Segmented Flat Winding Electric Heater for Multi-Stage Operation
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Solution Overview
Problem
Existing devices for converting electricity into heat are optimized for a single mode of operation, limiting their flexibility for use as both electric heaters with multiple heating stages and load resistors, requiring multiple device configurations for different power consumption ranges.
Innovation Solution
A device with two flat winding supports made of electrically insulating material, where a first and second electric heating element are wound and inserted into a housing with additional insulation to ensure electrical isolation, allowing for varying heat output by switching or connecting the heating elements in series or parallel, and using different voltages with high dielectric strength insulation to manage galvanic separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single flat winding support with one heating element is used, then the device structure is simple, but the device can only operate in one mode and cannot achieve multiple heating stages
Solution Approach 1:
The heating device is segmented into multiple independent heating elements (first heating element and second heating element), each wound on separate flat winding supports. This segmentation allows each element to be independently controlled and switched, enabling multiple operational modes including individual operation of each element, simultaneous operation, series connection, and parallel connection, thereby achieving multiple heating stages without requiring multiple separate devices.
Solution Approach 2:
The device is designed with multi-functionality by incorporating multiple heating elements that can operate in various configurations. The heating elements can be switched individually or connected in series/parallel to provide different power consumption ranges and heating outputs, making the single device universally applicable for both heater applications with multiple stages and load resistor applications with different energy requirements.
2Adaptability or versatility
If multiple heating elements are added to achieve multiple heating stages, then operational flexibility improves, but the insulation requirements and device complexity increase
Solution Approach 1:
Electrically insulating plates are introduced as intermediary elements between the heating elements and between the heating elements and the housing. These insulating plates ensure reliable electrical isolation, preventing short circuits while allowing the multiple heating elements to be densely packed and efficiently arranged within the housing, thereby maintaining high reliability despite the increased number of components.
Solution Approach 2:
The insulating plates are strategically positioned at specific locations where electrical isolation is most critical - between adjacent heating elements and between the heating elements and the conductive housing. This localized application of insulation ensures that reliability is enhanced precisely where needed, without adding unnecessary insulation material or complexity throughout the entire device.
3Power
If the device is designed for high power consumption range, then it can handle large energy dissipation, but it cannot efficiently operate at lower power levels
Solution Approach 1:
The device incorporates dynamic switching capability that allows the heating elements to be connected in different configurations (individually, in series, or in parallel) based on the required power level. This dynamic reconfiguration enables the device to adapt its total power consumption across a wide range, from low power when only one element operates to high power when all elements operate simultaneously or in parallel, thereby achieving both high maximum power capability and efficient operation at lower power levels.
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
Enables flexible operation as both electric heaters with multiple heating stages and load resistors, allowing for efficient energy dissipation and compact, reliable insulation, even under mechanical stress, with a high number of operational modes.
Implementation Method 1
Electric current is sent through an electric heating element, typically a resistance wire or heat conductor, and it generates heat
Implementation Method 2
The first flat winding support being disposed in the housing electrically insulated relative to the housing by the first insulation, a second flat winding support disposed in the housing galvanically separated from the first flat winding support by the further insulation, second electrical insulation and a second electric heating element wound on the second flat winding support
Data Source
AI summary
A device (100, 200, 1100, 2100) converts electricity into heat. A first flat winding support (110, 130, 210a, 210b, 230a, 230b, 310a, 310b, 330a, 330b, 510, 610, 630, 710, 1110, 1130, 2110, 2130) including electrically insulating material, has a first electric heating element (140, 150, 240a, 240b, 250a, 250b, 340a, 340b, 350a, 350b, 540, 640, 650, 740, 750) wound thereon. The first flat winding support with wound first electric heating element is inserted into a housing (190, 290, 1190, 2190) electrically insulated against the housing. A second flat winding support, including electrically insulating material, has a second electric heating element (140, 150, 240a, 240b, 250a, 250b, 340a, 340b, 350a, 350b, 540, 640, 650, 740, 750), which is galvanically separated from the first electric heating element, wound thereon. The second flat winding support with wound second electric heating element is inserted into the housing electrically insulated against the housing.