Wound Heating Element Spacers for Defined Flow Channels
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Solution Overview
Problem
Existing wound heating elements, particularly those using PTC heaters, struggle to provide large surface areas for heat transfer and efficient flow of the heat transfer medium due to their form and size, making it difficult to fit into compact installation spaces.
Innovation Solution
A spacer device comprising a windable carrier with spacer elements that define a gap between adjacent layers, allowing for easier assembly and adjustment of the heating medium flow, with varying geometry to control the cross-sectional shape and flow characteristics of the wound heating element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If PTC heaters made of ceramic are used for heating, then heating function is provided, but large surface area for heat transfer cannot be achieved and efficient flow of heat transfer medium is not possible
Solution Approach 1:
The heating element is divided into multiple thin heating films that are wound around a central axis to form a spiral structure. This segmentation allows the heating surface to be expanded while maintaining compact overall dimensions, resolving the contradiction between achieving large heat transfer surface area and maintaining efficient fluid flow.
Solution Approach 2:
The heating film is transformed from a flat two-dimensional structure into a three-dimensional spiral configuration. By winding the heating film in a spiral pattern around a central axis, the patent achieves large surface area within a compact volume while creating internal channels for efficient heat transfer medium flow.
2Volume of stationary object
If wound heating elements are used to fit large heating film into compact installation space, then installation space is reduced, but assembly complexity increases
Solution Approach 1:
Spacer elements are pre-attached to the heating film before winding, establishing defined spacing between adjacent heating film layers in advance. This preliminary action simplifies the overall assembly process by eliminating the need for complex alignment procedures during winding, as the spacers automatically maintain proper layer spacing.
Solution Approach 2:
Spacer elements serve as intermediary components between adjacent heating film layers. These spacers simplify assembly by providing a mechanical means to maintain consistent spacing, reducing the complexity of directly aligning and securing multiple heating film layers during the winding process.
3Manufacturing precision
If spacer elements are arranged between layers of heating film to provide distance, then defined channel height is achieved, but assembly complexity increases
Solution Approach 1:
The spacer elements are merged with the heating film by being pre-attached to it, creating an integrated assembly. This combining of spacer and heating film into a single unit reduces assembly complexity, as the spacers are already in their correct positions and orientations before the winding process begins.
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
Enables efficient assembly and adjustment of the heating medium flow, allowing for defined channel heights and cross-sectional shapes, enhancing heat transfer and fluid flow within compact installations.
Implementation Method 1
heating elements with a large surface are to be placed in a compact installation space... heating a fluid by electrical energy
Data Source
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AI summary
The invention relates to a spacer device (13) for producing wound heating elements (31), the spacer device (13) comprising a windable carrier (75) with spacer elements (9) arranged thereon, wherein the spacer elements (9) have a base by which the spacer elements (9) are connected to the carrier (75), or wherein the carrier (75) is formed by adjacent bases contacting each other, and wherein in unwound condition a gap (73) is formed between adjacent spacer elements (9) in winding direction of the carrier (75). The invention further relates to a wound heating element (31) comprising such spacer devices (13) and a heat exchanger comprising the wound heating element (31).