Heating element with open-cell structure
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Solution Overview
Problem
Conventional heating elements have limited energy transfer efficiency due to a small area-to-volume ratio, are structurally weak, and prone to deformation and creep under high temperature operations, making them unsuitable for uniform heating of irregular objects and adapting to voltage/current sources.
Innovation Solution
A three-dimensional latticework matrix heating element with an open structure, featuring openings, voids, and pores, designed for enhanced thermal energy transfer and structural strength, allowing for flexible configurations and integration with secondary bodies, manufactured via additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional thin wires or strips are used as heating elements, then the device complexity is low, but the energy transfer efficiency is limited due to small area-to-volume ratio
Solution Approach 1:
The heating element transitions from conventional two-dimensional thin wires or strips to a three-dimensional latticework structure. This dimensional change dramatically increases the surface area-to-volume ratio, enabling significantly enhanced energy transfer efficiency while maintaining reasonable structural complexity through the use of repeating unit cells.
Solution Approach 2:
The heating element employs a porous latticework structure with open cells that provide high surface area for heat transfer. The porous nature of the three-dimensional matrix allows fluid penetration and maximizes contact between the heating element and the fluid being heated, thereby improving energy transfer efficiency.
2Area of stationary object
If larger heating elements are used to increase heating capacity, then the heating coverage is improved, but the structural strength decreases causing deformation and creep
Solution Approach 1:
The heating element is divided into multiple repeating unit cells that form a latticework structure. This segmentation allows the heating element to achieve large overall dimensions for increased heating coverage while each individual unit cell maintains structural integrity. The modular nature of the segmented structure prevents deformation and creep even at large scales.
Solution Approach 2:
The heating element combines the heating function with a structurally robust latticework framework. The three-dimensional matrix structure provides both the necessary heating surface area and the mechanical strength to resist deformation and creep under thermal and gravitational loads, effectively creating a composite functional-structural system.
3Adaptability or versatility
If conventional solid heating elements are used, then the structural integrity is good, but the adaptability to voltage/current sources and uniform heating of irregular objects is limited
Solution Approach 1:
The heating element incorporates electrical conductors integrated within the latticework structure that can be configured to match different voltage and current source requirements. This dynamic configurability allows adaptation to various electrical sources while the surrounding latticework provides structural integrity, enabling the heating element to maintain its composition stability under different operational conditions.
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 latticework matrix provides a high surface area-to-volume ratio, improving thermal energy transfer efficiency, structural integrity, and flexibility, enabling effective heating of fluids and solids while withstanding mechanical and thermal stresses.
Implementation Method 1
enhanced thermal energy transfer from a body of the heating element to a receiving phase such as a fluid flowing in contact with the heating element or to a solid body to be heated by radiation
Implementation Method 2
enhanced thermal energy transfer from a body of the heating element to a receiving phase such as a fluid flowing in contact with the heating element or to a solid body to be heated by radiation
Implementation Method 3
Electric heaters typically include an electrical resistance heating element to heat a fluid or a solid object. Conventionally, relatively thin wires, strips or tubes of metal alloy are used as the heating elements with the heating effect achieved by the passage of current and the wire's, or tube's, electrical resistance
Data Source
AI summary
A heating element comprises a main body having a three-dimensional matrix with an open structure including openings and internal voids, cavities and/or pores extending throughout the main body. The three-dimensional matrix is provided as a lattice having a repeating unit cell extending in three directions. The present heating element is adapted for maximised surface area so as to provide an effective and efficient thermal energy transfer medium.