Tubular Heating Element Embedded in Powder Granulate
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Solution Overview
Problem
Existing electrical heating devices face issues with inadequate heat removal due to void formation, high production costs, and uneven thermal contact, leading to failure and inefficiency, particularly in cylindrical geometries and dense winding configurations.
Innovation Solution
A tubular heating element with a metal jacket is partially embedded in a powder or granulate, which provides a homogeneous thermal contact and reduces production complexity, allowing for flexible geometry adaptation and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tubular heating element is cast in place, then the heating element is securely embedded, but voids form spontaneously leading to inadequate heat removal
Solution Approach 1:
The heating element is pre-formed with a metal jacket before embedding. This preliminary preparation ensures structural integrity and prevents void formation during the embedding process, as the pre-formed element can be carefully positioned and secured without spontaneous cavity formation
2Reliability
If grooves are introduced in metal or insulating material surfaces to embed the heating element, then thermal contact is improved, but the production work involved is high
Solution Approach 1:
The heating element is extracted from the complex groove-making process entirely. Instead of creating grooves to accommodate the heating element, the element is pre-formed with an integrated metal jacket that provides its own embedding structure, eliminating the need for separate groove formation operations in the metal or insulating material
Solution Approach 2:
The metal jacket is merged with the heating element itself, combining the heating function and the embedding structure into a single integrated component. This eliminates the need for separate embedding structures like grooves, reducing production complexity while maintaining thermal contact quality
3Reliability
If the heating element is pressed into metal interfaces, then secure embedding is achieved, but the heating element deforms and ohmic resistance changes
Solution Approach 1:
The metal jacket acts as a protective cushion around the heating element before embedding. This pre-formed protective layer prevents direct contact between the heating element and the metal interface, cushioning against deformation and compression forces during the embedding process, thereby maintaining dimensional stability and consistent ohmic resistance
4Power
If dense windings with small pitches are used, then heating efficiency is improved, but complete enclosure of windings cannot be achieved
Solution Approach 1:
The metal jacket provides a porous or mesh-like embedding structure that can penetrate and surround even densely wound heating elements with small pitches. This porous embedding approach allows complete enclosure of the windings while maintaining the high heating efficiency of dense windings, as the metal jacket structure can adapt to and surround tightly packed windings
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
This solution results in a cost-effective, reliable, and efficient heat removal system with improved thermal contact homogeneity, preventing failures associated with uneven heating and deformation, and enabling flexible geometric designs for various applications.
Implementation Method 1
tubular heating element, which comprises the actual heating conductor
Implementation Method 2
the powder or granulate... provides a homogeneous thermal contact... efficient heat dissipation
Data Source
Figure 1a~1c
Figure 2a~2f
Figure 2g~2k
AI summary
The invention relates to an electric heating device (10, 30, 40, 50, 60, 70, 100), in particular for heating surfaces of components onto which the electric heating device (10, 30, 40, 50, 60, 70, 100) is pushed or placed, with at least one tubular heating element (1, 11, 31, 41, 51, 61, 71, 82, 101) having a metal sheath, and with at least one boundary surface in which the tubular heating element (1, 11, 31, 41, 51, 61, 71, 82, 101) is at least partially embedded in at least one powder or granulate (2, 32, 42, 52, 62, 72, 102), wherein the powder or granulate (2, 32, 42, 52, 62, 72, 102) is in contact with at least parts of the at least one boundary surface, and a method for Manufacture of an electric heating device (10, 30, 40, 50, 60, 70, 100) for heating surfaces of components onto which the electric heating device (10, 30, 40, 50, 60, 70, 100) is pushed or placed during its use,comprising at least the steps of providing at least one boundary surface and a tubular heating element (1, 11, 31, 41, 51, 61, 71, 82, 101) arranged relative to the boundary surface; of at least partially embedding the tubular heating element (1, 11, 31, 41, 51, 61, 71, 82, 101) in a powder or granules (2, 32, 42, 52, 62, 72, 102) which at least partially abuts the at least one boundary surface; and of compacting at least the powder or granules (2, 32, 42, 52, 62, 72, 102).