Heating apparatus for facilitating uniform high-power heating of liquid and methods of manufacturing a heating apparatus

A heating apparatus for facilitating uniform high-power heating of liquid, the heating apparatus comprising:

• a frame configured for supporting a container;
• a heater attached to the frame, wherein the heater is configured for generating heat;
• a diffusion plate mechanically integrated with the frame, wherein the diffusion plate is positioned between the heater and the container, wherein the diffusion plate is configured for:
• receiving the heat from the heater;
• and
• distributing the heat uniformly to the container containing the liquid, wherein the liquid comprises sugar, wherein the distributing of the heat uniformly to the container reduces at least one of caramelization of the sugar in the liquid and burning of the sugar in the liquid on the bottom surface of the container;
• and
• a controller electrically coupled to the heater, wherein the controller is configured for regulating an electrical power supplied to the heater to control the generating of the heat.

A heating apparatus for facilitating uniform high-power heating of liquid, the heating apparatus comprising:

• a frame comprising a rigid elongated body formed from a plurality of horizontal members and a plurality of vertical members joined to define an open structure having an upper plane and a lower plane, wherein the frame is configured for supporting a load above the upper plane;
• a heater comprising at least one heating element formed as a continuous metal coil having an upper heat-emitting surface and a lower mounting surface, wherein the heater is mechanically attached to the frame by facing the upper heat-emitting surface upward, wherein the heater is configured for generating heat;
• a diffusion plate comprising a solid planar metal body having a flat upper surface and a flat lower surface, wherein the diffusion plate is positioned above the heater, wherein the diffusion plate is mechanically integrated with the frame, wherein the flat lower surface of the diffusion plate faces the upper heat-emitting surface of the heater to receive the heat from the upper heat-emitting surface, wherein the flat upper surface of the diffusion plate is configured for direct contact with a bottom surface of a container containing the liquid, wherein the flat upper surface is configured for transferring the heat to the bottom surface of the container uniformly to reduce at least one of caramelization of sugar in the liquid and burning of the sugar in the liquid on the bottom surface of the container, wherein the solid planar metal body of the diffusion plate is a monolithic metal plate body having a continuous internal volume and a plurality of opposing major faces, wherein the monolithic metal plate body is formed from a material exhibiting high thermal conductivity, wherein the heat is received from the upper heat-emitting surface at a localized region on the flat lower surface spreads laterally across the continuous internal volume before the heat reaches the flat upper surface, wherein the transferring of the heat to the bottom surface is based on the reaching of the heat in the flat upper surface;
• a controller electrically connected to the heater, wherein the controller is configured for regulating an electrical power supplied to the heater to control the generating of the heat;
• and
• a power terminal configured to receive the electrical power, wherein the power terminal is electrically connected to each of the heater and the controller.

A method of manufacturing a heating apparatus, the method comprising:

• receiving, by a material handling station, a plurality of elongated metal frame members formed as extruded profiles;
• cutting, by a machining station, the plurality of elongated metal frame members to predefined lengths corresponding to a plurality of horizontal members and a plurality of vertical members of a frame;
• fastening, by an assembly fixture, the plurality of horizontal members and the plurality of vertical members together using flanged button head socket cap screws and inside corner brackets to form a rigid elongated body of the frame defining an upper plane and a lower plane;
• positioning, by a placement tool, a heater within the frame by facing an upper heat-emitting surface upward, wherein the heater comprises at least one heating element having the upper heat-emitting surface and a lower mounting surface, wherein the heater is configured for generating heat;
• attaching, by a mechanical fastening tool, the heater to the frame to maintain a fixed spatial relationship between the heater and the frame;
• forming, by a plate fabrication station, a diffusion plate as a solid planar metal body having a flat upper surface and a flat lower surface;
• mounting, by a fastening assembly, the diffusion plate to the frame above the heater to reduce at least one of caramelization of sugar in a liquid and burning of the sugar in the liquid, wherein the flat lower surface of the diffusion plate faces the upper heat-emitting surface of the heater, and the flat upper surface of the diffusion plate is exposed for a direct contact with a bottom surface of a container containing the liquid;
• installing, by an enclosure mounting station, a controller in accordance with National Electric Code (NEC) requirements onto the frame, wherein the controller is compliant with UL 508 safety standards;
• electrically connecting, by a wiring station, the controller to the heater in accordance with the NEC requirements to enable regulating of an electrical power supplied to the heater;
• and
• electrically connecting, by the wiring station, a power terminal to each of the heater and the controller in accordance with the NEC requirements, wherein the power terminal is configured to receive the electrical power.