Variable Undulation Density Resistor for Hairdryer Heat Distribution
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Solution Overview
Problem
Current electrical resistors in hairdryers suffer from inefficient heat distribution and exchange due to fixed undulation density, leading to reduced efficiency and potential overheating, especially when air flow is obstructed by internal components, resulting in non-optimal performance and construction limitations.
Innovation Solution
An electrical resistor with a variable undulation density along its length and radius, allowing for localized control of heat exchange by adjusting the number of waves and winding tension, enabling optimized thermal power distribution and reduced overheating through tailored geometric conformations and support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the resistor uses fixed undulation density along the entire length, then the construction is simple, but the heat exchange efficiency is reduced because different regions cannot be optimized for their specific air flow conditions
Solution Approach 1:
The patent applies local quality by varying the undulation density along the length of the resistance wire. The wire is divided into multiple sections with different undulation densities - higher density in regions with better air flow and lower density in regions with obstructed air flow. This allows each region to be optimized for its specific heat exchange conditions, improving overall thermal efficiency without requiring a complete redesign of the entire resistor structure.
Solution Approach 2:
The resistance wire is segmented into multiple sections along its extension axis, with each section having a specific undulation density. This segmentation allows independent optimization of different regions while maintaining a unified construction approach. The wire can be manufactured by winding with varying tension or using multiple winding passes to achieve the desired segmented undulation pattern.
2Reliability
If the air flow is obstructed by internal components like cables and motor fastening elements, then the device structure is complete, but certain regions of the resistor become overheated due to insufficient air cooling
Solution Approach 1:
The patent addresses air flow obstruction by implementing local quality adjustments in the undulation density. Regions where air flow is obstructed by cables or motor components are identified and assigned lower undulation densities, reducing the thermal power generated in those specific areas. This prevents overheating in obstructed regions while maintaining efficient heat exchange in well-ventilated areas.
Solution Approach 2:
The patent changes the physical parameter of undulation density in response to air flow conditions. By varying this parameter along the length of the resistor, the system adapts to local air flow obstructions caused by internal components. The undulation density is reduced in regions where air flow is blocked, thereby reducing heat generation in those areas and preventing overheating.
3Adaptability or versatility
If the resistor has conical extension with variable radius, then the design flexibility is improved, but the winding construction becomes non-optimal with fewer waves per turn in regions with greater radius
Solution Approach 1:
The patent resolves the conical extension problem by applying local quality through variable undulation density. In regions with greater radius, the undulation density is increased to compensate for the reduced number of waves per turn. This ensures that each local region contributes optimally to heat exchange regardless of the varying radius, maintaining manufacturing precision and winding effectiveness throughout the conical structure.
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 achieves enhanced heat exchange efficiency, increased electric power supply, and improved structural sturdiness by dynamically varying undulation density and geometric conformations, optimizing performance and construction across different regions of the resistor.
Implementation Method 1
electrical resistor (1) to be used in air-heating apparatus with a wave-shaped resistance wire (2)
Implementation Method 2
the air flow impinges on the resistor longitudinally
Data Source
Figure 1~4
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Figure 9~10
AI summary
An electrical resistor for heating apparatus comprises a least one resistance wire that is shaped according to at least one wave form and defines coils fitted along an extension axis, and at least one insulating support adapted tc carry the coils and extending along the extension axis; the electrical resistor is of such a nature that the wave form defines a varying undulation density.