Radiant Insulated Heater Structure for 1200°C Glass Processing
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Solution Overview
Problem
Conventional heaters face challenges in achieving high temperatures of 1200 degrees Celsius or more without requiring a large power supply device, and existing designs either deform or block heat radiation due to contact or insulation issues.
Innovation Solution
A heater design featuring a heat generating member, a tubular member, and an intermediate insulating member that allows heat rays to pass through, preventing contact and enabling high-temperature operation with a smaller power supply device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional heater design with insulating material is used, then electrical insulation is achieved, but heat radiation is blocked and high temperature heating is prevented
Solution Approach 1:
The patent introduces a heat-ray-transmissive intermediate member as a mediator between the heat generating member and the tubular member. This intermediate member transmits heat rays while providing electrical insulation, resolving the contradiction between electrical insulation and heat radiation efficiency. The intermediate member allows the system to achieve both reliable electrical insulation and effective high-temperature heating.
2Power
If a large current is applied to the heater, then heating power is increased, but a large-scale power supply device is required
Solution Approach 1:
The patent replaces the conventional high-current heating mechanism with a radiation-based heating mechanism. By using a heat generating member that radiates heat rays directly to the tubular member, the system achieves high heating power without requiring large currents, thereby eliminating the need for large-scale power supply devices.
3Loss of energy
If the heat generating member contacts the tubular member, then heat transfer is maximized, but electrical short circuit occurs
Solution Approach 1:
The heat-ray-transmissive intermediate member serves as an intermediary that maintains the necessary electrical insulation between the heat generating member and the tubular member while still allowing heat rays to pass through efficiently. This resolves the contradiction by providing both electrical isolation and thermal coupling through radiation.
4Reliability
If insulating material is placed between heat generating member and tubular member, then electrical insulation is provided, but heat ray transmission is blocked
Solution Approach 1:
The intermediate member is designed with specific local properties - it is transparent to heat rays in the infrared spectrum while maintaining electrical insulation. This localized quality allows the material to simultaneously provide electrical insulation and transmit heat rays, resolving the contradiction between these two requirements.
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 heater can reach temperatures of 1200 degrees Celsius or more efficiently, reducing system size and eliminating the need for large power supplies while maintaining effective heat transfer.
Implementation Method 1
a heat generating member (120, 220, 320) which is conductive and radiates heat rays by being fed with electric power
Implementation Method 2
the intermediate member is arranged and/or configured so as not to block, among the heat rays radiated from the heat generating member, at least light having a wavelength of from 1 μm to 2 μm from reaching the tubular member
Implementation Method 3
a heat generating member (120, 220, 320) which is conductive and radiates heat rays by being fed with electric power
Data Source
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AI summary
According to the present invention, provided is a heater including a heat generating member being conductive and configured to radiate heat rays by being fed with electric power, a tubular member constituted by a metal and accommodating the heat generating member, and an intermediate member arranged between the heat generating member and the tubular member and constituted by an electrically insulating material, wherein the intermediate member is arranged and/or configured so as not to block, among the heat rays radiated from the heat generating member, at least light having a wavelength of from 1 µm to 2 um from reaching the tubular member, a maximum distance between the intermediate member and the tubular member is twice or less the thickness of the intermediate member, and a maximum distance between the heat generating member and the intermediate member is less than twice the thickness of the intermediate member.