Flexible Silicone Rubber Heater for Complex Fluid Line Geometry
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Solution Overview
Problem
Existing fluid transmission line heaters are inflexible and cannot accommodate complex geometries, requiring precise sizing and are prone to damage when bent, and often integrated with the line, making replacement costly and difficult.
Innovation Solution
A flexible heater system comprising oblong bodies made of thermally conductive compressible material with a silicone rubber support layer and heater element, allowing conformability to complex shapes and easy removal for cleaning and replacement without replacing the entire line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional wire wound heater elements are used, then heating function is provided, but the heater cannot accommodate complex geometries and requires precise sizing
Solution Approach 1:
The patent uses a flexible silicone rubber heater element that can conform to complex geometries of fluid transmission lines. The silicone rubber material allows the heater to be bent and shaped to fit around pipes, elbows, tees, and other components with varying cross-sections, eliminating the need for precise sizing and custom fabrication required by rigid wire wound elements.
Solution Approach 2:
The patent changes the physical state and properties of the heater material from rigid wire wound structure to flexible silicone rubber. This parameter change allows the heater to adapt its shape and conform to different geometries, providing versatility while simplifying installation and manufacturing.
2Adaptability or versatility
If heater is bent to accommodate structural obstacles, then adaptability is improved, but electrical heater elements can be damaged
Solution Approach 1:
The silicone rubber heater element inherently possesses flexibility and elasticity, allowing it to be bent and conform to complex shapes without damaging the heating element. The flexible material structure distributes mechanical stress throughout the body, preventing localized damage that would occur with rigid wire wound elements.
Solution Approach 2:
The patent employs composite construction with silicone rubber as the base material, which combines flexibility with thermal conductivity. This composite approach maintains the structural integrity of the heater element while enabling it to withstand bending and deformation required for accommodating structural obstacles.
3Loss of energy
If heater is integrated with fluid line, then heating efficiency is improved, but replacement requires replacing entire line
Solution Approach 1:
The patent designs the heater as a separate, removable component that can be independently replaced. The silicone rubber heater element is configured to fit around the fluid line but is not permanently integrated, allowing it to be detached and replaced without replacing the entire fluid line assembly. This segmentation maintains heating efficiency through close contact while enabling easy maintenance.
Solution Approach 2:
The heater element is designed as a replaceable component that can be discarded and replaced independently. When the heater becomes worn or damaged, only the heater element needs to be replaced rather than the entire fluid line, reducing maintenance costs and downtime while preserving the heated fluid line infrastructure.
4Manufacturing precision
If heater must closely fit pipe geometry, then heating uniformity is improved, but heater cannot be used on components with different geometries
Solution Approach 1:
The silicone rubber heater element provides a flexible shell that can conform to various pipe geometries including round pipes, rectangular ducts, elbows, tees, and reducers. The material's elasticity allows it to closely fit different shapes while maintaining uniform thermal contact, eliminating the need for geometry-specific heater designs.
Solution Approach 2:
The patent creates a universal heater design that can be applied to multiple types of components with different geometries. The flexible silicone rubber construction allows a single heater type to serve multiple functions across various pipe sizes and shapes, improving versatility while maintaining manufacturing precision through the material's conformability.
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 system provides uniform heating to complex-shaped fluid lines, reduces the need for precise alignment, and allows for easy cleaning and replacement of heater components without replacing the entire fluid line, enhancing flexibility and reducing maintenance costs.
Implementation Method 1
a first oblong body which comprises: a block of resiliently compressible, conforming material... a heater element layer supporting an electrical heater element; wherein said heater element layer is superimposed over said silicone rubber support layer
Implementation Method 2
a block of resiliently compressible, conforming material... that can conform to the complex-shaped structures of a fluid transmission line
Data Source
AI summary
A flexible, substantially lamellar silicone foam rubber-based heater for heating fluid lines such as high temperature gas supply and exhaust lines used in microelectronic semiconductor fabrication uses a flexible, oblong substantially longitudinally uniform heater body including an oblong block of a thermally conductive, resiliently compressible material for conforming the heater to a line of complexly shaped components connected in series. The block can be supported by a silicone rubber support layer in contact with a flexible heater element containing layer, and an outer silicone foam rubber insulation layer. Fasteners, such as separatable retaining bands spaced along the line can hold the heater in place. A matable pair of bodies, or a single folded body can enwrap the line.