Hot air blower with ceramic heating element

Abstract

There is provided a heating element for an electric air heater including an electric power source, a ceramic base, and a conductive heating film substantially uniformly deposited on at least a portion of a surface of the base and electrically connected to the power source. There is also provided a method for manufacturing the heating element. There is further provided an electric hot air blower including a housing having an air inlet and an air outlet, a fan operatively connected to an electric motor, and an electric heating element located inside the housing that includes a ceramic base and a conductive film substantially uniformly deposited on a surface of the base and electrically connected to a power source. The electric heating element is located along an air flow path of the blower for heating air flow.

1 . A heating element for an electric air heater, comprising: 
 an electric power source;    a ceramic base; and    a conductive heating film substantially uniformly deposited on at least a portion of a surface of said base and electrically connected to said power source.    
     
     
         2 . The heating element of  claim 1 , wherein said electric heater emits far infrared radiation when heated to a selected temperature.  
     
     
         3 . The heating element of  claim 1 , wherein said conductive film includes electrodes adhered onto a portion of said surface of said ceramic base.  
     
     
         4 . The heating element of  claim 1 , wherein said ceramic base is made from ceramic material containing aluminum oxide.  
     
     
         5 . The heating element of  claim 4 , wherein said ceramic base has a thickness between about 0.5 mm and 3 mm.  
     
     
         6 . The heating element of  claim 1 , wherein said conductive heating film is deposited on an exterior surface of said ceramic base.  
     
     
         7 . The heating element of  claim 1 , wherein said ceramic base has a shape selected from the group consisting of: cylindrical, tubular, square tubular, conical, and columnar.  
     
     
         8 . The heating element of  claim 7 , wherein said ceramic base has a cylindrical shape having radially extending ribs or protrusions.  
     
     
         9 . The heating element of  claim 7 , wherein said ceramic base includes a plurality of ceramic tubular structures surrounded by an exterior ceramic tubular structure.  
     
     
         10 . An electric hot air blower comprising: 
 a housing having an air inlet and an air outlet;    a fan operatively connected to an electric motor; and    an electric heating element located inside said housing that includes a ceramic base and a conductive film substantially uniformly deposited on at least a portion of a surface of said base and electrically connected to a power source,    wherein said electric heating element is located along an air flow path of said blower for heating air flow.    
     
     
         11 . The hot air blower of  claim 10 , further comprising a power control assembly including a voltage dropping device electrically connected to said electric motor, wherein said voltage dropping device includes a second ceramic base and a second conductive film substantially uniformly deposited on at least a portion of a surface of said second base and electrically connected to said motor.  
     
     
         12 . The hot air blower of  claim 10 , wherein said electric heating element heats said air flow and acts as a voltage dropping resistor device to reduce a voltage applied to said motor from said power source.  
     
     
         13 . The hot air blower of  claim 10 , wherein said conductive film includes electrodes adhered onto part of said surface of said ceramic base.  
     
     
         14 . The hot air blower of  claim 10 , wherein said conductive heating film is deposited on an exterior surface of said ceramic base.  
     
     
         15 . The hot air blower of  claim 10 , wherein said ceramic base has a shape selected from the group consisting of: cylindrical, tubular, square tubular, conical, and columnar.  
     
     
         16 . The hot air blower of  claim 10 , wherein said heating element is installed on a bracket located between said fan and said air outlet.  
     
     
         17 . The hot air blower of  claim 11 , wherein said voltage dropping device is selected from the group consisting of: one or more dropping resistor elements connected in series with said motor, and at least two dropping resistor elements connected in parallel with said motor.  
     
     
         18 . A method for manufacturing a heating element for a hot air blower, comprising the steps of: 
 depositing a conductive heating film on at least a portion of a surface of a ceramic base; and    forming electrodes in electrical contact with said conductive film for connection to an electric power source.    
     
     
         19 . The method of  claim 18 , further comprising the step of adhering said film to said surface by sintering.  
     
     
         20 . The method of  claim 19 , wherein said step of depositing is accomplished by spraying a slurry of conductive material to said surface.