat distribution while maintaining manufacturing simplicity through modular coil construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the heater provide different heating functions through strategically placed coil runs. The coil configuration creates zones of heating on both sides of the plate, with each run positioned to optimize local heat distribution patterns

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If coil ends are routed to opposite sides of the plate, then heat distribution may be improved, but terminal connections become complex and require expensive ceramic insulators

Engineering Contradiction:

Improveheat distribution balanceVSAvoidterminal connection complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

All coil ends are merged and routed to the same side of the support plate, consolidating terminal connections into a single location. This eliminates the need for ceramic insulators on multiple sides and simplifies the terminal connection structure while maintaining balanced heat distribution through proper coil run arrangement

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coil runs themselves serve as intermediaries that carry current across the support plate structure. By routing all ends to one side through carefully designed coil paths, the system eliminates the need for additional insulating intermediary components

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If wire leads are made longer to reach terminal block, then connection flexibility is improved, but supporting the connector portions becomes more difficult and costly

Engineering Contradiction:

Improveconnection flexibilityVSAvoidsupport structure requirements

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The coil ends are preliminarily positioned and routed along predetermined paths before reaching the terminal block. This preliminary arrangement minimizes lead length and eliminates the need for additional support structures by incorporating the routing into the coil assembly itself

Inventive Principle:

Principle #10Preliminary action

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 design achieves uniform heat distribution, reduces the likelihood of mechanical instability and shorting, and allows for the use of heavier gauge wire, enhancing mechanical stability and efficiency while minimizing the complexity and cost of terminal connections.

Implementation Method 1

Each of the electric heater elements, 10a and 10b, is arranged in series of electrically continuous coils... Upon energizing the first stage of heat, only the air on one side of the plate is heated

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS9320083B2Multiple stage open coil electric resistance heater with balanced coil power arrangement and method of use

Publication Date: 2016.04.19 TUTCO INC

AI summary

An open coil electrical resistance heater subassembly for use in a heater has a support plate dividing the heater into at least two portions. At least two resistance wire coils are supported on the support plate using a plurality of insulators. Each insulator is configured to provide support to a portion of the resistance wire coil. The at least two resistance wire coils are arranged with respect to the support plate so that the coil power for each coil is distributed generally evenly between the top and bottom of the support plate and across the width of the support plate.