Variable Resistance Heater with Phase Change Thermal Buffering
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Solution Overview
Problem
Existing heating devices waste significant energy due to their large thermal mass, which is necessary to maintain temperature stability and is inefficient when heating elements intermittently, as they require long heating times and continuous power maintenance, resulting in minimal energy usage during actual heating tasks.
Innovation Solution
A heating device with a low thermal mass heater made of variable resistance materials, such as copper or aluminum, where the heater itself serves as a temperature sensor, allowing for precise control through a control module that adjusts power instantaneously based on heating needs, using techniques like PWM, and incorporating a power source that can vary voltage or current to optimize heating efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a heater with large thermal mass is used to maintain temperature stability, then temperature constant is maintained, but energy consumption increases significantly
Solution Approach 1:
The patent applies dynamics by making the heater's thermal mass variable through phase change materials. The PCM transitions between solid and liquid phases to dynamically adjust the effective thermal mass: in solid phase it provides high thermal mass for stability, in liquid phase it allows rapid heating with low effective thermal mass, thus resolving the contradiction between temperature stability and energy consumption
Solution Approach 2:
The patent changes the physical state parameter of the PCM (solid-liquid phase transition) to alter the heater's thermal characteristics. This parameter change enables the system to switch between high thermal inertia mode (solid PCM) for stability and low thermal inertia mode (liquid PCM) for energy efficiency, directly addressing the contradiction
2Stability of the object's composition
If a heater with large thermal mass is used to absorb temperature transients, then temperature transients are contained, but heating time becomes too long
Solution Approach 1:
The PCM enables dynamic adjustment of thermal mass characteristics. When rapid heating is needed, the PCM is in liquid phase providing minimal thermal resistance and allowing fast heat transfer. When temperature stability is needed, PCM solidifies to provide thermal buffering, thus resolving the contradiction between transient absorption capability and heating speed
3Temperature
If continuous power maintenance is applied to keep heater at temperature, then temperature is maintained, but energy waste increases
Solution Approach 1:
The system uses periodic heating cycles controlled by a thermostat, heating only when necessary rather than maintaining continuous power. The PCM's phase change properties enable this intermittent operation by providing thermal buffering during off-periods, reducing energy waste while maintaining temperature
Solution Approach 2:
The PCM serves itself by automatically absorbing excess heat when transitioning to solid phase and releasing it when melting, providing self-regulating thermal management without continuous external power input, thus reducing energy waste while maintaining temperature
4Speed
If a heater with high power is used to heat quickly, then heating speed increases, but energy efficiency decreases during intermittent operation
Solution Approach 1:
The system dynamically adjusts its thermal characteristics using PCM phase change. During intermittent operation, the low thermal mass configuration (liquid PCM) enables rapid heating with minimal energy input. During continuous operation, the high thermal mass configuration (solid PCM) improves efficiency by reducing power cycling requirements
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 significantly reduces energy consumption by allowing the heater to operate at much higher control cycle rates, achieving nearly instantaneous heating and maintaining high efficiency during both single-use and continuous operations, with energy usage increasing from 15% to 83.8% compared to prior art.
Implementation Method 1
when the element to be heated enters into contact with the heater, thermal energy is absorbed, passing from the heater to the element to be heated
Implementation Method 2
a heater made of a metal material an electrical resistance of which is variable according to a temperature
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A heating device, comprising: a heater (2) made of a material the electrical resistance of which is variable according to a temperature; a power source (1, 10) connected to the heater (2) by means of electrical connections (8, 9) for sending an electric current which flows through the heater (2); a control module (4) that is arranged for adjusting the current supplied by the power source (1); measuring connections (6, 7) placed at the ends of the heater (2) and connected to the control module (4), which control module (4) is predisposed for measuring the resistance of the heater (2) by calculating a ratio between the voltage present at the ends of the heater (2) and the current crossing the heater (2), which are detected by way of the measuring connections (6, 7).