Stackable Heater Trays With Cutouts For Thermal Expansion

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Solution Overview

Problem

Furnace structures and heating elements face premature failure due to uneven thermal expansion, leading to cracks and breakage, as they expand at different rates when exposed to high temperatures, causing mechanical instability and electrical shorts.

Innovation Solution

The use of stackable trays with alignment pins and cutout portions allows for expansion of heating elements, preventing mechanical stress and electrical shorts, while a unique bussing scheme and thermocouple placement ensure efficient heat distribution and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If heating elements are held firmly by ceramic separators at fixed points for mechanical stability, then mechanical stability is improved, but the heating elements expand or elongate beyond these points leading to premature failure or breakage

Engineering Contradiction:

Improvemechanical stabilityVSAvoidheating element lifespan

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The heating element is designed with a dynamic configuration where the central portion is positioned closer to the furnace wall than the end portions. This asymmetric positioning allows the heating element to expand and elongate in a controlled manner toward the central region, accommodating thermal expansion without creating excessive mechanical stress that would lead to breakage at the ceramic separator fixed points.

Inventive Principle:

Principle #15Dynamics

2Strength

If furnace structure components are made rigid to maintain structural integrity, then structural integrity is improved, but uneven thermal expansion causes cracks and breakage

Engineering Contradiction:

Improvestructural integrityVSAvoidfurnace structure durability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The furnace structure incorporates localized flexible elements specifically at strategic positions where thermal expansion stresses are most pronounced. These flexible elements are integrated into the rigid furnace structure to provide localized compliance, allowing different regions of the furnace to expand at different rates without causing cracks or breakage in the overall structure.

Inventive Principle:

Principle #3Local quality

3Use of energy by moving object

If heating elements are positioned closer to the furnace wall for efficient heat transfer, then heat transfer efficiency is improved, but thermal expansion causes mechanical stress and electrical shorts

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidheating element reliability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The heating element employs a dynamic positioning strategy where the central portion is placed closer to the furnace wall for efficient heat transfer, while the end portions extend outward. This configuration, combined with the asymmetric expansion accommodation, allows the heating element to maintain optimal thermal contact while providing built-in clearance for thermal expansion, preventing both mechanical stress and electrical shorts.

Inventive Principle:

Principle #15Dynamics

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 solution enhances the lifespan of heating elements by accommodating thermal expansion, preventing mechanical failure and electrical shorts, and allows for efficient thermocouple placement, resulting in a high-performance heater with improved reliability and cost-effectiveness.

Implementation Method 1

a first alignment pin that insulates a first heating element disposed in the first stackable tray

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

an area between the outer diameter and the inner diameter of the stackable trays comprises at least one cutout portion that allows expansion of the material(s) when the high performance heater is at high temperatures

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

heating elements such as resistance wires

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS8987641B2High performance heater

Publication Date: 2015.03.24 EMAMI ARSALAN

AI summary

Systems and methods are provided for a high performance heater. In an embodiment, the high performance heater comprises a first stackable tray comprising a first alignment pin that insulates a first heating element disposed in the first stackable tray; a second stackable tray comprising a second alignment pin that insulates a second heating element disposed in the second stackable tray, wherein a top of the first alignment pin fits into a cutout of a bottom of the second alignment pin when the first and second stackable trays are stacked, and wherein the first and second stackable trays comprise one or more materials, an outer diameter and an inner diameter, and wherein an area between the outer diameter and the inner diameter of the stackable trays comprises at least one cutout portion that allows expansion of the material(s) when the high performance heater is at high temperatures.