WO2023089431A1

WO2023089431A1 - Heater assembly

Info

Publication number: WO2023089431A1
Application number: PCT/IB2022/060515
Authority: WO
Inventors: Sreenivasa H V
Original assignee: S, Rekha T
Priority date: 2021-11-17
Filing date: 2022-11-01
Publication date: 2023-05-25

Abstract

The heater assembly (100) comprises of a heating element (102) and at least one first coupling member (104). The heating element (102) comprises of first zone (108) and second zone (110), wherein the second zone (110) is disposed towards ends of the first zone (108). The first coupling member (104) is detachably coupled to the heating element (102) in a. manner that at least a portion of the first coupling member (104) interfaces with at least a portion of the second zone (110). The heater assembly (100) further comprises of at least one second coupling member (106a, 106b), wherein the second coupling member (106) is detachably coupled to the first coupling member (104).

Description

HEATER ASSEMBLY

BACKGROUND

[0001] Unless otherwise indicated herein, the materials described in this section are not prior art to the claims in this application and are not admitted to being prior art by inclusion in this section.

FIELD OF THE INVENTION

[0002] The subject matter in general relates to heating systems. More particularly, but not exclusively, the subject matter relates to a modular heating assembly.

DISCUSSION OF THE RELATED FIELD

[0003] Heating dementis) form a basic part of any heating system, wherein the heating elements are configured to perform the basic function of heating system i.e., delivering heat according to the requirements. The present invention relates to heating elements employed in electric furnaces. Different types of heating elements are available in the market and are being extensively used in industry. Silicon- Carbide (SiC) heating element is one among the many heating elements employed in electric furnaces. SiC heating element offers a range of benefits over the metallic heating elements. Benefits offered by the SiC heating element are that the SiC heating elements are higher resistance to oxidation, higher watt loading per square centimetre capacity, higher strength and better shock resistance, among others. For the reasons cited above, SiC heating elements are prioritized over metallic heating elements for at least a temperature range of about 1550°C.

[0004] Over a period of operation, the heating element(s) would require replacement for several reasons like deterioration, arcing, cracking and degradation on the hot zone, among others. However, with the SiC heating elements currently available in the market there are a few shortcomings. The SiC heating elements comprises of a hot zone and a cold zone, wherein the cold zones are used for electrical connection for power supply. In some cases, ends of the SiC heating element is usually welded with low resistance cold zones allowing the ends to operate at a much lower temperature as compared to the hot zone. The cold zones are integrated with the heating element by welding therefore forming a single unit of heating element with the cold zones. In some cases, the cold zones are formed on the heating element itself by coating or impregnating the heating element with other metal. In both the cases discussed above, the cold zones run a longer length as the cold zone terminals are required for electrical connections and electrical connections are possible only at a lower temperature for known reasons.

[0005] T he problem with heating elements with long integrated cold zones is that the whole setup has to be replaced with a new one if any issues arise with respect to the heating element. Replacing the entire setup every time is not a cost effective method as manufacturing of heating element and cold zones, and also the process of engaging the cold zones to the heating element is not only time consuming but also a costly process.

[0006] Hence there is a need for a heater assembly that is cost efficient and one that provides a modular setup which would ease the assembly and maintenance of the heater assembly.

SUMMARY

[0007] In one aspect of the embodiment, a heater assembly is provided. The heater assembly comprises of a heating element and at least one first coupling member. The heating element comprises of a first zone and a second zone, wherein the second zone is disposed towards at least one end of the first zone. The first coupling member is detachably coupled to the heating element in a manner that at least a portion of the first coupling member interfaces with at least a portion of the second zone. The heater assembly further comprises of at least one second coupling member, wherein the second coupling member is detachably coupled to the first coupling member. During operation, the first zone of the heating element, is at a higher temperature as compared to the second zone of the heating element.

BRIEF DESCRIPTION OF DRAWINGS

[0008] Embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:

[0009] FIG. 1A is a perspective view of a heater assembly 100, in accordance with an embodiment;

[0010] FIG. IB is an exploded perspective view of a heater assembly 100, in accordance with an embodiment,

[0011] FIG. 2A is a perspective view of a heating element 102, in accordance with an embodiment;

[0012] FIG. 2B is a cross section view of the heating element 102, in accordance with an embodiment,

[0013] FIG. 3 A is a perspective view of a heating element 300 with a second cavity 306, in accordance with an embodiment,

[0014] FIG. 3B is a cross section view of the heating element 300, in accordance with an embodiment,

[0015] FIG. 4A is a perspective view of a heating element 400 step turned at its ends, in accordance with an embodiment;

[0016] FIG. 4B is a cross section view of the heating element 400 step turned at its ends, in accordance with an embodiment;

[0017] FIG. 5 A is a perspective view of a heating element 500 with three zones, in accordance with an embodiment;

[0018] FIG. 5B is a cross section view of the heating element 500 with three zones, in accordance with an embodiment;

