Corrosive fluid heater, tank and manufacturing method
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Solution Overview
Problem
Existing systems for storing and heating aqueous urea solutions in vehicles, such as those used in SCR processes, face issues with freezing, inefficiency, and material limitations, particularly in light vehicles where stainless steel plungers are costly and cumbersome, and plastic overmolded heaters suffer from low heat conductivity and expansion-related defects.
Innovation Solution
A heater for corrosive fluids, like aqueous urea solutions, featuring an anodized aluminum or aluminum alloy heat diffuser with a housing for a heating block, eliminating the need for plastic overmolding and enhancing heat conduction and corrosion resistance, allowing for higher temperature operation without bulkiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic overmolding is used to protect heating members, then corrosion resistance is improved, but heat conduction efficiency deteriorates and device bulk increases
Solution Approach 1:
The invention extracts and removes the plastic overmolding layer from the heating device structure. By eliminating this insulating plastic layer, the heating element achieves direct thermal contact with the corrosive fluid, significantly improving heat conduction efficiency while maintaining corrosion resistance through alternative means (heating element material selection and anodized aluminum housing).
Solution Approach 2:
The invention employs composite material construction where the heating device consists of an anodized aluminum housing ( providing corrosion resistance) combined with heating elements made from materials suitable for direct fluid contact. This composite approach allows each material to perform its optimal function without the need for plastic overmolding.
2Reliability
If plastic overmolding is used to protect heating members, then corrosion resistance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The invention removes the complex plastic overmolding process from the manufacturing sequence. This eliminates the need for multi-material molding, material compatibility management, and defect repair processes associated with plastic coatings, thereby simplifying manufacturing while maintaining protective functions through the anodized aluminum structure.
3Loss of energy
If stainless steel plunger is used as heat exchanger, then heat conduction efficiency is improved, but device bulk and cost increase
Solution Approach 1:
The invention adopts a more economical approach by using an anodized aluminum housing with integrated heating elements instead of expensive stainless steel plungers. The anodized aluminum provides sufficient structural integrity and corrosion resistance for the application, reducing material costs and device bulk while maintaining functional effectiveness.
Solution Approach 2:
The invention changes the material parameters from high-density stainless steel to lighter anodized aluminum, optimizing the weight-to-strength ratio. The anodization process modifies the aluminum surface properties to achieve corrosion resistance comparable to stainless steel, while the overall device bulk is reduced through optimized heating element integration.
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
The solution provides effective and efficient heating with improved corrosion resistance and reduced risk of defects, enabling higher temperature operation and efficient heat transfer without the limitations of plastic overmolded heaters.
Implementation Method 1
at least the first portion of the heat diffuser is made of anodized aluminum or of anodized aluminum alloy and is configured to be in direct contact with the corrosive fluid
Implementation Method 2
at least one heating block comprising at least one heating member configured to heat the corrosive fluid
Implementation Method 3
at least the first portion of the heat diffuser is made of anodized aluminum or of anodized aluminum alloy
Data Source
AI summary
The object of the invention is a heater of a corrosive fluid comprising at least one heat diffuser having at least a first portion intended to be immersed in a corrosive fluid, and at least a second portion intended to be arranged out of the corrosive fluid, at least one heating block comprising at least one heating member configured to heat the corrosive fluid, said heat diffuser comprising at least one housing in which the at least one heating block is housed at least partially, at least the first portion of the heat diffuser being made of anodized aluminum or of anodized aluminum alloy and is configured to be in direct contact with the corrosive fluid.The object of the invention is also a corrosive fluid tank comprising a heater according to the invention and a method for manufacturing a heat diffuser of the heater according to the invention.