U.S. patent number 3,912,905 [Application Number 05/445,053] was granted by the patent office on 1975-10-14 for electric resistance heating device.
This patent grant is currently assigned to The Kanthal Corporation. Invention is credited to Roger Rolf Giler.
United States Patent |
3,912,905 |
Giler |
October 14, 1975 |
Electric resistance heating device
Abstract
A heating device includes electric resistance wire and a glass
plate cover for the wire, the wire being made of molybdenum
disilicide, having a positive temperature coefficient of
resistance, and comprising at least two series-interconnected
sections of differing cross-sectional areas. The wire is supported
on the flat surface of a refractory body, and is adjacent to but
spaced from the glass plate cover, the body enclosing both sections
with the side of the glass plate cover which faces the wire. The
two sections of differing cross-sectional areas may be proportioned
relative to each other and to the electric power used, so that upon
initial energization, the section of smaller cross-sectional area
receives maximum power and almost immediately flashes to
incandescence while converting the space enclosed by the body and
the glass plate cover into a heating chamber heating the section of
larger cross-sectional area which, with increasing temperature,
increases in resistance to lower the current through the section of
lower cross-sectional area, the power consumption of the device
then stabilizing at a lower value. Incorporation of the device into
the horizontal flat top of a cooking stove, for heating a cooking
vessel on top of the glass plate mainly by radiation, provides for
a substantially instantaneous high cooking heat followed by
stabilization of the temperature.
Inventors: |
Giler; Roger Rolf (Wilton,
CT) |
Assignee: |
The Kanthal Corporation
(Bethel, CT)
|
Family
ID: |
23767428 |
Appl.
No.: |
05/445,053 |
Filed: |
February 25, 1974 |
Current U.S.
Class: |
219/461.1;
338/218 |
Current CPC
Class: |
H05B
3/748 (20130101); H05B 3/141 (20130101); H05B
2203/018 (20130101) |
Current International
Class: |
F24C
15/10 (20060101); H05B 3/68 (20060101); H05B
3/14 (20060101); H05B 3/74 (20060101); H05B
003/68 () |
Field of
Search: |
;219/443,445,449,460,461,462,463,464,522,552,553 ;317/98
;338/217,218 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
494,189 |
|
Jul 1953 |
|
CA |
|
645,326 |
|
May 1937 |
|
DD |
|
Primary Examiner: Mayewsky; Volodymyr Y.
Attorney, Agent or Firm: Kenyon & Kenyon Reilly Carr
& Chapin
Claims
What is claimed is:
1. An electric cooking stove assembly comprising a flat glass plate
forming a cooking surface area, a convoluted molybdenum disilicide
wire forming a layer positioned substantially parallel with and
below said plate and covering an area substantially co-extensive
with said cooking surface area, said wire having opposite ends for
connection with electric power and having at least one portion
between said ends, which portion has a larger cross-sectional size
than the balance of the wire, said wire forming a continuous
circuit from one of its ends to its other end with said portion in
series with the balance of the wire, a refractory body forming a
flat surface extending substantially co-extensively with said layer
of wire and having upstanding refractory fibers on which said layer
of wire is supported and with the fibers fused to the wire, and a
refractory annulus peripherally surrounding said layer of wire and
interconnecting said glass plate and refractory surface so as to
substantially enclose a space containing said layer of wire.
2. The assembly of claim 1 in which said molybdenum disilicide wire
is convoluted in zigzag form.
3. The assembly of claim 1 in which said molybdenum disilicide wire
is convoluted in spiral coil form.
Description
BACKGROUND OF THE INVENTION
Electric resistance heated cooking stoves using hot plates
comprising a coil of refractory insulated, metal alloy electric
resistance wire enclosed by a metal sheath, have been commercially
successful but have suffered from the objection of slow heating
upon initial energization. This has given gas stoves with their
substantially instantaneous heating a competitive advantage.
To overcome such slow heating, the prior art has proposed the use
of an electric hot plate comprising a transparent glass plate cover
with open or unsheathed metal alloy electric resistance wire
beneath the cover with the wire diameter and length proportioned
relative to the domestic power supply voltage, so that with initial
energization the wire substantially immediately becomes
incandescent, cooking utensils on the cover being heated mainly by
direct radiation. Insofar as is known, this has been unsuccessful
because the excessive wire temperatures following initial
energization, result in an impractical short service life of any
cooking stove incorporating such a hot plate construction. Hermetic
enclosure of the wire to permit its operation in a vacuum in the
manner of an electric lamp, has been considered to be
impractical.
Electric resistance materials of non-metallic nature, capable of
operating at substantially higher temperatures than metal alloys,
have been available. Silicon carbide is one example, but this has
the disadvantage of being slow-acting, its electrical resistivity
being highest when cold. That is to say, silicon carbide has a
negative temperature coefficient of resistance.