[0019] FIG. 6A is a perspective view of a first coupling member 104, in accordance with an embodiment;

[0020] FIG. 6B is a cross section view of the first coupling member 104, in accordance with an embodiment;

[0021] FIG. 7 A is a perspective view of a first coupling member 700, in accordance with an embodiment;

[0022] FIG. 7B is a cross section view of the first coupling member 700, in accordance with an embodiment;

[0023] FIG. 8A is a perspective view of a first coupling member 800, in accordance with an embodiment; [0024] FIG. 8B is a cross section view of the first coupling member 800, in accordance with an embodiment;

[0025] FIG. 9A is a perspective view of a first coupling member 900, in accordance with an embodiment;

[0026] FIG. 9B is a cross section view of the first coupling member 900, in accordance with an embodiment;

[0027] FIG. 10 i s a cross section view of a heater assembly 1000, in accordance with an embodiment;

[0028] FIG. 11 is a cross section view of a. heater assembly 1100, in accordance with an embodiment;

[0029] FIG. 12 i s a cross section view of a heater assembly 1200, in accordance with an embodiment;

[0030] FIG. 13 is a cross section view of a heater assembly 1300, in accordance with an embodiment;

[0031] FIG. 14 i s a cross section view of a heater assembly 1400, in accordance with an embodiment; and

[0032] FIG. 15 is a perspective view of a heater assembly 1500, in accordance with an embodiment.

DETAILED DESCRIPTION

[0033] The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show illustrations in accordance with example embodiments. These example embodiments, which may be herein also referred to as “examples” are described in enough detail to enable those skilled in the art to practice the present subject matter. However, it may be apparent to one with ordinary skill in the art, that the present invention may be practised without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to unnecessarily obscure aspects of the embodiments. The embodiments can be combined, other embodiments can be utilized, or structural, logical, and design changes can be made without departing from the scope of the claims. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope is defined by the appended claims and their equivalents.

[0034] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive “or,” such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated.

[0035] In the embodiments that shall be discussed, components may define a circular cross section. However, the components may not be limited to circular profile and may define any geometrical cross-section or combination of different geometrical cross-secti ons .

[0036] Referring to FIGS. 1A-1B, a heater assembly 100 is disclosed, in accordance with an embodiment. The heater assembly 100 may comprise of a heating element 102, at least one first coupling member 104a and 104b (referred as 104 in general) and at least one second coupling member 106a and 106b (referred as 106 in general). The heating element 102 may be made of, but not limited to, Silicon-Carbide (SiC). The SiC heating element 102 is a liner type resistance heater configured to convert electrical energy into heat energy. Therefore, when electric current is passed through the heating element 102, heat may be generated because of the electrical resistance offered by the heating element 102. The heating element 102 may comprise of at least a first zone 108 and at least one second zone 110a and 110b (referred as 110 in general). The second zones 110a and 110b may be disposed towards ends of the first zone 108 of the heating element 102. The first zone 108 and the second zone 110 of the heating element 102 may be configured to have different electrical resistances and therefore may operate at different temperatures. The first zone 108, during operation, may be configured to operate at higher temperature as compared to the second zone 110. The first coupling member 104 may be configured to be detachably coupled to the heating element 102 in a manner that at least a portion of the first coupling member 104 interfaces with at least a portion of the second zone 110. The second coupling member 106 may be configured to be detachably coupled to the first coupling member 104 in a manner that at least a portion of the first coupling member 104 interfaces with the second coupling member 106. The second coupling member 106 may be configured to be coupled to a power supply via electrical connections 112a and 112b (referred as 112 in general) to provide power supply to the heating element 102.

[0037] In an embodiment, the electrical connections 112 may be made of, but not limited to, braided aluminium straps, wherein the braided aluminium straps may be connected to the second zones 110 of the heating element 102.

[0038] Referring to FIGs. 2A-2B, heating element 102 is disclosed, in accordance with an embodiment. The heating element 102 may be a hollow tube. The heating element 102 may have two ends i.e., a first end 202 and a second end 204. The first end 202 and the second end 204 may be disposed towards extremes of the heating element 102 in a manner that the first end 202 may be disposed opposite to the second end 204. The heating element 102 may be made of, but not limited to, Silicon-Carbide (SiC). SiC offers high electrical resistance and therefore offers higher working temperatures when electric current is passed through the heating element 102.

[0039] In an embodiment, the heating element 102 may comprise of at least two zones, first zone 108 and second zone 110a and 110b, wherein the second zone 110a and 110b may be disposed on either side of the first zone 108 towards the first end 202 and the second end 204, respectively. The first zone 108 and the second zone 110 of the heating element 102 may be configured to have different surface electrical resistances. The second zones 110 of the heating element 102 may be configured to have a lower surface electrical resistance as compared to the surface electrical resistance of the first zone 108. Higher electrical resistance offers higher working temperature and lower electrical resistance offers lower working temperature. Therefore, the first zone 108 may also be referred to as a hot zone and the second zone 110 may be referred to as a cold zone. Surface electrical resistance of the SiC heating element 102 may be varied by coating the heating element 102 with any of the metallic materials 206 like, but not limited to, silicon, aluminium, titanium, and titanium -aluminium.

