Superalloy Wave Spring for High-Temperature Heater Retention
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Solution Overview
Problem
Existing air heater systems for internal combustion engines face issues with wave springs deforming due to excessive repetitive cycling, leading to loss of functionality and potential for open or short circuits, especially when subjected to high temperatures and vibration.
Innovation Solution
The use of wave springs constructed from superalloys, such as Inconel 718, which maintain a substantially constant force up to 650°C, providing robust suspension and resistance to deformation under extreme conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wave springs are constructed from stainless steel sheet, then the heater performs well during normal use, but the springs deform and take a set under excessive repetitive cycling and high temperatures
Solution Approach 1:
The patent changes the material parameters of the wave spring by transitioning from stainless steel to a superalloy composition containing nickel, chromium, cobalt, and other alloying elements. This material parameter change enables the spring to maintain its mechanical properties and dimensional stability at temperatures up to 650°C, preventing the deformation and permanent setting that occurs with conventional stainless steel under repetitive thermal cycling
Solution Approach 2:
The patent employs a composite alloy material with specific proportions of nickel (20-40%), chromium (15-30%), cobalt (5-20%), and other elements to create a wave spring that combines the benefits of corrosion resistance, high-temperature strength, and fatigue resistance. This composite material approach resolves the contradiction by providing both normal-use reliability and resistance to thermal deformation
2Duration of action of moving object
If the heater is subjected to excessive repetitive cycling, then the wave springs may take a set and become permanently deformed, but using conventional materials does not prevent this deformation
Solution Approach 1:
The patent modifies the material parameters by using a superalloy with enhanced high-temperature strength and creep resistance. This allows the wave spring to withstand excessive repetitive cycling without permanent deformation, maintaining its elastic properties and functionality even after prolonged exposure to thermal cycling conditions that would cause conventional springs to fail
3Temperature
If the wave spring is exposed to high temperatures, then the material may lose its elastic properties and deform, but conventional stainless steel cannot maintain performance above moderate temperatures
Solution Approach 1:
The patent changes the material composition parameters to include high-temperature superalloying elements such as nickel, chromium, and cobalt in specific proportions. These compositional changes enable the wave spring to maintain its strength and elastic properties at temperatures up to 650°C, resolving the contradiction between extended temperature range and maintained mechanical strength
Solution Approach 2:
The patent uses a composite superalloy material that combines multiple alloying elements to achieve both high-temperature resistance and maintained strength. The synergistic effect of nickel for heat resistance, chromium for oxidation resistance, and cobalt for strength at elevated temperatures creates a material that simultaneously achieves extended temperature range and preserved mechanical properties
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 superalloy wave springs ensure consistent performance and retention of the heating element, preventing deformation and maintaining electrical and mechanical integrity even at high temperatures, thus addressing the issues of deformation and vibration-induced failures.
Implementation Method 1
The spring is formed from a superalloy and is operable to output a substantially constant force at a predetermined deflection up to approximately 650° C.
Data Source
AI summary
A method of manufacturing a heater having a heating element, an insulator and a spring is disclosed. The method includes forming a spring from an annealed superalloy material, heat treating the spring after forming, positioning the heating element in contact with the insulator, and biasedly engaging the spring with the insulator to maintain contact between the insulator and the heating element.