An apparently more suitable material is one of the refractory metal
silicides, particularly molybdenum disilicide. As commercially
available, this material is in the form of approximately 90% by
weight of molybdenum disilicide with a balance of ceramics. It has
a positive temperature coefficient of resistance, and if made in
the form of wire with a cross-sectional area, or diameter, to
length ratio suitable for use with the domestic power supply,
nominally in the area of 120 volts in the U.S., it should
substantially immediately flash to incandescence when initially
energized.
However, if such wire is used in the form of a layer of coils,
loops, etc., beneath a glass plate, with the intention of providing
a transparent glass plate type of hot plate for a domestic cooking
stove, there is the problem of controlling the power so that upon
reaching incandescence with the consequent increase in electrical
resistivity, overheating is avoided. Such overheating could result
in destructive heating of the glass plate cover, and if continued,
destruction of the wire.
All electric heating devices are sold in a highly competitive
market, and this is particularly true in the case of domestic
cooking stoves. This prohibits the use of industrial control
systems such as are used to control molybdenum disilicide rod-type
industrial furnace heating applications.
One object of the present invention is to use molybdenum disilicide
wire, or wire made of other refractory metal silicides should they
become commercially available, in applications where the wire
operates behind a cover through which the heat is passed, such as a
glass plate cover, with such a wire heating element capable of
inherently flashing to incandescence when initially energized, but
which will thereafter stabilize and operate at a predetermined
desired power consumption without using control equipment of the
industrial type.
SUMMARY OF THE INVENTION
According to the invention, the above object is attained by making
the refractory metal silicide wire, such as molybdenum disilicide,
in the form of at least two series-interconnected sections of
differing cross-sectional areas and substantially enclosing both of
these sections together with the side of the cover which faces the
wire.
The cover particularly contemplated is the previously referred to
transparent glass plate and the means used to enclose the two wire
sections and the adjacent side of the glass plate, is a refractory
body forming a flat surface on which the wire is formed as a single
layer comprising loops or coils of the wire. More than two sections
of the differing cross-sectional areas may be used; the differing
sections are preferably butt-welded directly end-to-end. Preferably
the just-mentioned body is made from a compacted fibrous refractory
material, the wire, necessarily being of small cross-sectional area
as to all of the sections, being hooked or stapled to this flat
surface by molybdenum disilicide fastening elements. If wire made
of other refractory metal silicides is used, the fastening elements
should be made of corresponding material.
The various sections of differing cross-sectional areas have these
areas and their lengths proportioned relative to the voltage of the
available power source so that upon initial energization the
sections of smaller cross-sectional size receive maximum power and
become incandescent substantially instantaneously. The space in
which the wire is enclosed by the cover or glass plate on one side
and the refractory body on the other side, is proportioned in size
so that this space, ordinarily containing air, becomes rapidly
heated, this, together with the electric resistance heating,
heating the section or sections of larger cross-sectional area and
thus increasing the resistance in the circuit of the various
series-interconnected sections to an extent resulting in operation
of all of the sections, and the power consumption, becoming quickly
stabilized at any desired value. In this way the device is made
inherently self-stabilizing, although providing substantially
instantaneous high temperature production, and all without using
external control equipment of any kind.
The described use of hooks or staples is primarily because of
shipping problems. Once the device is operating horizontally, as in
a domestic cooking stove application, there is no need for
fastening of the wire, but this need does exist during handling
involved by shipment, and possibly by other conditions.
To eliminate the fastening elements, and using the body with its
flat surface made of fibrous refractory material, the flat surface
on which the wire is placed, may be roughened or up inherently made
fuzzy; that is to say, a surface having upstanding refractory
fibers can be provided. BBeing thin and upstanding, when the wire
is placed on these fibers, energization of the wire at the plant
where the device is manufactured, such as would ordinarily be done
for testing, results in temperatures fusing the fibers so that with
cooling of the wiire the wire adheres to the fibers and is anchored
in position without the need for the elements described. The type
of refractory referred to is commercially available in a form which
in its compacted condition satisfactorily resists the molybdenum
disilicide wire operating temperature but which when in the form of
upstanding fibers, fuses under such temperatures.
BRIEF DESCRIPTION OF THE DRAWINGS up or Being wire
Specific examples of the invention are illustrated by the
accompanying drawings in which:
FIG. 1 is a top view showing the glass plate cover broken away to
more clearly reveal the construction;
FIG. 2 is a cross section taken on the line 2--2 in FIG. 1;
FIG. 3 in cross section shows a fragment of the FIG. 2 construction
and illustrates the attachment of the wire to the upstanding fibers
as previously described; and
FIG. 4 is a top view of another example of the invention, this
showing this construction prior to the application of the cover
such as the glass plate .