[0040] In an embodiment, the second zone 110 of the heating element 102 may be conceived by coating at least a portion of the heating element 102 towards the first end 202 and the second end 204 with any of the metallic materials 206 like, but not limited to, silicon, aluminium, titanium, and titanium -aluminium. The metallic coating may fill up the pores in the SiC heating element 102 thereby lowering the surface electrical resistance of the heating element 102 thereby forming the second zone 110. The lower surface electrical resistance of the second zone 110 in turn allows the second zone 110 to operate at a much lower temperature as compared to the first zone 108.

[0041] In an embodiment, the heating element may be a solid rod.

[0042] Referring to FIGS 3A-3B, a heating element 300 is disclosed in accordance with an embodiment. The heating element 300 may be provided with a second cavity 306 that may be configured to extend into at least a portion of the heating element 300. The heating element 300 may comprise of at least two zones, a first zone 308 and a second zone 310. The second zone 310 may be conceived by coating inner surface of the second cavity 306 with any of the metallic materials 206 like, but not limited to, silicon, aluminium, titanium, and titanium-aluminium. The second cavity 306 may be coated with metallic material for a required length.

[0043] In an alternate embodiment, a heating element may be a hollow tube with a predetermined thickness defining hollow’ space along its length. At least a portion of the heating element may be coated with metallic materials to conceive a second zone. The metallic materials may be coated either on an outer surface of the heating element or inner surface of the heating element.

[0044] In an embodiment, electrical resistance of at least a portion of hollow heating elements may be varied by filling up the portion of hollow space with good electrical conducting materials known in the industry, thereby allowing to operate at lower temperatures.

[0045] In an embodiment, zirconium and amorphous graphite is mixed with a hardener to create a paste of the said materials. This paste of zirconium, graphite and hardener may be filled towards ends of the hollow heating element and then allowed to cure for 24 hours at room temperature. Upon curing, the paste hardens thereby conceiving a second zone which is configured to operate at lower temperatures.

[0046] In yet another embodiment, a paste of silicon (75%), graphite (15%) and coke with resin (10%) may be filled towards ends of the hollow heating element. The ends of the heating element may be preheated at 130°C for 20 mins. The ends may then be sintered at about 1200°C for 20 mins. At this stage the silicon may fuse with graphite and coke forming a solid thereby conceiving a second zone which is configured to operate at lower temperatures. The purpose here is to convert a hot zone into a cold zone.

[0047] Referring to FIGS 4A-4B, a heating element 400 is disclosed in accordance with an embodiment. The heating element 400 may be a hollow tube. The heating element 400 may comprise of a first end 402 and a second end 404. At least a portion of the heating element 400 towards the first end 402 and the second end 404 may be step turned to have a smaller diameter. At least a portion of the step turned heating element 400 may be coated with any of the metallic materials like, but not limited to, silicon, aluminium, titanium, and titanium-aluminium to conceive the portion into second zone 410. The heating element 400 may have a similar configuration as that of the heating element 102 discussed in the foregoing with at least two zones, first zone 408 and second zone 410 and is therefore not repeated for the sake of brevity.

[0048] Referring to FIGS. 5A-5B, heating element 500 with three zones is disclosed, in accordance with an embodiment. The heating element 500 may comprise of a third zone 502 in addition to the first zone 108 and second zones 110. The third zone 502 may be disposed between the first zone 108 and second zone 110 of the heating element 500 . The surface electrical resistance of the third zone 502 of the heating element 500 may be configured to be higher than that of the second zone 110 but lower than that of the first zone 108 of the heating element 500, thereby enabling working temperature of the third zone 502 of the heating element 102 to be higher than that of the second zone 110 but lower than that of the first zone 108 of the heating element 500. The third zone 502 may be configured to function as a transition zone between the first zone 108 and the second zone 110 of the heating element 500, wherein temperature from the first zone 108 transitions from a higher temperature to a lower temperature at the second zone 110, The third zone 502 may be conceived by coating at least a portion of the heating element 500 with any of the metallic materials 504 like, but not limited to, silicon, aluminium, titanium, or titanium-aluminium. The metallic coating may fill the pores in the SiC heating element 500 thereby lowering the surface electrical resistance of the heating element 500 thereby forming the third zone 502. The second zone 110 may then be conceived by coating at least a portion of the third zone 502 of the heating element 500 with any of the metallic materials 506 like, but not limited to, silicon, aluminium, titanium, or titanium-aluminium.

[0049] In an embodiment, the third zone 502 may be conceived by coating at least a portion of the heating element 500 with Titanium- Aluminium and the second zone 110 may be conceived by further coating at least a portion of the third zone 502 with Aluminium.

[0050] In an alternate embodiment, the heating element 102 may be provided with a plurality of zones as per requirements.

