Coolant heating device for vehicle
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Solution Overview
Problem
Electric vehicles face challenges in heating coolant due to the absence of an engine-generated heat source, leading to reduced heat transfer and potential overheating of the sheath heater when its heat-emitting portion is exposed to air rather than water, causing damage.
Innovation Solution
A coolant heating device with a housing, an upper space part for air collection, a water-level-sensing mechanism, and a controller that manages the sheath heater operation and air discharge to prevent overheating by ensuring the sheath heater is not exposed to air for extended periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a sheath heater is provided in a coolant housing for heating coolant, then the coolant can be heated effectively, but air may be generated in the housing causing the heat-emitting portion to be exposed to air, leading to reduced heat transfer and overheating
Solution Approach 1:
The housing is divided into a lower heating space and an upper air collection space, with the sheath heater confined to the lower space. This segmentation prevents air from contacting the heat-emitting portion while maintaining effective heat transfer to the coolant.
Solution Approach 2:
A water level sensor acts as an intermediary device that detects the coolant level and controls the sheath heater operation. It serves as a mediator between the physical state of the coolant and the control system, preventing overheating by stopping heater operation when air exposure is detected.
2Productivity
If the sheath heater operates continuously to heat coolant, then heating efficiency is maintained, but the heat-emitting portion may be exposed to air causing damage
Solution Approach 1:
The water level sensor provides continuous feedback on the coolant level to the control system. When the coolant level drops and air enters the heating space, the sensor triggers the control unit to stop or reduce sheath heater operation, creating a feedback loop that prevents air exposure damage while maintaining heating efficiency.
Solution Approach 2:
The system performs preliminary detection of air entry through the water level sensor before significant air accumulation occurs. By detecting coolant level changes early, the control system can take preventive action by adjusting heater operation before the heat-emitting portion is exposed to air.
3Ease of operation
If air is allowed to accumulate in the coolant housing, then air discharge is simplified, but heat transfer is reduced and sheath heater temperature increases
Solution Approach 1:
Air is extracted from the heating space through a dedicated air discharge device located in the upper portion of the housing. This separates the air removal function from the heating function, allowing air to be discharged without interfering with the heat transfer process in the lower heating space.
Solution Approach 2:
The housing is designed with vertical dimensionality, creating distinct upper and lower spaces. The upper space collects air while the lower space maintains efficient heat transfer, utilizing the vertical dimension to separate air accumulation from the heating zone.
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
Prevents overheating of the sheath heater, reduces the risk of damage, and enhances operational efficiency by effectively managing air discharge and coolant levels, thereby maintaining the sheath heater's integrity and preventing malfunctions in the water pump and valve.
Implementation Method 1
a heat-emitting portion of the sheath heater may be exposed to air, rather than to water, leading to a reduction in heat transfer
Data Source
AI summary
A coolant heating device for a vehicle includes: a housing storing coolant therein and having a sheath heater therein; an upper space part protruding upwards from a top surface of the housing and having an inner space via which an inner space of the housing communicates with the upper space part; a water-level-sensing part disposed inside the upper space part to sense a level of coolant in the housing; and a controller for controlling operation of the sheath heater based on the level of coolant sensed by the water-level-sensing part.