DETAILED DESCRIPTION OF THE INVENTION
Having reference first to FIGS. 1 and 2, the molybdenum disilicide
resistance wire is shown as comprising three sections 1, 2 and 3,
the section 1 being the one of larger diameter or cross sectional
area and butt-welded end-to-end to the sections 2 and 3 which are
of smaller diameter or cross sectional area relative to that of the
section 1. The points where the sections are interwelded can be
located by the connections of the wires 4 which are provided with a
switch 5 for the purpose of shunting out the section 1 made of the
wire of larger size, should this be desired.
The cover is shown as a flat glass plate 6 having any of the
compositions suitable for elevated temperature service, and means
are shown for substantially enclosing the sections 1 through 3
together with the side of the glass plate 6 facing the wire, this
means comprising the body 7 and an annulus 7a which spaces the flat
surface 7b of this body from the inside of the glass plate 6. In
this way the previously described space 8 is formed. The mutually
opposing faces of the inside of the glass plate 6 and the flat
surface 7b are spaced rather closely together, but the wire should
not contact the glass cover plate. As shown, the wire is formed as
a single layer without overlapping wire portions.
The sections 1 through 3 are, of course, in series with each other,
terminals 9 being provided for connection with the electric power
supply.
The supporting or enclosing body 7 is made of vacuumformed ceramic
fibers made by Johns-Manville under the tradename "FIBERCHROME" and
consists basically by weight of 55% SiO.sub.2, 40.5% Al.sub.2
O.sub.3 and 4% of Cr.sub.2 O.sub.3, the fibers being bonded
together by means of an inorganic binder forming the balance. This
material is rated for maximum operating temperatures of
2700.degree.F. The body 7 may be made of other corresponding
commercially available materials and the spacer 7a shown by FIG. 2
could be integral with the portion providing the flat surface
7b.
By abrasion or roughening of the surface 7b its fibers may be made
to upstand as shown at 7c in FIG. 3. When the device is fabricated
in the horizontal position with the wire on the surface 7a
roughened as described, the wire may be energized to flash its
temperature above the melting temperature of the fibers 7c, the
heating then being promptly terminated. This results in fusion, or
at least incipient fusion, of the fibers on which the wire rested,
cooling bonding the wire to the fibers so that the wire cannot
shift out of position during shipment of the device, or other
handling. To effect such flash heating, the switch 5 shown by FIG.
1 may be closed so that the stabilizing wire section 1 is out of
the circuit. This fastening of the wire may be done either before
or after application of the glass cover plate 6.
An experimental device according to this invention has been reduced
to practice substantially as disclosed by FIGS. 1 and 2. The part 7
was made of a 1 3/8 inch thick pad of the specific ceramic fiber
material previously described, and the part 7a was formed by a 1/2
inch thick flat pad of the same material, placed between the flat
pad 7 and the glass plate 6 and having a suitable cut-out hole.
Using molybdenum disilicide wire, the wire forming the section 1
had a diameter of 0.031 inch and the sections 2 and 3, made of the
same material, had a diameter of 0.024 inch. The total length of
the wire, including all of the sections, was designed for use with
the usual U.S. domestic power voltage or around 120 volts.
The design of the above was such that when the section 1 was cut
out of circuit, as by closing the switch 5 in the illustrated
instance, the unit consumed 1140 watts at a voltage of 120 volts.
With the section 1 in the circuit with the sections 2 and 3, the
sections 2 and 3 almost immediately reached incandescence and as
the temperature built up inside of the space 8 the power stabilized
at approximately 880 watts, representing continuous operation.
Under such stabilized conditions, the wire was incandescent
substantially throughout all of the sections.
FIG. 4 is provided to show an instance when the wire is in the form
of a continuous spiral coil, the sections of smaller cross
sectional area being shown at 10 and those of larger
cross-sectional area being shown at 11. In this instance there is a
large multiplicity of the differing sections, all interconnected in
series by butt-welding of the sections end-to-end.
As required for cooking purposes, the device of the present
invention may be provided with a suitable voltage controller such
as represented by currently available, inexpensive solid state
controllers, such as incorporate silicon controlled rectifiers.
Also, sections may be cut in and out of circuit as indicated.
The flat surface of the body 7 should be a fibrous material surface
to reduce heat transfer from the wire to the body as much as
possible. Intimate contact of the wire with a flat, solid ceramic
surface, for example, results in so much loss of heat by conduction
into what is then a heat-sink, as to prevent the described
operation. If it was possible, it would be best to support the wire
without it losing any heat to the supporting medium.
Mention has been made of 120 volt operation. The device can be
designed for other line voltages, such as 240 volts for
example.
The terminals 9 are shown as being larger than the wire sections 2
and 3. This is because at the present time "cold" terminals are
required for connection with the disilicide wire. For the same
reason the wires 4 are shown connected via similar terminals
4a.
* * * * *