Fluid heater

Abstract

The fluid heater according to an embodiment of the present invention comprises: a heating plate; heating elements disposed in a plurality of rows on one surface of the heating plate; and electrodes disposed on one surface of the heating plate and connected, respectively, to the heating elements disposed on either side, wherein, by redistributing the load applied to the heating elements, the heating elements may have different widths in at least some sections.

Description

Fluid heating heater

[0001] The present invention relates to a fluid heating heater, and more specifically, to a fluid heating heater for heating a fluid, such as coolant, circulating inside a vehicle.

[0002] Under the policy of environmentally friendly industrial development and the development of energy sources to replace fossil fuels, electric vehicles, hybrid cars, and fuel cell vehicles are the sectors receiving the most attention in the automotive industry recently. However, unlike conventional vehicles using petroleum-based engines, electric, hybrid, and fuel cell vehicles cannot or do not allow the application of heating systems using coolant.

[0003] In other words, in the case of conventional vehicles powered by petroleum-based engines, a significant amount of heat is generated from the engine. Consequently, a cooling water circulation system is provided to cool the engine, and the heat absorbed by the cooling water is utilized for interior heating. However, since electric vehicles, hybrid vehicles, and fuel cell vehicles do not generate as much heat as the engine, there were limitations to using these conventional heating methods.

[0004] Accordingly, various studies are being conducted on electric vehicles, hybrid vehicles, and fuel cell vehicles, such as adding a heat pump to the air conditioning system to use it as a heat source, or providing a separate heat source like an electric heater. Among these, electric heaters are currently widely used because they can heat the coolant more easily without significantly affecting the air conditioning system.

[0005] Referring to U.S. Patent No. 10939505 (Title: Electrical heating system for a motor vehicle), the deflection section formed on the inner side of the heating element structure was shaped like a drop to prevent the concentration of current density, but there was a problem in that the current density increased and the temperature rose because the width of the conductor track of the deflection section became narrow.

[0006] One embodiment of the present invention provides a fluid heating heater that prevents the current density and temperature from rising in one part of the deflection section and enables the current density and temperature to be evenly distributed throughout by forming a dead zone between heating elements formed at the ends of the deflection section.

[0007] In addition, one embodiment of the present invention provides a fluid heating heater that prevents the current density and temperature from rising in a part of the deflection section and ensures that the current density and temperature are evenly distributed throughout by applying a curved structure to the deflection section and expanding the width of the heating element.

[0008] The problems that the present invention aims to solve are not limited to those mentioned above, and other problems not mentioned herein will be clearly understood by those skilled in the art from the description below.

[0009] A fluid heating heater according to one embodiment of the present invention comprises a substrate; and a heating element formed on the substrate, formed in a shape that starts from the outside and rolls inward, and has a deflection portion formed on the inside in which the direction of the current is switched to the opposite direction, wherein an insulating gap is formed spaced apart between the heating elements, and a dead zone can be formed in which the width between the heating elements in the portion where the deflection portion is formed is wider than the width between other heating elements.

[0010] A dead zone heating element is disposed in the above dead zone, and the insulation gap between the dead zone heating element and the heating element may be formed.

[0011] The width of the heating element forming the deflection portion can be formed wider than the width between other heating elements.

[0012] The width of the heating element forming the deflection portion can be formed to be 20% wider than the width between other heating elements.

[0013] The width of the above dead zone may be 2.5 mm or less.

[0014] The end of the above-mentioned deflection part can be formed as a curved surface.

[0015] The heating element may be removed without being placed in the above dead zone.

[0016] In the above dead zone heating element, a tapered section with a narrowing width is formed at the opposite end of the deflection section, so that the dead zone can be narrowed.

[0017] In the dead zone heating element extending in the opposite direction from the deflection section, a tapered section with a narrowing width is formed so that the dead zone can be narrowed.

[0018] In the above dead zone, a tapered section with a narrowing width may be formed at the opposite end of the deflection section.

[0019] A tapered section with a narrowing width may be formed in the dead zone extending in the opposite direction from the above deflection section.

[0020] According to one embodiment of the present invention, by forming a dead zone between heating elements formed at the ends of the deflection section, it is possible to prevent the current density and temperature from rising in one part of the deflection section and to ensure that the current density and temperature are evenly distributed throughout.

[0021] In addition, according to one embodiment of the present invention, by applying a curved structure to the deflection section and expanding the width of the heating element, it is possible to prevent the current density and temperature from rising in a part of the deflection section and to ensure that the current density and temperature are evenly distributed throughout. As a result, since the current density and temperature distribution become uniform on the deflection section side, the performance of the fluid heating heater can be improved.

