An electrical fluid heater
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Solution Overview
Problem
Conventional electrical fluid heaters face inefficiencies due to nonhomogeneous fluid distribution and dead zones, which impede effective heat exchange and performance, especially when the inlet and outlet are configured on the same side, leading to packaging issues and reduced efficiency.
Innovation Solution
The design features a pair of end plates with a U-turn trajectory configuration, multiple intermediate plates with distinct sections forming fluid flow passes, and fluid deflecting walls on the second end plate to ensure homogeneous fluid distribution and prevent dead zones, enhancing contact time and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple fluid flow passes are configured to increase fluid flow path and retain fluid adjacent to heating elements, then heat exchange efficiency is improved, but nonhomogeneous fluid distribution and dead zone formation occur
Solution Approach 1:
The heater body is segmented into multiple fluid flow passes (first fluid flow pass, second fluid flow pass, third fluid flow pass) with distinct inlet and outlet regions. Each pass is equipped with dedicated flow diverting means including deflectors and baffles positioned at specific locations to control fluid distribution independently, ensuring homogeneous fluid filling across all passes while maintaining extended fluid flow path for efficient heat exchange.
2Volume of moving object
If inlet and outlet are configured on the same side of the electrical heater, then packaging space is reduced, but fluid flow path length and dead zone formation are increased
Solution Approach 1:
Different regions of the heater body are assigned different functions: the first end plate and first portion of the second end plate handle inlet fluid distribution to the first fluid flow pass, while the second portion of the second end plate and first end plate manage outlet collection from subsequent passes. This localized functional differentiation enables compact same-side inlet/outlet configuration while maintaining sufficient fluid flow path length through strategic placement of flow diverting means in each region.
3Stability of the object's composition
If baffles are used to build pressure for homogenous filling of fluid flow passes, then fluid distribution is improved, but arch trajectory formation and dead zones downstream of baffles occur
Solution Approach 1:
Flow diverting means including deflectors and openings are introduced as intermediary elements between the inlet and the fluid flow passes. These intermediaries guide fluid flow to follow a controlled path that fills all passes homogeneously without creating arch trajectories or dead zones downstream of baffles.
4Duration of action of moving object
If multiple fluid flow passes are configured to increase contact time between fluid and heating elements, then heat exchange performance is improved, but sufficient pressure for uniform fluid filling becomes difficult to maintain
Solution Approach 1:
Flow diverting means including deflectors and openings are positioned upstream in the fluid flow path to pre-distribute fluid into multiple passes before the fluid reaches the heating elements. This preliminary distribution action ensures homogeneous fluid filling in all passes while maintaining sufficient pressure throughout the extended flow path, allowing increased contact time without pressure loss.
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 coolant distribution across all fluid flow passes, improving heat exchange efficiency and performance while preventing dead zones, thus addressing the inefficiencies of conventional heaters.
Implementation Method 1
an electrical resistive heater supplied with current
Implementation Method 2
heat exchange between the fluid flowing through the fluid flow passes and the heating elements
Implementation Method 3
The air to be heated circulates across the heat exchanger and extracts heat from the heating element
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A fluid heater (100) includes a first and a second end plate (10) and (20), heating elements (30) and intermediate plates (40). The first end plate (10) includes an inlet (12a) and an outlet (12b) for ingress and egress of fluid into and out of the fluid heater (100) to cause the fluid to follow a U-turn trajectory. The intermediate plates (40) and the heating elements (30) are arranged alternatively with respect to each other. The adjacent intermediate plates (40) define fluid flow passes adjacent the at least one corresponding heating element (30) to permit heat exchange between the fluid and the at least one corresponding heating element (30). The second end plate (20) includes fluid deflecting walls (50) formed on its surface to promote a homogeneous distribution of fluid in a first portion (20a) and a second portion (20b) of the second end plate (20).