[0051] Referring to FIGS. 6A-6B, first coupling member 104 is disclosed, in accordance with an embodiment. The heater assembly 100 may comprise of two first coupling members 104a and 104b, wherein each of the first coupling member 104 may be configured to be detachably coupled to the second zone 110 of the heating element 102 (refer FIG. 2B). The structural construction and configuration of the two first coupling members 104 may be similar and therefore construction of a single first coupling member 104 is hereby disclosed in greater detail. The first coupling member 104 may have, but not limited to, a similar profile as the heating element 102.

[0052] In an embodiment, the first coupling member 104 may comprise of a proximal end 602 and a distal end 604. The proximal end 602 of the first coupling member 104 may define a first cavity 606. The first cavity 606 of the first coupling member 104 may be configured to receive at least a portion of the heating element 102. The first cavity 606 may have a profile similar, but not limited to, the heating element 102. The first coupling member 104 may be configured to be detachably coupled to the heating element 102 in a manner that the first cavity 606 of the first coupling member 104 may be configured to receive at ieast a portion of the heating element 102, more specifically at least a portion of the second zone 110 of the heating element 102.

[0053] In an embodiment, the distal end 604 of the first coupling member 104 with the first cavity 606 may comprise of a protruding member 608, wherein the protruding member 608 may be provided with a first thread 610. The first thread 610 may be at least one external thread.

[0054] In an embodiment, first coupling member may be, but not limited to, soiid, hollow, or partially solid tube.

[0055] Referring to FIGS. 7A-7B, a first coupling member 700 is disclosed, in accordance with an embodiment. The first coupling member 700 may be configured to be detachably coupled to the second zone 110 of the heating element 102 (refer FIG. 2B). The structural construction and configuration the first coupling member 700 is hereby disclosed in greater detail. The first coupling member 700 may have, but not limited to, a similar profile as the heating element 102. The first coupling member 700 may comprise of a proximal end 702 and a distal end 704. The proximal end 702 of the first coupling member 700 may define a first cavity 706. The first cavity 706 of the first coupling member 700 may be configured to receive at least a portion of the heating element 102. The first cavity 706 may have a profile similar, but not limited to, the heating element 102. The first coupling member 700 may be configured to be detachably coupled to the heating element 102 in a manner that the first cavity 706 of the first coupling member 104 may be configured to receive at least a portion of the heating element 102, more specifically at least a portion of the second zone 110 of the heating element 102.

[0056] In an embodiment, the distal end 704 of the first coupling member 700 may be provided with a third cavity 708, wherein the third cavity 708 may be provided with a first thread 710. The first thread 710 may be at least one internal thread.

[0057] Referring to FIGS. 8A-8B, a first coupling member 800 is disclosed, in accordance with an embodiment. The first coupling member 800 may be configured to be detachably coupled to the second zone 310 of the heating element 300 (refer FIG. 3B). The structural construction and configuration the first coupling member 800 is hereby disclosed in greater detail. The first coupling member 800 may have, but not limited to, a similar profile as the second cavity 306 of the heating element 300. The first coupling member 800 may define a cavity 806. The cavity 806 of the first coupling member 800 may be provided with a third thread 808. The first thread 808 may be at least one internal thread. The first coupling member 800 may be configured to be detachably coupled to the heating element 300 in a manner that the second cavity 306 of the heating element 300 may be configured to receive at least a portion of the first coupling member 800.

[0058] Referring to FIGS. 9A-9B, a first coupling member 900 is disclosed, in accordance with an embodiment. The first coupling member 900 may be configured to be detachably coupled to the second zone 310 of the heating element 300 (refer FIG. 3B). The structural construction and configuration the first coupling member 900 is hereby disclosed in greater detail. The first coupling member 900 may have, but not limited to, a similar profile as the heating element 300. The first coupling member 900 may comprise of a proximal end 902 and a distal end 904. The proximal end 902 of the first coupling member 900 may comprise of a first protrusion 906. The first protrusion 906 of the first coupling member 900 may be configured to be received in at least a portion of the heating element 300. The first protrusion 906 may have a profile similar, but not limited to, the second cavity 306 of the heating element 300. The first coupling member 900 may be configured to be detachably coupled to the heating element 300 in a manner that the second cavity 306 of the heating element 300 may be configured to receive at least a portion of the first protrusion 906 of the first coupling member 900.

[0059] In an embodiment, the distal end 904 of the first coupling member 900 may be provided with a second protrusion 908, wherein the second protrusion 908 may be of any diameter. The second protrusion 908 may be provided with a third thread 910. The third thread 910 may be at least one external thread.

[0060] In an embodiment, first coupling member may be, but not limited to, solid, hollow, or partially solid tube.

[0061] In an embodiment, first coupling members may be made of metallic materials like, but not limited to, steel, stainless steel, copper, and aluminium. Since the first coupling members are made of metallic materials, the electrical resistance of the first coupling members are lower thereby operating at lower temperatures. The first coupling members may be detachably coupled to the heating element via different methods like, but not limited to, using adhesive, or press fit which comprises of hot press fit and cold press fit, or threaded coupling. The methods shall now be described in greater detail.

