Electrical heating device
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Solution Overview
Problem
Existing electrical heating devices face challenges in enhancing performance, particularly in achieving efficient fluid heating with minimal pressure loss and uniform flow, while maintaining a fluid-tight casing and effective heat transfer.
Innovation Solution
The electrical heating device incorporates a flat tube with heat-generating and heat-emitting elements arranged in a layered structure, where spring elements apply pretension for secure contact, and conductor elements with different polarities are used, along with insulating layers and a casing design that promotes uniform fluid flow and low-pressure loss, including corrugated rib elements for enhanced heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat-emitting elements are clamped against the flat tube using spring elements in a layered structure, then heat transfer efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the spring elements: they provide mechanical clamping force to ensure thermal contact between heat-emitting elements and the flat tube, while also serving as structural support within the layered assembly. This merging of clamping and support functions reduces the need for additional separate components, thereby improving heat transfer without proportionally increasing device complexity.
Solution Approach 2:
The spring elements are designed with multi-functionality, serving both as thermal contact pressure applicators and as structural components that maintain the layered structure's integrity. The conductor elements similarly serve dual purposes: electrical conduction and mechanical positioning. This multi-functionality allows the device to achieve effective heat transfer while keeping the overall structure relatively simple.
2Reliability
If conductor elements are inserted into the flat tube with electrical insulation, then safety for high-voltage applications is improved, but manufacturing complexity increases
Solution Approach 1:
The patent implements a nested structure where conductor elements are inserted into the flat tube, and electrical insulation layers are positioned between the conductor elements and the tube's inner circumferential surface. This nested arrangement provides effective electrical isolation for high-voltage applications while maintaining a compact structure. The insulation layers are integrated into the existing tube structure rather than adding separate external components, which helps manage manufacturing complexity.
3Reliability
If the casing is designed to be fluid-tight with inlet and outlet openings, then fluid sealing is improved, but flow uniformity may worsen
Solution Approach 1:
The casing design applies local quality by providing different structural characteristics in different regions: the walls are designed to be fluid-tight with specific inlet and outlet openings for sealing, while internal features such as corrugated rib elements create localized flow channels that promote uniform fluid distribution. The spring elements and layered structure are positioned to optimize both sealing and flow characteristics in their respective locations, allowing the device to achieve fluid tightness without compromising flow uniformity.
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 ensures efficient heating of fluids with reduced pressure loss, uniform flow, and effective heat transfer, making it suitable for high-voltage applications and lightweight designs, such as in motor vehicle systems.
Implementation Method 1
Heat-emitting elements abut against the flat tube while being subject to spring pretension
Implementation Method 2
The spring elements commonly clamp the layered structure on its outer side
Implementation Method 3
at least one heat-generating element being received in a flat tube and arranged in the casing
Implementation Method 4
Heat-emitting elements abut against the flat tube while being subject to spring pretension
Implementation Method 5
a flow of fluid to be heated flows against it within the casing
Data Source
AI summary
An electrical heating device includes a fluid-tight casing comprising inlet and outlet openings for the fluid to be heated, and at least one heat-generating element disposed in the casing. The heat generating element includes at least one PTC element and conductor elements of different polarities received in a flat tube. Heat heat-emitting elements abut against opposite sides of the flat tube. In order to increase the power density, the heat-emitting elements abut against the flat tube subject to spring pretension.