Electrical Fluid Heater with U-Turn Flow Path to Reduce Pressure Drop
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Solution Overview
Problem
Conventional electrical fluid heaters face issues with non-uniform fluid distribution, bulkiness, packaging problems, increased pressure drop, and complex brazing requirements, leading to inefficiencies and performance degradation.
Innovation Solution
The design features a casing with a partition groove dividing it into first and second chambers, an intermediate connecting portion forming an U-turn trajectory, and symmetrical, flat casings with centrally disposed inlets and outlets, ensuring uniform fluid distribution and reduced brazing sites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple plates are stacked to define fluid heating spaces, then the heater achieves compact configuration, but the device complexity and brazing difficulty increase
Solution Approach 1:
The patent merges multiple plates into a single integrated casing with internal partition grooves that define fluid heating spaces. This eliminates the need for multiple separate plates and their associated brazing joints, reducing manufacturing complexity while maintaining compact form factor.
Solution Approach 2:
The single casing is segmented into multiple fluid heating spaces using internal partition grooves. This allows the heater to maintain compact configuration with multiple heating zones without requiring multiple separate plates, thereby reducing brazing complexity.
2Loss of energy
If fluid flows through multiple plate holes and between heating elements, then heat exchange occurs, but pressure drop increases
Solution Approach 1:
The patent transitions from two-dimensional flow through plate holes to three-dimensional flow through strategically positioned openings in the heating elements. This allows fluid to access heating surfaces more directly, reducing flow path length and pressure drop while maintaining effective heat exchange.
Solution Approach 2:
The patent introduces intermediate fluid communication openings in the heating elements that act as mediators between the fluid passages and heating surfaces. These openings optimize fluid distribution and reduce pressure drop by eliminating the need for fluid to pass through multiple plate holes.
3Volume of moving object
If inlet and outlet are positioned on top of the heater, then compact configuration is achieved, but fluid distribution uniformity decreases
Solution Approach 1:
The patent repositions fluid inlet and outlet openings from the top surface to the lateral surfaces of the heater. This spatial reconfiguration allows for more uniform fluid distribution across the heating elements while maintaining compact overall dimensions.
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 configuration results in a compact, efficient, and high-performance electrical fluid heater with improved heat exchange, reduced air bubble formation, and simplified manufacturing, addressing packaging and brazing challenges.
Implementation Method 1
an electrical resistive element supplied with current in case of an electrical resistive heater
Implementation Method 2
The tube is electrically insulated from the electrodes and the electrical core but thermally in contact with them
Data Source
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AI summary
A fluid heater (100) includes at least one heating element (10) and at least one casing (20). The casing (20) includes a first and a second portion (20a) and (20b), a partition groove (22), an inlet and an outlet (24) and (26). The first and second portions (20a) and (20b) are assembled to define an enclosure receiving the heating element (10). The partition groove (22) divides casing (20) into a first chamber (20d) receiving fluid from the inlet (24) and defining a first pass "A" and a second chamber (20e) delivering fluid to the outlet (26) and defining a second, return pass "B". The casing (20) is formed with an intermediate connecting portion (28) to define an U-turn trajectory "C" forming fluid communication between the first and the second chambers (20d) and (20e) along plane of heating element (10) and extending in longitudinal direction along lateral side of heating element (10).