ADHESIVE COUPLING

[0062] Referring to FIG. 10 cross section of heater assembly 1000 is disclosed, in accordance with an embodiment. The heating element 102 and the first coupling member 104 may define, but not limited to, a circular cross-section. The first cavity 606 defined by the first coupling member 104 may have a marginally larger inner diameter as compared to outer diameter of the second zone 110 of the heating element 102. An adhesive material (not shown in the figures) like, but not limited to, Zirconium paste may be appli ed over at least an external portion of the second zone 110 of the heating element 102 that may be configured to be received by the first cavity 606 of the first coupling member 104. The first coupling member 104 may then be di sposed over the portion of the second zone 110 of the heating element 102 with the adhesive, in a manner that the second zone 110 of the heating element 102 interfaces with the first cavity 606, and then allowed to cure at room temperature. Upon curing, the first coupling member 104 may be coupled to the heating element 102,

[0063] Referring to FIG. 11 cross section of heater assembly 1100 is disclosed, in accordance with an embodiment. The heating element 400 and the first coupling member 104 may define, but not limited to, a circular cross-section. The first cavity 606 may have a marginally bigger internal diameter as compared to outer diameter of the step turned first end 402 and second end 404 of the heating element 400. Outer di ameter of the first coupling member 104 may be configured to be of a same diameter as that of outer diameter of the second zone 410 of the heating element 400 before step turning. Adhesive material like, but not limited to, Zirconium paste may be applied over at least an external portion of the step turned heating element 400 that may be configured to be received by the first cavity 606 of the first coupling member 104. The first coupling member 104 may then be disposed over the step turned portion of the heating element 400 with the adhesive, in a manner that the step turned portion of the heating element 400 interfaces with the first cavity 606, and then allowed to cure at room temperature. Upon curing, the first coupling member 104 may be coupled to the heating element 400.

[0064] Referring to FIG. 12 cross section of heater assembly 1200 is disclosed, in accordance with an embodiment. The heating element 300 and the first coupling member 800 may define, but not limited to, a circular cross-section. The first coupling member 800 may define, but not limited to, a similar profile as that of the second cavity 306 defined by the heating element 300. Outer diameter of the first coupling member 800 may be same or marginally smaller than internal diameter of the second cavity 306 defined by the heating element 300. An adhesive material like, but not limited to, Zirconium paste may be applied over at least an external portion of the first coupling member 800 and then be received by the second cavity 306 of the heating element 300, and then allowed to cure at room temperature. Upon curing, the first coupling member 800 may be coupled to the heating element 300.

[0065] In an embodiment, the heating element may define but not limited to, a circular or a polygonal cross-section. Similarly, the first cavity may define, but not limited to, a circular or any of polygonal cross-sections.

PRESS FIT COUPLING

[0066] In an embodiment, the first coupling member may be detachably coupled to the heating element via a hot press fit method or a cold press fit method. Both the hot press fit, and the cold press fit method will now be explained in greater detail.

[0067] (The heater assembly, that shall now be discussed, may be similar to the heater assembly 1000 disclosed in FIG. 10 and therefore can be referred to the same for understanding) In an embodiment, heating element 102 and first coupling member 104 may define, but not limited to, a circular cross-section. The first cavity 606 defined by the first coupling member 104 may be, but not limited to, a circular cross- section. The first cavity 606 defined by the first coupling member 104 may have a marginally smaller inner diameter as compared to outer diameter of the second zone 110 of the heating element 102. The first coupling member 104 may be heated such that the heating element 102 expands thereby expanding the inner diameter of the first coupling member 104. The first coupling member 104 may be configured to be hot pressed over at least a portion of the second zone 110 of the heating element 102. The first cavity 606 of the first coupling member 104 may be configured to receive at least a part of the heating element 102 when the first coupling member 104 is expanded by heating. Upon receiving the heating element 102, the first coupling member 104 may be allowed to cool, wherein upon cooling, the heating element 102 is trapped within the first cavity 606 of the first coupling member 104, thereby coupling the heating element 102 to the first coupling member 104.

[0068] (The heater assembly, that shall now be discussed, may be similar to the heater assembly 1100 disclosed in FIG. 11 and therefore can be referred to the same for understanding) In an embodiment, the heating element 400 and the first coupling member 104 may define, but not limited to, a circular cross-section. The first cavity 606 defined by the first coupling member 104 may be, but not limited to, a circular cross-section. The first cavity 606 may have its internal diameter marginally smaller than outer diameter of the step turned first end 402 and second end 404 of the heating element 400. Outer diameter of the first coupling member 104 may be configured to be of a same diameter as that of outer diameter of the second zone 110 of the heating element 400. The first coupling member 104 may be configured to be hot pressed over at least a portion of the step turned first end 402 and second end 404 of the heating element 400. The first cavity 606 of the first coupling member 104 may be configured to receive at least a part of the step turned first end 402 and second end 404 of the heating element 400 when the first coupling member 104 is expanded by heating. Upon receiving the part of the step turned first end 402 and second end 404 of the heating element 400, the first coupling member 1104 may be allowed to cool, wherein upon cooling the step turned first end 402 and second end 404 of the heating element 400 is trapped within the first cavity 606 of the first coupling member 104, thereby coupling the heating element 400 to the first coupling member 104.