[0022] FIG. 1 is a drawing illustrating a heating element of a fluid heating heater according to one embodiment of the present invention.

[0023] FIG. 2 is a diagram comparing the current density distribution of a heating element of a fluid heating heater according to one embodiment of the present invention with that of the prior art.

[0024] FIG. 3 is a diagram comparing the temperature distribution of a heating element of a fluid heating heater according to one embodiment of the present invention with that of the prior art.

[0025] Figure 4 is a graph comparing the temperatures of a conventional heating element and a heating element with a dead zone applied along line I-I of Figure 1.

[0026] Figure 5 is a diagram illustrating a comparison of the maximum temperature distribution of the deflection section according to the same heating element width and the wide heating element width.

[0027] Figure 6 is a diagram illustrating a comparison of the maximum temperature distribution at the center of the deflection section according to the same heating element width and the wide heating element width.

[0028] FIG. 7 is a drawing illustrating a fluid heating heater according to one embodiment of the present invention.

[0029] FIG. 8 is a drawing illustrating a heating element of a fluid heating heater according to another embodiment of the present invention.

[0030] FIG. 9 is a diagram showing the current density distribution of a heating element according to the embodiment illustrated in FIG. 8.

[0031] FIG. 10 is a drawing illustrating a heating element of a fluid heating heater according to another embodiment of the present invention.

[0032] FIG. 11 is an enlarged view of the main part of the embodiment illustrated in FIG. 10.

[0033] FIG. 12 is a drawing illustrating a heating element of a fluid heating heater according to another embodiment of the present invention.

[0034] FIG. 13 is an enlarged view of the main part of the embodiment shown in FIG. 12.

[0035] The present invention is capable of various modifications and may have various embodiments, and specific embodiments are illustrated in the drawings and described in detail. However, this is not intended to limit the present invention to specific embodiments, and it should be understood that it includes all modifications, equivalents, and substitutions that fall within the spirit and scope of the present invention. In describing the present invention, detailed descriptions of related prior art are omitted if it is determined that such detailed descriptions may obscure the essence of the present invention.

[0036] Terms such as "first," "second," etc., may be used to describe various components, but said components should not be limited by said terms. These terms are used solely for the purpose of distinguishing one component from another.

[0037] The terms used in this application are used merely to describe specific embodiments and are not intended to limit the invention. The singular expression includes the plural expression unless the context clearly indicates otherwise. In this application, terms such as "comprising" or "having" are intended to indicate the presence of the features, numbers, steps, actions, components, parts, or combinations thereof described in the specification, and should be understood as not precluding the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof.

[0038] Furthermore, throughout the specification, when the term "connected" is used, it does not mean only that two or more components are directly connected, but may also mean that two or more components are indirectly connected through other components, that they are connected not only physically but also electrically, or that they are a single unit although referred to by different names depending on their location or function.

[0039] Hereinafter, an embodiment of a fluid heating heater according to the present invention will be described in detail with reference to the accompanying drawings. In describing with reference to the accompanying drawings, identical or corresponding components are given the same reference numerals, and redundant descriptions thereof will be omitted.

[0040] FIG. 1 is a diagram illustrating a heating element of a fluid heating heater according to one embodiment of the present invention, FIG. 2 is a diagram illustrating the current density distribution of a heating element of a fluid heating heater according to one embodiment of the present invention, and FIG. 3 is a diagram illustrating the temperature distribution of a heating element of a fluid heating heater according to one embodiment of the present invention.

[0041] As illustrated herein, a fluid heating heater according to one embodiment of the present invention may include a substrate (1) and a heating element (20) formed on the substrate (1), formed in a shape that starts from the outside and rolls inward, and has a deflection portion (30) formed on the inside in which the direction of the current is switched to the opposite direction.

[0042] Fluid heating heaters can be, for example, thick-film heaters, and thick-film heaters are used as plate-shaped heating elements that maximize thermal efficiency and have thin and light characteristics by manufacturing high-performance heating elements on various substrates (iron plates, glass, ceramics, etc.) using printing techniques.

[0043] Referring to FIG. 1, the heating element (20) constituting the heating element layer (10) is formed on the substrate (1) and has a shape that rolls inward from the outside, for example, bending can be performed at the corners to form an overall rectangular shape. Additionally, the heating element (20) may have a right-angle spiral shape. The heating element (20) may have a shape in which a plurality of heating elements extend parallelly and roll inward from the outside.

