Support Insulators for Open Coil Heaters
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Solution Overview
Problem
Open coil electric heaters face a 'cross-over' problem where the coil can short to a metal plate during extreme conditions or unforeseen damage, leading to potential failure and safety concerns, and existing support insulators lack flexibility in providing adequate support.
Innovation Solution
The design includes an insulator body with metal plate attachment slots, coil support portions, and extension arms with slots that allow for secure mounting of the coil break-turn, preventing contact with the metal plate and providing adjustable support to avoid short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ceramic coil support insulators are used to hold coils, then the coils are supported on the metal plate, but the coil break-turn may touch the metal plate under extreme conditions causing short circuits
Solution Approach 1:
The support insulator is divided into multiple functional segments: a body portion for mounting on the metal plate, extension arms for supporting the coil break-turn, and coil support portions for holding the coils. This segmentation allows each part to perform its specific function independently, improving reliability without excessive complexity.
Solution Approach 2:
The support insulator extends in multiple dimensions from the metal plate surface. The body portion mounts on the plate while extension arms project outward to support the coil break-turn at an elevated position, creating spatial separation between the coil break-turn and the metal plate to prevent contact.
2Adaptability or versatility
If the support insulator provides fixed support for the coil break-turn, then short circuit prevention is achieved, but flexibility and adjustability in positioning are limited
Solution Approach 1:
The support insulator incorporates dynamic positioning capabilities through slots in the extension arms that allow adjustable positioning of the coil break-turn. This enables the structure to adapt to different coil configurations while maintaining reliable separation from the metal plate through the insulating material.
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 effectively prevents short circuits and enhances flexibility in supporting open coil electric heaters by securely routing the coil break-turn and providing adjustable positioning to maintain electrical clearance.
Implementation Method 1
The at least one open ended channel is adapted to receive a resistance wire of an open coil electric heater, the insulator body separating the resistance wire from the metal plate to avoid a short circuit of the open coil electric heater
Implementation Method 2
an insulator body having a longitudinal axis and a bottom portion including metal plate attachment slots
Implementation Method 3
at least one extension arm is provided that extends from the insulator body, the at least one extension arm having at least one extension arm slot at an end thereof
Data Source
AI summary
A support insulator for an open coil electric heater includes an insulator body having at least one coil support portion and plate attachment slots. The support insulator has an arm extending from the insulator body, the arm having a slot on an end thereof. Depending on the mounting of the support insulator, the slot can receive a resistance wire as a portion of a coil break-turn, a wire as part of a coil section, a part of a lead wire, or a part of a run of resistance wire that is not a coil break-turn or coil section.