Variable pitch resistance coil heater
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Solution Overview
Problem
Tubular heaters used in heat exchangers face performance issues such as increased hydrocarbons and fouling due to overheating, leading to bulky structures and potential failure, as they rely on constant heat generation that does not account for varying temperature gradients and heat sinks.
Innovation Solution
The use of resistance coils with varying pitches and diameters to create distinct heating zones along the tubular heater, allowing for a customizable temperature profile that adjusts heat output based on the location and temperature gradient, reducing overheating and improving heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If more tubular heaters are provided in the heat exchanger to increase heat capacity rate, then heat generation capability is improved, but the structure becomes bulky and performance deteriorates due to overheating
Solution Approach 1:
The resistance coil is designed with varying pitch along its length, creating different heating zones with different heat generation characteristics. The first portion has a first pitch and the second portion has a second pitch different from the first, allowing different sections to provide different levels of heating intensity appropriate for local thermal requirements, thus preventing overheating while maintaining high heat generation capability
Solution Approach 2:
The resistance coil is divided into multiple portions (first portion and second portion) with different pitch characteristics. This segmentation allows each portion to be optimized for specific heating requirements, enabling the system to achieve high heat capacity rate without requiring multiple separate tubular heaters that would create a bulky structure
2Ease of manufacture
If constant heat generation is used throughout the tubular heater, then manufacturing is simple, but overheating occurs due to not accounting for varying temperature gradients and heat sinks
Solution Approach 1:
The resistance coil features varying pitch where the first portion has a first pitch and the second portion has a second pitch different from the first. This allows different sections to provide different heating intensities matched to local temperature gradients and heat sink characteristics, preventing overheating while remaining manufacturable through standard coil winding processes with variable parameters
3Device complexity
If uniform pitch resistance coil is used, then device complexity is low, but heat distribution is inefficient leading to bulky structures
Solution Approach 1:
The resistance coil employs varying pitch with a first portion having a first pitch and a second portion having a second pitch different from the first. This optimization of heat distribution efficiency through variable pitch does not significantly increase device complexity, as it can be implemented through standard manufacturing processes that accommodate pitch variations, thereby improving productivity without proportionally increasing complexity
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 configuration enhances heat exchanger performance by optimizing heat distribution, reducing the size of the heater and exchanger, and preventing overheating, thereby increasing durability and reducing manufacturing costs.
Implementation Method 1
The resistance coil generates heat, which is transferred to the tubular sheath, which in turn heats a surrounding environment or part
Data Source
AI summary
A resistance element includes a resistance coil having a first end and a second end opposite the first end. The resistance coil defines a plurality of first portions defining a first constant diameter and a plurality of second portions defining a second constant diameter smaller than the first diameter. At least one of the first portions and the second portions has a continuously variable pitch. The resistance coil may also further define two third portions, each third portion being disposed adjacent to a corresponding first or second end. The resistance element may be disposed between first and second conducting pins in a heater.