[0044] In one embodiment, two heating elements (20) may extend parallelly from one end (12) of the heating element (20), roll inward, and then come outward. In the drawing, among the four heating elements (20) placed at the one end (12), the heating elements (20) placed at the top and bottom constitute one, and the heating element (20) placed in the middle constitutes one.

[0045] In this way, when the heating element (20) is rolled inward, a deflection section (30) can be formed in the central part where the direction of the current is switched to the opposite direction. That is, as the heating element (20) is rolled inward, the direction of the current is switched by 90 degrees at the part where it is bent at a right angle, and as shown in FIG. 2 (b), the direction of the current in the deflection section (30) is switched to the opposite direction, i.e., 180 degrees, passing through the ① -> ② -> ③ direction.

[0046] In the deflection section (30), which is a section where the direction of the current is reversed, the current is concentrated inward rather than outward, which is the shortest path, in order to minimize resistance. Additionally, in the deflection section (30), the concentration of current is severe, causing the current density and loss density to increase, thereby causing a localized temperature rise (hot spot). Therefore, in this embodiment, a dead zone (D) is formed between the heating elements (20) forming the deflection section (30). The dead zone (D) can be formed between the heating elements (20) placed on the inside. That is, the dead zone (D) can be formed along the length between the heating elements (20) forming the deflection section (30).

[0047] An insulating gap (22) is formed between the heating elements (20). The insulating gap (22) refers to a width that substantially separates the heating elements (20). This insulating gap (22) is a gap formed between the heating elements (20) that are shaped to roll inward from the outside, and the insulating gap (22) can have the same width throughout the fluid heating heater.

[0048] Meanwhile, in this embodiment, a dead zone (D) is formed that is relatively wider than the insulation gap (22) corresponding to the width between the heating elements (20). First, referring to FIGS. 1 and 2, a dead zone heating element (40) can be placed in the dead zone (D), and the dead zone heating element (40) is a part where practically no current flows. By forming a dead zone (D) on the deflection part (30) side in this way, the heating area is reduced, but the accumulation of heat due to current density can be eliminated, so the temperature of the heating elements (20) can be lowered on average and distributed evenly.

[0049] Referring to FIG. 2, in the conventional case, the insulation gap (22) between the heating elements (20) in which the deflection section (30) is formed is relatively narrow as in (a), so the current density appears significantly high near the apex where it bends at the deflection section (30). However, in the case of the fluid heating heater according to the present embodiment in which a dead zone (D) is formed, as in (b), the current density can spread out more evenly on the deflection section (30) side compared to the conventional case.

[0050] Additionally, referring to FIG. 3, in the conventional method, the insulation gap (22) between the heating elements (20) in which the deflection section (30) is formed is relatively narrow as in (a), so the temperature appears significantly high near the apex where the deflection section (30) bends. However, in the case of the fluid heating heater according to the present embodiment in which a dead zone (D) is formed, the temperature is lower and more uniformly formed on the deflection section (30) side compared to the conventional method as in (b).

[0051] Referring again to FIG. 2(b), the end of the deflection section (30) is formed as a gentle curved surface without a vertex, so that the current is not concentrated in one part but spreads evenly throughout. This can be seen as being formed because the gap between the heating elements (20) is widened by creating a dead zone (D) between the heating elements (20). If the deflection section (30) is configured in a teardrop shape as in the conventional method, the width of the heating elements (20) in the other areas is inevitably narrowed, and an increase in current density and temperature occurs in this area. Since the path changes abruptly at the end of the deflection section (30), the current density increases rapidly; therefore, in this embodiment, the end of the deflection section (30) is made to change smoothly by reflecting the curvature (R) to prevent an increase in current density.

[0052] Meanwhile, in FIG. 2, the width (W1) of the heating element (20) positioned in the current direction ② in the deflection section (30) can be formed relatively wider than the width (W2) of the conventional heating element (20). That is, in this embodiment, the width of the heating element (20) forming the deflection section (30) is made wider than in the conventional one so that the current can spread widely and flow evenly. In one embodiment, the width (W1) of the heating element (20) forming the deflection section (30) can be formed to be 20% or more of the width (W2) of the conventional heating element (20), but is not limited thereto.

[0053] As described above, in this embodiment, the deflection section (30) forms a dead zone (D) between the heating element (20) formed at the end, and by applying a curved structure to the deflection section (30) and expanding the width of the heating element (20), the current density and temperature are prevented from rising in a part of the deflection section (30) and the current density and temperature are evenly distributed throughout. As a result, since the current density and temperature distribution are uniform on the deflection section (30) side, the performance of the fluid heating heater can be improved.