[0069] (The heater assembly, that shall now be discussed, may be similar to the heater assembly 1200 disclosed in FIG. 12 and therefore can be referred to the same for understanding) In an embodiment, the heating element 300 and the first coupling member 800 may define, but not limited to, a circular cross-section. The cavity 806 defined by the first coupling member 800 may be, but not limited to, circular or any of polygonal cross-section. The first coupling member 800 may define, but not limited to, a similar profile as that of the second cavity 306 defined by the heating element 300 . Outer diameter of the first coupling member 800 may be same as that of internal diameter of the second cavity 306 defined by the heating element 300. At least a portion of the first coupling member 800 may be configured to be received within the second cavity 306 of the heating element 300 by cold pressing the first coupling member 800 into the second cavity 306 of the heating element 300. The first coupling member 800 may be frictionally held within the second cavity 306 of the heating element 300, thereby coupling the first coupling member 800 to the heating element 300.

[0070] In an alternate embodiment, the heating element may be a hollow tube, wherein first end and second end of the heating element may be configured to receive at least a portion of the first coupling member.

THREADED COUPLING

[0071] In an embodiment, heating element and first coupling member may define, but not limited to, a circular cross-section. At least a portion of outer surface of first end and second end of the heating element may be coated with metallic materials like, but not limited to, silicon, aluminium, titanium, and titaniumaluminium thereby conceiving second zone. The coating of the metallic materials may be sufficiently thick to be engraved with at least one external thread. The first coupling member towards its proximal end may be provided with a first cavity, wherein the first cavity may define at least one internal thread. The heating element may be configured to be detachably coupled to the first coupling via the threads provided on the heating element and the first cavity of the first coupling member. The internal thread(s) on the first coupling member may be configured to interface with the external thread(s) on the heating element when the first coupling member is coupled to the heating element.

[0072] In an alternate embodiment, heating element and first coupling member may define, but not limited to, a circular cross-section. The heating element may define second cavity towards its first end and second end. At least a portion of inner surface of the second cavity of the heating element may be coated with metallic materials like, but not limited to, silicon, aluminium, titanium, and titaniumaluminium thereby conceiving second zone. The coating of the metallic materials may be sufficiently thick to be engraved with at least one internal thread. The first coupling member towards its proximal end may be provided with at least one external thread. The heating element may be configured to be detachably coupled to the first coupling via the threads provided on the first coupling member and the second cavity of the heating element. The internal thread(s) provided in the cavity of the heating element may be configured to interface with the external thread(s) on the first coupling member, when coupled.

[0073] In an alternate embodiment, heating element may be a hollow tube, wherein its first end and second end may be coated with metallic materials like, but not limited to, silicon, aluminium, titanium, and titanium-aluminium to conceive second zone. The coating of the metallic materials may be sufficiently thick to be engraved with at least one internal thread. The first coupling member with at least one external thread may be configured to be coupled to the heating element via the threads provided on the first coupling member and the heating element.

[0074] In the embodiments discussed in the foregoing, distal end of the first coupling member may be configured to be detachably coupled to the second coupling member in a manner that at least a portion of the first coupling member may be configured to interface with at least a portion of the second coupling member. Different embodiments of the second coupling members with different ways in which the first coupling member may be coupled to the second coupling member will now be discussed in greater detail.

[0075] Referring to FIG.1A-1B and FIG. 10, heater assembly 1000 is disclosed, in accordance with an embodiment. The second coupling member 106 may define a fourth cavity 1002 on its one end. End opposite to the end with the fourth cavity 1002 may be configured to allow electrical connections for supplying power to the heating element 102 via the second coupling member 106 and the first coupling member 104. The fourth cavity 1002 may define a second thread 1004 for enabling coupling of the first coupling member 104 with the second coupling member 106. The second thread 1004 may be at least one internal thread. The external thread(s) 610 on the first coupling member 104 may be configured to interface with the internal thread(s) 1004 on the second coupling member 106, when coupled,

[0076] Referring to FIG. 12, an alternate embodiment of heater assembly 1200 comprising a second coupling member 1202 is disclosed. The second coupling member 1202 may comprise of a protruding member 1204, wherein the protruding member 1204 may be provided with a fourth thread 1206. The fourth thread 1206 may be at least one external thread. The external thread(s) 1206 on the protruding member 1204 of the second coupling member 1202 may be configured to interface with the internal thread(s) 806 on the first coupling member 800, when coupled.

