Serpentine Aircraft Heating Elements for Vibration Resistance
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Solution Overview
Problem
Aircraft air heaters face challenges with pressure drop, uneven heating, and vulnerability to vibration due to thin, flat heating elements, which require additional support structures that restrict airflow and increase weight, and they often switch between laminar and turbulent flow patterns, affecting efficiency and durability.
Innovation Solution
The use of serpentine, non-planar, or corrugated heating elements supported only at the sides by non-conductive rings, made of high resistance nickel chromium alloy, with thermal and resistance sensors for temperature control, and three-phase electrical current to maintain efficient airflow and robustness without internal support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If thin, flat heating elements are used to reduce weight and improve heat transfer, then weight is reduced and heat transfer is improved, but the elements become too weak to withstand vibration without additional support structures
Solution Approach 1:
The patent applies curvature to the heating elements by using serpentine (sinusoidal) patterns instead of flat configurations. This curvature provides structural strength to withstand vibration while maintaining the thin, lightweight design. The serpentine shape allows the elements to flex and resist vibrational forces without requiring additional support structures that would block airflow.
2Strength
If support structures are added to strengthen thin heating elements, then element strength is improved, but airflow area is reduced and pressure drop increases
Solution Approach 1:
The serpentine configuration provides the necessary strength through its curved geometry without requiring additional support structures. The curvature itself acts as the strengthening mechanism, eliminating the need for internal supports that would restrict airflow and increase pressure drop.
3Reliability
If support structures are added to prevent element failure, then reliability is improved, but device complexity increases
Solution Approach 1:
The serpentine shape integrates the strengthening function directly into the heating element geometry itself, rather than requiring separate support structures. This single geometric feature simultaneously provides heating capability and structural strength, reducing overall device complexity.
4Stress or pressure
If thin, flat heating elements are used to minimize pressure drop, then pressure drop is reduced, but the elements switch between laminar and turbulent flow patterns reducing efficiency
Solution Approach 1:
The serpentine configuration of the heating elements creates a more stable flow pattern. The curved geometry guides airflow smoothly through the heater, preventing the sporadic transition between laminar and turbulent flow that occurs with flat elements. This maintains heating efficiency while keeping pressure drop low.
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 minimizes pressure drop, ensures even heating, enhances airflow stability, reduces the need for additional fans, and makes the heater more robust and lightweight, capable of withstanding vibration and varying airflow rates while maintaining temperature control.
Implementation Method 1
A power supply supplies electrical current to the heating elements such that air passing through the air passage is heated by the heating elements
Data Source
AI summary
A heater for heating air passing through a conduit to an aircraft cabin includes a first support ring in the conduit, defining an air passage there through. A plurality of serpentine heating elements is provided, with each heating element extending across the air passage and being supported at both sides of the air passage by the support ring. The serpentine heating elements are generally parallel to each other and evenly spaced in the air passage. A power supply supplies electrical current to the heating elements such that air passing through the air passage is heated by the heating elements. The heating elements may are non-planar, wavy, corrugated in shape, permitting them to be supported only at their side edges.