[0054] FIG. 4 is a graph comparing the temperatures of a conventional heating element and a heating element with a dead zone applied along line I-I of FIG. 1. Referring to FIG. 4, in the case of a conventional heating element, the temperature rises because heat accumulates in the central part due to the increase in current density. However, in the case of a heating element (20) with a dead zone (D) applied as in the present embodiment, the heat accumulation in the central part is eliminated, so the temperature distribution becomes even and the maximum temperature can be lowered.

[0055] Figure 5 is a diagram showing a comparison of the maximum temperature distribution of the deflection section according to the same heating element width and the wide heating element width, and Figure 6 is a diagram showing a comparison of the maximum temperature distribution at the center of the deflection section according to the same heating element width and the wide heating element width.

[0056] In the drawing, having the same heating element (20) width means that the heating element (20) width in section ② of FIG. 2 (b) is the same as that in sections ① and ③. And having a wide heating element (20) width means that the heating element (20) width in section ② of FIG. 2 (b) is wider than that in sections ① and ③.

[0057] Referring to FIG. 5, when comparing the width of the same heating element (20) and the width of the wide heating element (20), the trend of the maximum temperature of the deflection section (30) decreasing according to the width of the dead zone (D) appears similar. However, it can be seen that when the width of the wide heating element (20) is used, the maximum temperature of the deflection section (30) is lower than when the width of the same heating element (20) is used.

[0058] Referring to FIG. 6, regarding the width of the dead zone (D), it can be seen that when the width of the dead zone (D) is widened, the temperature tends to decrease in inverse proportion to this, but when the width of the dead zone (D) exceeds 2.5 mm, the temperature increases again. Therefore, in one embodiment, the width of the dead zone (D) can be formed to be 2.5 mm or less for optimal temperature distribution conditions. Also, as can be seen in the figure, when the heating element (20) has a wide width, the maximum temperature of the deflection part (30) is lower than when the heating element (20) has the same width.

[0059] FIG. 7 is a drawing illustrating a fluid heating heater according to one embodiment of the present invention.

[0060] Referring to FIG. 7, the fluid heating heater comprises a substrate (1) that can be simultaneously configured as a heat exchanger to transfer heat output released to the fluid to be heated. For example, the substrate (1) can preferably be made of a metal material having a high heat transfer coefficient, particularly, for instance, aluminum or an aluminum alloy, in a very cost-effective manner as far as manufacturing technology is concerned.

[0061] In the case of a specific exemplary embodiment formed of an electrically conductive material, an insulating layer (2) having high thermal conductivity is formed on the substrate (1). For example, the insulating layer (2) may be formed using, for example, aluminum oxide. The insulating layer (2) may be formed on the substrate (1) using, for example, a thermal spray method. In particular, when the substrate (1) is formed of, for example, aluminum, it is possible to form the insulating layer (2) by intentionally oxidizing the surface of the substrate (1).

[0062] Additionally, a heating element layer (10) may be formed on the insulating layer (2). The heating element layer (10) may be formed from a metal material and, for example, may include a nickel-chromium alloy. The heating element layer (10) may also be formed using a thermal spraying method. Furthermore, the heating element layer (10) may be formed on the insulating layer (2) using a printing method or a casting method. An additional insulating layer (4) may be formed on the surface of the heating element layer (10). The additional insulating layer (4) may be formed using, for example, aluminum oxide.

[0063] FIG. 8 is a drawing illustrating a heating element of a fluid heating heater according to another embodiment of the present invention, and FIG. 9 is a drawing illustrating the current density distribution of the heating element according to the embodiment illustrated in FIG. 8.

[0064] Referring to FIGS. 8 and 9, a fluid heating heater according to another embodiment of the present invention has a configuration almost identical to that of the above-described embodiment, but differs in configuration in that the heating element (20) placed in the dead zone (D) is removed. That is, in this embodiment, the heating element (20) is not placed on the dead zone (D) so that the flow of current toward the dead zone (D) is fundamentally blocked. In this embodiment, the heating element (20) can be etched by a laser or the like while the heating element layer (10) is formed.

[0065] FIG. 10 is a drawing illustrating a heating element of a fluid heating heater according to another embodiment of the present invention, and FIG. 11 is a drawing illustrating an enlarged view of the main part of the embodiment illustrated in FIG. 10.

