Removable Ceramic Kiln Heating Element Holder
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Solution Overview
Problem
Existing pottery and glass kiln heating element retention systems face issues with heating elements fusing into the brick or ceramic holders due to over-firing or glaze accidents, making removal and replacement difficult, and requiring costly and time-consuming kiln dismantling for repairs, which can lead to premature failure due to contamination.
Innovation Solution
A quick-change system for pottery or glass kilns featuring a removably positioned ceramic holder with a supporting surface and angled bore, and a pin for secure placement within a channel, allowing easy installation and removal of the heating element without disassembling the kiln.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating elements are held in channels formed in the kiln wall or embedded in hard ceramic holders, then the heating elements are retained in position, but the heating elements can fuse into the brick or ceramic holder due to over-firing or electrical arcing, making removal and replacement difficult
Solution Approach 1:
The invention divides the heating element retention system into separate modular components: a removable ceramic holder and the kiln wall channel. The holder contains the heating element and can be independently removed via the access opening, while the channel remains fixed in the kiln wall. This segmentation allows the holder to be replaced without dismantling the entire kiln structure.
Solution Approach 2:
The invention extracts the heating element holder from the permanent kiln structure and makes it removable through an access opening. The holder is designed to be inserted into and removed from the channel without dismantling the kiln, separating the retention function from the permanent structure and enabling easy replacement.
2Strength
If hard ceramic element holders are permanently embedded into the softer insulating brick, then the heating elements are securely held, but damaged holders cannot be removed without dismantling the entire kiln
Solution Approach 1:
The invention transforms the static, permanent embedding of the holder into a dynamic, removable arrangement. The holder can be inserted into and removed from the channel through the access opening, allowing it to transition between fixed and removable states. This enables maintenance without permanent attachment.
Solution Approach 2:
The invention incorporates an access opening that is prepared in advance during kiln construction, allowing future removal and replacement of holders without dismantling. The channel is also pre-formed in the kiln wall to receive the holder, enabling easy installation and removal operations.
3Reliability
If heating elements are pressed or pinned into place in channels, then the elements are retained, but glaze spills or burnout contaminate the channel making replacement elements fail prematurely
Solution Approach 1:
The invention extracts the heating element holder from the channel and makes it removable. The holder contains the heating element and can be removed through the access opening, taking any contamination (glaze spills or burnout debris) with it. This prevents contaminated material from remaining in the channel to affect replacement elements.
Solution Approach 2:
The invention enables the holder to be discarded (removed) when contaminated, and a fresh holder can be inserted. The removable design allows the holder to be taken out through the access opening, eliminating contaminated material from the system without requiring channel cleaning or kiln dismantling.
4Ease of repair
If the entire kiln is dismantled to fix damaged heating element holders, then complete repair is possible, but the process is time consuming, expensive and beyond the technical ability of most users
Solution Approach 1:
The invention segments the repair task from the entire kiln structure. Only the holder needs to be removed and replaced, not the entire kiln. The access opening provides a dedicated pathway for holder replacement, isolating the maintenance operation from the rest of the kiln assembly.
Solution Approach 2:
The invention enables users to perform maintenance themselves through the simple insert-remove operation via the access opening. The design eliminates the need for specialized dismantling equipment or expertise, allowing ordinary users to replace holders by hand through the pre-prepared opening.
Data Source
AI summary
A kiln of the pottery or glass type and of insulating firebrick or ceramic fiber with an interior wall includes: a ceramic holder for holding a wound electrical heating element; a channel in the interior wall for receiving and supporting the ceramic holder. The ceramic holder is removably positionable within the slot with means for receipt and holding the wound electrical heating element when the ceramic holder is positioned within the channel in a first preferred embodiment, the ceramic holder has a supporting surface for receipt of the heating element and an inner, upper lip for holding the heating element on the ceramic holder. The interior wall has a horizontal retaining slot aligned with the ceramic holder supporting surface, the supporting surface has an outer end received within the retaining slot and an inwardly angled bore and a pin passing through the bore into the interior wall for holding the ceramic holder removably in place. In an alternate embodiment, the channel has an upper outwardly projecting corner and a lower vertical slot, the ceramic element holder has a vertical outer wall integral with the supporting surface with an upper end for positioning and pivoting within the upper corner and an outer lower lip for positioning within the lower vertical slot when the ceramic element holder is positioned in place.