Electrical Heating Device Mechanical Support to Reduce Vibration Noise

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Solution Overview

Problem

Existing electrical heating devices in motor vehicles, particularly in electric or hybrid vehicles, experience noise and increased wear due to vibrations during operation, primarily caused by the cantilevered mounting of electrical heating elements.

Innovation Solution

The electrical heating device incorporates an additional mechanical connection element within the liquid circulation chamber, which connects the electrical heating elements to the internal surface of the housing, thereby reducing the cantilever effect and absorbing tolerance ranges. This setup also forms a thermal bridge for more accurate temperature measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If electrical heating elements are mounted cantilevered to the inner wall, then sealing measures can be concentrated on one wall, but noise and wear increase due to vibrations during vehicle operation

Engineering Contradiction:

Improvesealing concentrationVSAvoidnoise and wear

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The mechanical support function is segmented into two independent connections: one connection to the inner wall for sealing and electrical access, and a second connection via the mechanical connection element to provide additional support. This segmentation allows each connection to have specialized functions, reducing the cantilever effect and vibration-related noise while maintaining sealing concentration at the inner wall.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical connection element is pre-positioned within the liquid circulation chamber to establish a second support path before vibrations occur. This preliminary structural arrangement absorbs tolerance ranges and prevents excessive cantilever deflection during vehicle operation, thereby reducing noise and wear before they can manifest.

Inventive Principle:

Principle #10Preliminary action

2Power

If heating power is increased by adding more electrical heating elements, then sufficient heating performance is achieved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveheating powerVSAvoidnumber of heating elements

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The mechanical connection element serves multiple functions simultaneously: it provides structural support to reduce cantilever effects, acts as a thermal bridge for heat dissipation, and enables accurate temperature measurement. This multi-functionality allows the device to achieve sufficient heating power without proportionally increasing the number of heating elements, thereby controlling device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If the cantilever of electrical heating elements is reduced, then noise and wear are minimized, but additional mechanical connection elements increase device complexity

Engineering Contradiction:

Improvenoise and wearVSAvoidnumber of mechanical connections

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The mechanical connection element merges multiple functions into a single component: structural support (reducing cantilever), thermal conduction (thermal bridge), and temperature sensing support. This merging approach reduces the need for separate components for each function, thereby minimizing the increase in device complexity while effectively reducing noise and wear through shortened cantilever.

Inventive Principle:

Principle #5Merging (Combining)

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 solution effectively reduces noise generation and wear by stabilizing the electrical heating elements within the housing, while also enhancing temperature measurement accuracy by providing a thermal bridge even when the liquid is absent.

Implementation Method 1

an electric current flows to raise the temperature of a heating body extending longitudinally inside a housing of this heating device

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The additional mechanical connection also forms a thermal bridge between the electrical heating element or elements and the housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12296650B2Electrical heating device, in particular for a motor vehicle

Publication Date: 2025.05.13 VALEO SYST THERMIQUES SAS

AI summary

The invention relates to a device for electrically heating (1) a liquid, comprising a heating body (11), and a housing (3) defining, at least in part, a chamber (30) for circulating the liquid, the heating body (11) comprising at least one electric heating element (7, 9) extending in the chamber (30) and attached to an inner wall of the device defining, at least in part, the chamber (30) for circulating the liquid, so as to form a first mechanical connection. According to the invention, the electric heating device (1) comprises at least one mechanical connecting element (21) arranged in the chamber (30) and mechanically connecting the at least one electric heating element (7, 9) to an inner surface of the housing (3) extending opposite the heating body (11), so as to form a second mechanical connection separate from the first mechanical connection.