[0077] Referring to FIG. 13, an alternate embodiment of heater assembly 1300 comprising a second coupling member 1302 is disclosed. First coupling member 700 may be detachably coupled to the heating element 102 by adhesive coupling or press fit coupling discussed in the foregoing. Distal end 704 of the first coupling member 700 may define third cavity 708, wherein the third cavity 708 may be provided with a first thread 710. The first thread 710 may be at least one internal thread. The second coupling member 1302 may comprise of a protruding member 1304, wherein the protruding member 1304 may be provided with a second thread 1306. The second thread 1306 may be at least one external thread. The external thread(s) 1306 on the second coupling member 1302 may be configured to interface with the internal thread(s) 710 on the first coupling member 700, when coupled.

[0078] Referring to FIG. 13, an alternate embodiment of heater assembly 1400 comprising first coupling member 900 and second coupling member 1402 is disclosed. First protrusion 906 of the first coupling member 900 towards proximal end 902 may be received by the second cavity 306 defined by the heating element 300. The second coupling member 1402 may define a third cavity 1404 on its one end. The third cavity 1404 may define a second thread 1406 for enabling coupling of the second coupling member 1402 with the first coupling member 900. The second thread 1406 may be at least one internal thread. The external thread(s) 910 on the first coupling member 900 may be configured to interface with the internal thread(s) 1406 on the second coupling member 1402, when coupled.

[0079] In an alternate embodiment, the first coupling member and the second coupling member may be detachably coupled by push fit, wherein any one among the first coupling member or the second coupling member may be provided with a cavity' and any one among the first coupling member or the second coupling member may be provided with a protruding member with a profile similar to the cavity. At least a portion of the protruding member may be configured to be received by at least a portion of the cavity, thereby coupling the first coupling member to the second coupling member.

[0080] In an embodiment, electrical connections may be directly given to the first coupling member, wherein the first coupling member is sufficiently long that the second zone remain unaffected by higher operating temperatures from the first zone of the heating element.

[0081] Referring to FIG. 15, an alternate embodiment of a heater assembly 1500 is disclosed. The heater assembly 1500 comprises of a heating element 1502. The heating element may be provided with at least two zones, a first zone 1504 and a. second zone 1506. The second zone 1506 of the heating element 1502 may be provided on one end and the first zone 1504 may extend away from the second zone 1506. The second zone may be conceived by same method disclosed in the foregoing. The heating element 1502 may be hollow' and may be provided with a gap 1508 that runs helically through its length in a manner on one end two terminals are formed, and on another end the gap 1508 ends in a manner that a continuity of the heating element 1502 is provided. The heater assembly 1500 may comprise of only one first coupling member 1510 configured to be detachably coupled to the second zone 1506 of the heating element 1502. A second coupling member 1512 may be provided that may be configured to be detachably coupled to the first coupling member 1510. The coupling of the first coupling member 1510 to the heating element 1502, and the coupling of the first coupling member 1510 to the second coupling member 1512 may be achieved by any of the methods discussed in the foregoing.

[0082] In an embodiment, electrical connections 1514 for power supply may be coupled to the second coupling member 1512.

[0083] In an alternate embodiment, electrical connections 1514 for power supply may be directly coupled to the first coupling member 1510.

[0084] In an embodiment, the first and the second coupling member may be made of metallic materials like, but not limited to, steel, stainless steel, copper, and aluminium. Since the first coupling member and the second coupling member are made of metallic materials the electrical resistance is lower thereby operating at lower temperatures.

[0085] In another embodiment, wherein heating elements are priorly welded with cold zones at its ends, surface coating of the heating element would then not be necessary. The pre-welded cold zones may be configured to be detachably engaged to metallic coupling members, to which electrical connection for supplying power to the heating element may be coupled. In cases with pre-welded cold zones, heating element with the pre-welded cold zone may be replaced, thereby reusing the metallic coupling member.

[0086] The configurations of the heater assembly disclosed in the foregoing offers a wide range of benefits. With the modular design of the heater assembly, it is possible to only replace the heating element from the heater assembly as the heating element is configured to be detachably coupled to the coupling members, in cases which call for replacement of heating element. Since the coupling members are detachably coupled, same coupling members may be reused by just replacing the heating element and therefore not necessitating replacement of the coupling members with every replacement of the heating element. Furthermore, since the coupling members are made of metallic materials, they offer lower electrical resistance therefore offering lower operating temperatures and also low power consumption. The coupling members can be manufactured at a lower cost and are also basically unbreakable thereby offering longer life. The metallic coupling members can be reused and can also be recycled.

[0087] In addition to the advantages, the modular design of the heater assembly offers easy assembling and disassembling of the heater assembly, which in turn offers ease in overall maintenance.

[0088] The processes described above is described as a sequence of steps. This was done solely for the sake of illustration. Accordingly, it is contemplated that some steps may be added, some steps may be omitted, the order of the steps may be re-arranged, or some steps may be performed simultaneously.

