Ceramic Heater Layout for Switchable Heat Output and Fast Response
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Solution Overview
Problem
Conventional heating devices for hybrid and electric vehicles face challenges in reducing size and weight, and in providing prompt heating due to the use of cast-based heat transfer blocks, and existing ceramic heaters do not offer high watt density or easy calorific value switching.
Innovation Solution
A ceramic heater design featuring a rod-shaped ceramic support member with multiple line-shaped heating elements buried in its side surface, allowing for efficient heat generation and easy calorific value switching through independent energization of the elements, along with a hydrophilic surface treatment to prevent heat shock damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a cast-based heat transfer block is used, then heating function is provided, but device size and weight cannot be reduced
Solution Approach 1:
The heating device is divided into separate components: a heat generation unit with heating elements and a heat transfer medium container. This segmentation allows each component to be optimized independently, reducing overall device size and weight while simplifying manufacturing processes.
Solution Approach 2:
The heating elements are extracted from the traditional cast heat transfer block structure and positioned separately within the heat transfer medium. This extraction enables the use of lighter materials and reduces the overall device weight while maintaining heating functionality.
2Speed
If a cast-based heat transfer block is used, then heating function is provided, but prompt heating response cannot be achieved
Solution Approach 1:
The heating system transitions from a static cast block design to a dynamic configuration where heating elements can be independently controlled and adjusted. This allows for rapid response to heating demands by selectively activating specific heating zones.
Solution Approach 2:
Multiple heating elements are segmented and distributed within the heat transfer medium, allowing localized and rapid heat generation. This segmentation enables faster thermal response compared to a single large cast block.
3Adaptability or versatility
If multiple heating elements are used, then calorific value switching is enabled, but device complexity increases
Solution Approach 1:
The heating system is segmented into multiple independent heating elements that can be individually controlled. This allows for stepless calorific value adjustment by activating different combinations of heating elements, providing versatility without requiring a completely separate heating system for each output level.
4Productivity
If heating elements are disposed in the heat generation region, then heating efficiency is improved, but heat shock damage risk increases
Solution Approach 1:
The heat transfer medium serves as an intermediary between the heating elements and the surrounding environment. It absorbs and distributes heat gradually, preventing direct thermal shock to the heating elements while maintaining high heating efficiency through optimal heat transfer.
Solution Approach 2:
The system controls the temperature parameters of the heat transfer medium to prevent excessive temperature gradients. By maintaining appropriate temperature differentials and flow rates, heat shock damage is prevented while preserving heating efficiency.
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 ceramic heater achieves efficient heating with reduced size and weight, allowing for easy switching of calorific value and uniform heating of the heat transfer medium, while preventing damage from vibrations and heat shock.
Implementation Method 1
a line shaped heating element which is buried in a side surface of the support member, generates heat by being energized
Data Source
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AI summary
An object of the invention is to provide a ceramic heater capable of easily switching a calorific value. SOLUTION In the ceramic heater 200 according to the invention comprising; a rod shaped support member 211 composed of ceramic; line shaped heating elements 212 which are buried in a side surface of the support member 211, generating heat by being energized and forming a heat generation region H1; and terminal sections 213 which are connected to the heating elements 212 and disposed on one end side of the support member 211; the number of the heating elements 212 is two or more pieces; and any of the heating elements 212 is disposed entirely of the heat generation region HI.