Electric Heating Block with Deformable Side Walls for Fin Protection
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Solution Overview
Problem
Conventional electric heating blocks face challenges in securely holding heating elements without damaging fins, which limits the use of less resistant and more thermally efficient fins due to the need for crushing, which can compromise the mechanical strength and thermal performance.
Innovation Solution
An electric heating block design featuring tubes with deformable side walls that compress inwardly to hold heating elements, allowing for the use of less resistant and more thermally efficient fins without risking damage, and a manufacturing method involving assembly, introduction of heating elements, and controlled deformation of the tube's side walls to secure them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire heating block is compressed after assembly with heat sinks to secure heating elements, then the heating elements are held securely, but the fins may be damaged due to insufficient mechanical strength
Solution Approach 1:
The tube is segmented into different wall sections with distinct functions: side walls are designed to be deformable for securing heating elements, while main walls maintain structural integrity to support fins. This segmentation allows differential mechanical properties within the same tube structure.
Solution Approach 2:
Different regions of the tube have different mechanical properties: side walls have enhanced deformability through curved external faces and central grooves, while main walls maintain sufficient strength to support fins. This local quality differentiation resolves the contradiction between securing heating elements and protecting fins.
2Strength
If fins are stiffened to prevent damage during crushing, then fin mechanical strength is improved, but thermal performance is limited and device complexity increases
Solution Approach 1:
The tube structure is segmented so that only the side walls undergo deformation to secure heating elements, while the main walls and fins remain undeformed and maintain their optimal thermal geometry. This avoids the need to stiffen fins.
Solution Approach 2:
The side walls are pre-formed with curved external faces and central grooves that facilitate controlled deformation during assembly. This preliminary preparation allows the deformation to occur locally without affecting the fins, eliminating the need for fin stiffening.
3Ease of manufacture
If conventional crushing methods are used to secure heating elements, then manufacturing simplicity is maintained, but fin damage occurs and thermal performance is compromised
Solution Approach 1:
The tube is segmented into deformable side walls and rigid main walls, allowing localized deformation that secures heating elements without affecting the fins. This maintains manufacturing simplicity while improving thermal performance.
Solution Approach 2:
The mechanical parameters of the tube walls are modified: side walls have curved external faces and central grooves that reduce their stiffness and enable controlled deformation, while main walls retain sufficient stiffness to support fins. This parameter differentiation allows secure heating element retention without fin damage.
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 design enables the use of less resistant and more thermally efficient fins while maintaining the heating elements securely without crushing the heating block, enhancing thermal performance and handling during manufacturing.
Implementation Method 1
The side walls have an external face and an internal face. The external faces of the tube's side walls are curved inward and have a central groove to facilitate the deformation of the tube under lateral compression.
Implementation Method 2
The heating elements are held in the tube by compression between the main walls through an inward deformation of the side walls.
Implementation Method 3
These heating elements include, for example, PTC (Positive Temperature Coefficient) resistors.
Implementation Method 4
The tubes serve to electrically insulate the heating elements from the outside while allowing thermal conduction between the heating elements and the heat sinks.
Implementation Method 5
at least one fin (10) for fluid flow
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Electric heater unit comprising at least one fin intended to have a fluid passing through it and at least one tube accommodating one or more electric heating element(s), said tube having two large walls and two lateral walls, said fin being fixed to one and/or the other of the large walls of the tube, said heating elements being held in said tube by compression between said large walls through an operation of deforming the lateral walls towards the inside of the tube.