An electric fluid heater
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Solution Overview
Problem
Conventional electrical fluid heaters face issues with non-uniform fluid distribution, air pockets, and inefficient heat exchange, leading to reduced performance and thermal stresses during brazing connections.
Innovation Solution
The design includes a stacked configuration of plates with aligned openings to form fluid heating spaces, ensuring direct contact between the fluid and heating elements, and strategic placement of inlets and outlets to prevent air pockets, while using ribs for brazing connections to homogenize temperature and reduce thermal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional fluid heating spaces are defined by housing or modular plates without direct contact configuration, then the structure is simple to manufacture, but the heat exchange efficiency deteriorates due to non-uniform fluid distribution and air pockets
Solution Approach 1:
The heater is divided into multiple heating zones with individual heating elements arranged in series along the fluid flow path. Each heating element is separated by spacing elements that create distinct fluid heating spaces, allowing segmented heat exchange that improves uniformity while maintaining manufacturing simplicity through modular assembly
Solution Approach 2:
Spacing elements are introduced as intermediary components between heating elements and fluid flow paths. These elements create controlled gaps that ensure uniform fluid distribution and prevent air pocket formation, thereby improving heat exchange efficiency without complicating the overall manufacturing process
2Volume of moving object
If heating elements are arranged in compact configuration to reduce size, then the device compactness improves, but the heat exchange surface area deteriorates
Solution Approach 1:
Heating elements are arranged in a linear series configuration along the fluid flow direction rather than compact clustering. This one-dimensional arrangement extends the heat exchange surface area along the flow path while maintaining a compact cross-sectional footprint, effectively increasing surface area without significantly increasing overall heater volume
3Productivity
If brazing connections are made without temperature homogenization, then the brazing process is fast, but thermal stresses increase causing connection failures
Solution Approach 1:
The brazing structure incorporates localized thermal management features where spacing elements and plate configurations create uniform heat distribution zones during the brazing process. This local quality control ensures homogeneous temperature fields at connection points, reducing thermal stresses while maintaining efficient brazing speeds through optimized joint design
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration ensures uniform fluid distribution, improved heat exchange efficiency, and convenient brazing, preventing air pockets and thermal stresses, thereby enhancing the performance and efficiency of the electrical fluid heater.
Implementation Method 1
an electrical resistive element supplied with current in case of an electrical resistive heater
Implementation Method 2
heat exchange between the fluid flowing through fluid heating spaces and the heating elements
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An electrical fluid heater (100) includes a fluid inlet (12a) and a fluid outlet (12b), at least one heating elements (30) and a plurality of plates (40). The plurality of plates (40) are stacked to form a fluid flow path between the fluid inlet and the fluid outlet for the fluid to be heated by the at least one heating element (30). The at least one heating element (300 being sandwiched between adjacent plates (40) thereby defining fluid heating spaces from either sides of the at least one heating element to permit heat exchange between the fluid flowing through the fluid heating spaces and the at least one heating element (30). Each of the plates (40) includes at least one opening (41a, 41b), in particular formed on a substantial portion thereof, such that the fluid flowing through the fluid heating spaces is in direct contact with the heating elements (30).