[0089] Although embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the system and method described herein. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

[0090] Many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. It is to be understood that the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the personally preferred embodiments of this invention.

Claims

CLAIMS We Claim:

1. A heater assembly (100), wherein the assembly (100) comprises: a heating element (102) comprising: a first zone (108); and a second zone (110a, 110b) disposed towards at least one end of the first zone (108); and at least one first coupling member (104a, 104b), wherein: at least a portion of the first coupling member (104a, 104b) interfaces with at least a portion of the second zone (110a, 110b); and the first coupling member (104a, 104b) is detachably coupled to the heating element (102), characterized in that, the assembly comprises: at least one second coupling member (106a, 106b), wherein the second coupling member (106a, 106b) is detachably coupled to the first coupling member (104a, 104b); wherein: the first zone (108) of the heating element (102), during operation, is at a higher temperature compared to the second zone (110a, 110b) of the heating element (102), and the second zone (110a, 110b) of the heating element (102) is conceived by coating at least a portion of the heating element (102) with a metallic material that is configured to reduce surface electrical resistance in the second zone (110a, 110b).

2. The heater assembly (100) as claimed in claim 1 , wherein the metallic material is a Titanium-Aluminum material.

3. The heater assembly (100) as claimed in claim 1 , wherein coating the second zone ( 110a, 110b) of the heating element (102) with metallic material reduces surface electrical resistance of the second zone (110a, 110b).

4. The heater assembly ( 100) as claimed in claim 1 , wherein: the first coupling member (104a, 104b) comprises of a proximal end (602) and a distal end (604), wherein: the proximal end (602) of the first coupling member (104a, 104b) defines a first cavity (606), wherein the first cavity (606) is configured to receive at least a portion of the second zone (110a, 110b) of the heating element (102); and the distal end (604) of the first coupling member (104a, 104b) is provided with a first thread (610).

5. The heater assembly (100) as claimed in claim 4, wherein: the second coupling member (106a, 106b) is provided with a second thread (1004); and the first thread (610) towards the distal end (604) of the first coupling member (104a, 104b) interfaces with the second thread (1004) on the second coupling member (106a, 106b) thereby detachably coupling the first coupling member (104a, 104b) to the second coupling member (106a, 106b).

6. The heater assembly (100) as claimed in claim 1, wherein: the first coupling member (800) comprises of a proximal end (802) and a distal end (804); the heating element (300) defines a second cavity (306), wherein the second cavity (306) is configured to receive at least a portion of the first coupling member (800); and the first coupling member (800) comprises of a third thread (808).

7. The heater assembly (100) as claimed in claim 6, wherein: the second coupling member (1202) is provided with a fourth thread (1206), and the third thread (808) on the first coupling member (800) interfaces with the fourth thread (1206) on the second coupling member (1202) thereby detachably coupling the first coupling member (800) to the second coupling member (1202).

8. The heater assembly (100) as claimed in claim 1, wherein the first coupling member (104a, 104b) is detachably coupled to the heating element (102) via press fit.

9. The heater assembly (100) as claimed in claim 1, wherein the first coupling member (104a, 104b) is detachably coupled to the heating element (102) using an adhesive.

10. The heater assembly (100) as claimed in claim 1, wherein the heating element (102) is made of Silicon-Carbide.

11. The heater assembly (100) as claimed in claim 1, wherein the first coupling member (104a, 104b) is made of a metallic material.

12. The heater assembly (100) as claimed in claim 1 , wherein the second coupling member (106a, 106b) is made of a metallic material.

13. The heater assembly (100) as claimed in claim 1 comprises of a third zone (502a, 502b) disposed between the first zone (108) and the second zone (110a, 110b), wherein the third zone (502a, 502b) is configured to function as a transition zone between the first zone (108) and the second zone (110a, 110b).

14. The heater assembly (100) as claimed in claim 13, wherein the third zone (502a, 502b) is conceived by coating the heating element (102) with at least one metallic material.

15. The heater assembly (100) as claimed in claim 14, wherein the third zone (502a, 502b) of the heating element (102) is coated with Titanium- Aluminum to reduce surface electrical resistance in the third zone (502a, 502b) of the heating element (102).

16. The heater assembly (100) as claimed in claim 15, wherein the second zone (110a, 110b) of the heating element (102) is coated with at least one metallic material.

17. The heater assembly (100) as claimed in claim 16, wherein the second zone (110a, 110b) of the heating element (102) is coated with Aluminum.

18. The heater assembly (100) as claimed in claim 13, wherein: surface electrical resistance of the first zone (108) of the heating element (102) is greater than the surface electrical resistance of the second zone (110a, 110b) and the third zone (502a, 502b); the surface electrical resi stance of the second zone (110a, 110b) of the heating element (102) is lower than the surface electrical resistance of the first zone (108) and the third zone (502a, 502b); and the surface electrical resistance of the third zone (502a, 502b) of the heating element (102) is greater than the surface electrical resistance of the second zone (110a, 110b) and lower than the electrical resistance of the first zone (108).