[0066] Referring to FIGS. 10 and 11, the opposite end of the deflection portion (30) constituting the fluid heating heater according to the present embodiment may be formed such that the dead zone (D) is narrowed. The dead zone heating element (40) on the end side where the deflection portion (30) is formed is formed in the same way as in the above-described embodiment, and the opposite end of the deflection portion (30) may be formed such that the dead zone (D) is narrowed.

[0067] At this time, the shape described above can be naturally formed when the heating element (20) placed at the opposite end of the deflection section (30) is extended at an angle, and the dead zone heating element (40) placed in the dead zone (D) can also be formed so that the width of the end portion narrows. That is, the width of the dead zone heating element (40) extending in the opposite direction from the deflection section (30) can be formed so that the width narrows as it goes in the opposite direction from the end portion. A tapered portion (42) with a narrowing width can be formed at the end portion of the dead zone heating element (40). Of course, the dead zone heating element (40) may be placed in the dead zone (D) or removed.

[0068] FIG. 12 is a drawing showing a heating element of a fluid heating heater according to another embodiment of the present invention, and FIG. 13 is a drawing showing an enlarged view of the main part of the embodiment shown in FIG. 12.

[0069] Referring to FIGS. 12 and 13, the dead zone (D) may be formed to narrow along the opposite direction of the deflection portion (30) constituting the fluid heating heater according to the present embodiment. The dead zone heating element (20) is formed such that the width of the dead zone (D) narrows as it moves in the opposite direction from the deflection portion (30).

[0070] At this time, the shape described above can be naturally formed when the heating element (20) placed at the opposite end of the deflection section (30) is extended at an angle, and the dead zone heating element (40) placed in the dead zone (D) can also be formed so that its width narrows as it moves away from the deflection section (30). That is, the width of the dead zone heating element (40) extending in the opposite direction from the deflection section (30) can be formed so that its width narrows as it moves in the opposite direction. A tapered section (42) with a narrowing width can be formed on one side of the dead zone heating element (40). Of course, the dead zone heating element (40) may be placed in the dead zone (D) or removed.

[0071] As described above, according to the embodiment illustrated in FIGS. 10 to 13, the dead zone (D) is formed in isolation between the heating elements (20), so the flow of current can be fundamentally blocked, thereby preventing the rise in current density and temperature around the deflection part (30).

[0072] Although the present invention has been described above with reference to specific embodiments, those skilled in the art will understand that various modifications and changes can be made to the invention without departing from the spirit and scope of the invention as set forth in the following claims.

[0073] [Explanation of the symbol]

[0074] 1: Substrate 2: Insulating layer

[0075] 4: Additional insulation layer 10: Heating element layer

[0076] 12: First part 20: Heating element

[0077] 22: Insulation gap 30: Deflection section

[0078] 40: Dead zone heating element 42: Tapered section

Claims

1. Substrate; and It includes a heating element formed on the above substrate, formed in a shape that starts from the outside and rolls inward, and has a deflection portion formed on the inside in which the direction of the current is switched to the opposite direction. A fluid heating heater in which an insulating gap is spaced apart between the heating elements, and a dead zone is formed in which the width between the heating elements in the portion where the deflection portion is formed is wider than the width between other heating elements.

2. In Paragraph 1, A fluid heating heater in which a dead zone heating element is disposed in the dead zone, and the insulation gap is formed between the dead zone heating element and the heating element.

3. In Paragraph 1, A fluid heating heater in which the width of the heating element forming the deflection portion is formed wider than the width between other heating elements.

4. In Paragraph 3, A fluid heating heater in which the width of the heating element forming the deflection portion is formed to be 20% wider than the width between other heating elements.

5. In Paragraph 1, A fluid heating heater having a dead zone width of 2.5 mm or less.

6. In Paragraph 1, A fluid heating heater in which the end of the deflection portion is formed as a curved surface.

7. In Paragraph 1, A fluid heating heater in which the heating element is not placed in the above dead zone and is removed.

8. In Paragraph 2, A fluid heating heater in which a tapered section with a narrowing width is formed at the opposite end of the deflection section of the above dead zone heating element, thereby narrowing the dead zone.

9. In Paragraph 2, A fluid heating heater in which a tapered section is formed in the dead zone heating element extending in the opposite direction from the deflection section, thereby narrowing the dead zone.

10. In Paragraph 1, A fluid heating heater in which a tapered section with a narrowing width is formed at the opposite end of the deflection section in the above dead zone.

11. In Paragraph 1, A fluid heating heater in which a tapered section is formed in the dead zone extending in the opposite direction from the deflection section, with a narrowing width.

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