Electric heating device
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Solution Overview
Problem
Existing electric heating devices for motor vehicles face challenges in operational safety, reliability, and manufacturing complexity due to the connection of heating modules to power electronics, leading to potential electrical disturbances and malfunctions.
Innovation Solution
A conductor arrangement with a rail form that projects and contacts the outer shells of heating modules, ensuring they are at the same electrical potential as the housing, providing a stable and simple electrical connection while minimizing fluid flow disruption and allowing for easy detection of electrical issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact tongues project from openings of the conductor element to contact outer shells, then electrical connection is established, but the construction size increases and manufacturing complexity increases
Solution Approach 1:
The conductor element is divided into a base portion and multiple contact portions that can be independently positioned. Each contact portion has a contact surface that contacts the outer shell, allowing simplified construction without complex protruding tongues while maintaining reliable electrical connection.
Solution Approach 2:
The contact portions are arranged in a direction transverse to the longitudinal direction of the heating module, utilizing the transverse dimension for electrical connection. This dimensional approach simplifies the conductor element design by avoiding complex protruding structures while ensuring reliable contact with outer shells.
2Reliability
If outer shells are electrically connected to housing for operational safety, then safety increases, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The conductor element is integrated with the housing such that the base portion is received in the housing and electrically connects outer shells to the housing. This merging of functions achieves operational safety through equipotential connection while simplifying manufacturing by reducing the number of separate components and assembly steps.
Solution Approach 2:
The conductor element serves multiple functions: it provides electrical connection between outer shells, connects them to the housing for safety grounding, and structurally integrates with the housing. This multi-functionality achieves operational safety without increasing manufacturing complexity.
3Productivity
If heating modules are spaced apart in flow path, then heating efficiency improves, but electrical connection stability between modules deteriorates
Solution Approach 1:
Contact portions extend in a direction transverse to the longitudinal direction of the heating module to contact outer shells of spaced-apart heating modules. This transverse arrangement maintains electrical connection stability while allowing heating modules to be spaced apart for optimized heating efficiency.
Solution Approach 2:
The conductor element is pre-configured with contact portions positioned to contact outer shells before the heating modules are installed. This preliminary arrangement ensures stable electrical connection between spaced-apart modules, maintaining connection reliability while allowing flexible spacing for 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
This solution enhances operational safety and reliability by ensuring equipotential connections, simplifies manufacturing, and reduces operational disturbances, allowing for easier detection of electrical issues such as leaks or undesirable currents.
Implementation Method 1
The respective heating module has at least one electrical heating element, for example a PTC element. When electrically supplied, the heating element generates heat and thus heats the fluid flowing through the heating volume.
Data Source
AI summary
An electric heating device for a motor vehicle may include a heating volume and at least two spaced heating modules. A flow path of a fluid may lead through the heating volume. At least two spaced heating modules may be arranged in the heating volume. The at least two spaced heating modules may extend in a longitudinal direction. The at least two spaced heating modules may be spaced apart from one another in a transverse direction extending transversely to the longitudinal direction.