Soldered Heating Cable Assembly for Uniform Electric Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric heating sources face challenges such as low energy efficiency, high thermal inertia, non-uniform temperature distribution, and reduced reliability and service life, particularly at high temperatures.
Innovation Solution
A method for producing an electric heating source that involves a body with housings for mineral-insulated heating cables, using a pure solder material in solid, powder, or sheet form, and a vacuum degassing and casting process to achieve full metal contact and uniform temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional mechanical support or intermediate compounds are used to attach heating cables to metal plates, then ease of manufacture is improved, but thermal contact quality deteriorates leading to high thermal inertia and non-uniform temperature distribution
Solution Approach 1:
The patent changes the physical state of the solder material from solid to liquid through temperature control during the attachment process. The solder is heated to its melting point to become liquid, enabling it to flow and penetrate into the clearance between the heating cable and housing, then solidifies upon cooling to create a metallurgical bond. This phase change parameter allows achieving excellent thermal contact without complex mechanical fastening systems.
Solution Approach 2:
The patent employs a composite attachment system consisting of solder material that combines the properties of both liquid (for flow and penetration) and solid (for structural support and thermal conduction). The solder forms a metallurgical bond between the heating cable and the metal plate, creating a composite structure that ensures excellent thermal contact while maintaining ease of manufacture through a single-casting process.
2Use of energy by moving object
If heating elements operate at high temperatures to achieve high energy efficiency, then energy efficiency is improved, but service life and reliability deteriorate due to thermal stress and material degradation
Solution Approach 1:
The solder acts as an intermediary material between the heating element and the metal plate housing. It creates a metallurgical bond that distributes thermal stress more evenly across the interface, reducing peak stresses on the heating element. The solder layer with its specific thermal and mechanical properties serves as a buffer that protects the heating element from direct thermal shock and mechanical stress, thereby extending service life while maintaining high operating temperatures for energy efficiency.
3Temperature
If clearance between heating elements and housing is reduced to improve thermal contact, then temperature uniformity is improved, but manufacturing precision requirements increase making production more difficult
Solution Approach 1:
The patent utilizes the temperature parameter to change the state of the solder from solid to liquid. By heating the assembly to the melting point of the solder, the material becomes fluid and can automatically flow to fill any clearance gaps between the heating elements and housing. This eliminates the need for tight manufacturing tolerances, as the liquid solder self-adjusts to achieve optimal thermal contact. Upon cooling, the solder solidifies, locking the components in place with excellent thermal coupling.
4Reliability
If complex attachment systems are used to ensure reliable thermal contact, then thermal contact quality is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single solder material: thermal conduction, mechanical attachment, stress distribution, and clearance filling. Instead of using separate components for each function (such as thermal paste, mechanical fasteners, and shims), the solder performs all these roles simultaneously through its metallurgical bonding properties. This single-casting process creates a unified structure that ensures reliable thermal contact while minimizing device complexity.
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 method enhances energy efficiency, reduces thermal inertia, improves temperature uniformity, increases reliability and service life, and simplifies manufacturing and maintenance, while achieving high temperatures with moderate heating element temperatures.
Implementation Method 1
the solder melts and fills the housing around the heating cables
Implementation Method 2
a casting plateau, during which the solder melts and fills the housing around the heating cables
Implementation Method 3
the device is heated in a vacuum degassing plateau
Implementation Method 4
Full metal contact is achieved between the cables and the body, delivering an improved uniformity of temperature
Implementation Method 5
An infrared source, at approximately 850° C., which is employed for the welding of thermoplastic parts
Data Source
AI summary
A method for creating an electric heating source, including a body equipped with one or more housings containing mineral-insulated heating cables. The housings communicate with one or more reservoirs which accept a purely metallic solder material in solid, powder or sheet form. The device is heated in a vacuum degassing plateau, followed by a casting plateau during which the solder melts and fills the housing around the heating cables, resulting in full metal contact between the cables and the body, providing a more uniform temperature and a shorter response time to heating or cooling. Also, a heating source obtained in this manner, including an infrared faired source or an immersion heater for the heating of a liquid bath of molten metal.