Wire Mesh Heating Segment for Fast-Response Liquid Heating
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Solution Overview
Problem
Existing liquid heaters using Nichrome wire struggle to achieve a De Luca Element Ratio of 0.1137 ohms/m^2 for efficient high-speed cooking, requiring either a large element with high heat capacity or multiple resistors in parallel, which are impractical for quick cooking times and manufacturing.
Innovation Solution
A wire mesh segment with a calibrated strand diameter of 0.3 mm and spacing of 0.3 mm, operating at 24V, is designed to achieve the desired De Luca Element Ratio, allowing for a resistive mesh element that quickly heats liquids flowing through its voids, enabling rapid heating and efficient cooking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large element with high heat capacity is used to achieve the desired De Luca Element Ratio, then heating efficiency is improved, but response time increases and manufacturing complexity increases
Solution Approach 1:
The heating element is segmented into a mesh structure consisting of multiple thin wire strands arranged in a grid pattern. This segmentation allows the element to achieve the required De Luca Element Ratio through distributed resistance across many strands rather than requiring a single large-mass element, thereby reducing thermal inertia and improving response time while maintaining heating efficiency.
Solution Approach 2:
The invention transitions from traditional linear or planar heating elements to a three-dimensional mesh structure. By distributing the heating function across multiple dimensions (width, height, and depth of the mesh), the element achieves the target De Luca Element Ratio with reduced mass and improved thermal response characteristics.
2Power
If multiple resistors in parallel are used to achieve the desired De Luca Element Ratio, then heating efficiency is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
Multiple individual resistor strands are merged into a single integrated mesh structure. The wire mesh element combines numerous parallel resistance paths into one unified component that can be installed as a single unit, reducing assembly complexity while maintaining the electrical characteristics of multiple parallel resistors.
Solution Approach 2:
The wire mesh structure serves multiple functions simultaneously: it provides the required electrical resistance, creates a large surface area for heat transfer, enables fluid flow through its open structure, and can be manufactured as a standardized component. This multi-functionality reduces overall system complexity compared to assembling multiple discrete resistors.
3Loss of time
If a wire mesh structure is used to achieve quick response time, then response time is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The invention specifies calibrated parameters for the wire mesh structure, including strand diameter of 0.3 mm and spacing of 0.3 mm, operating at 24V. By establishing standardized parameter ranges rather than requiring exact precision, the design achieves quick response time while accommodating normal manufacturing tolerances.
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 wire mesh design achieves a quick response time of less than 2 seconds for heating liquids to 1400 degrees K, allowing for efficient and fast cooking with a low-mass, easily assembled heater that can be integrated into ovens or plumbing systems.
Implementation Method 1
The wire mesh segment can include a Nichrome wire. Nichrome wire is commonly used in appliances such as hair dryers and toasters as well as used in embedded ceramic heaters.
Data Source
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AI summary
There is provided a liquid heater including: a conduit; a circuit for carrying a DC current; and a wire mesh segment disposed in the conduit and configured to receive the current, wherein the wire mesh segment has a conically shaped surface. There is provided a liquid heater kit including: a DC power supply; and a wire mesh segment configured to be disposed in a conduit and to receive a current from the DC power supply, wherein the wire mesh segment has a conically shaped surface.