Extruded Heater Profile With Transverse Flow for Better Heat Transfer

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Solution Overview

Problem

Existing heating apparatuses for motor vehicles and other applications face inefficiencies in production complexity and heat transfer, with limited thermal conduction and high production costs due to multiple separate components and ineffective heat transfer mechanisms.

Innovation Solution

The heating apparatus employs an extruded profile as both a heat exchanger and housing, featuring openings and slits to enhance heat transfer through vortex formation, reducing component count and assembly complexity, while maintaining mechanical stability and efficient heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If multiple separate fins are arranged on heating rods to increase heat transfer surface area, then heat transfer efficiency improves, but device complexity and production cost increase

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidnumber of components

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent combines multiple separate fins into a single integrated extruded profile structure. The heating element is embedded within the extruded profile itself, which forms a unified heat exchanger component with multiple internal chambers and external fins already formed during extrusion. This eliminates the need to assemble multiple separate fins onto heating rods, reducing component count while maintaining heat transfer surface area.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The extruded profile serves multiple functions simultaneously: it acts as the housing structure, the heat exchanger with integrated fins, and the mounting framework. The single extruded component performs what previously required multiple separate parts (heating rod housing, fins, supports), simplifying the overall device while maintaining thermal performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If many separate components are assembled to achieve satisfactory thermal conduction, then heat transfer improves, but production time and assembly complexity increase

Engineering Contradiction:

Improvethermal conductionVSAvoidproduction efficiency

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The heat exchanger structure with integrated fins and chambers is pre-formed through extrusion before assembly. The heating element is then embedded into this pre-formed structure in a single operation. This preliminary formation of the complex geometry eliminates the need for multiple subsequent assembly steps to position and secure separate fins and supports, significantly improving production efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the heating element embedding, fin attachment, and structural support functions into a single integrated extruded profile. This consolidation means that thermal conduction pathways are built-in during extrusion rather than requiring separate assembly operations, reducing production steps while ensuring satisfactory thermal contact.

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If air flows tangentially to fins for heating, then device simplicity is maintained, but heat transfer effectiveness is limited

Engineering Contradiction:

Improveflow path designVSAvoidheat transfer effectiveness

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The extruded profile is segmented into multiple internal chambers separated by thin walls. This segmentation creates multiple flow paths for the air or liquid medium to pass through, increasing the effective heat exchange surface area and improving heat transfer effectiveness while maintaining a relatively simple external structure and flow direction.

Inventive Principle:

Principle #1Segmentation

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 significantly improves heat transfer efficiency, reduces production costs and complexity, and allows for flexible adaptation to various applications with minimized dimensional variations and storage requirements.

Implementation Method 1

PTC heating elements that generate heat

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

heat transfer from the heating rods to the fins

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a gaseous or liquid medium can flow through the extruded profile in transverse direction

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 4

a strong vortex motion can be produced, and this especially when the walls of the extruded profiles are provided with slits

Methodology Applied

Scientific EffectVortex flow: Vortex Ring

Data Source

PatentUS8975561B2Electric heating apparatus, especially for motor vehicles

Publication Date: 2015.03.10 BORGWARNER LUDWIGSBURG GMBH

AI summary

The invention describes a heating apparatus comprising at least one heater (9) in which one or more electric heating elements (11) are arranged, and at least one heat transmitter (1), which is connected with the at least one heater (9), comprises heat transmitter surfaces and is formed from an extruded profile (1a, 28, 28a) in which the at least one heater (9) is fitted,in which at least part of the walls (6, 22, 22a) of the extruded profile (1a), which are not in contact with a heating element (11), is provided with openings through which a gaseous or liquid medium can flow through the extruded profile (1a, 28, 28a) in transverse direction to the direction of extrusion (17).