Flow heater
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Solution Overview
Problem
Flow heaters for electric cars face challenges in achieving a compact design, low manufacturing costs, and high efficiency for quickly heating large quantities of liquid, particularly water or aqueous solutions, given their high operating voltage and existing design limitations.
Innovation Solution
A flow heater design utilizing a housing made of deep-drawn sheet metal with conductive tracks printed or thermally sprayed on one of the housing parts, eliminating the need for a separate substrate, and incorporating an electrically insulating layer, fins for enhanced heat transfer, and a compact outer housing for insulation and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a molded housing is used in prior art flow heaters, then the structural integrity is ensured, but the manufacturing cost increases and weight increases
Solution Approach 1:
The housing is formed by deep-drawing a single metal sheet into a three-dimensional shape, merging the functions of multiple separate housing components into one integrated structure. This eliminates the need for separate molds and reduces the number of parts, thereby lowering manufacturing cost and weight while maintaining structural integrity through the continuous metal construction.
Solution Approach 2:
The traditional molded housing construction is replaced by a deep-drawn metal sheet construction. This substitution changes the manufacturing method from molding to metal forming, enabling cost-efficient production and weight reduction while preserving the necessary mechanical strength and structural properties of the housing.
2Ease of manufacture
If a separate substrate is used for the heating resistor, then the electrical insulation is ensured, but the manufacturing cost increases and the device complexity increases
Solution Approach 1:
The heating resistor is integrated directly onto the housing structure itself, eliminating the need for a separate substrate. The housing serves dual functions as both structural enclosure and mounting platform for the heating element, reducing part count and manufacturing complexity while maintaining electrical insulation through proper design of the deep-drawn metal construction.
Solution Approach 2:
The housing is designed to perform multiple functions: it provides structural enclosure, serves as the mounting surface for the heating resistor, and contributes to thermal management. This multi-functionality eliminates the need for separate substrates and reduces overall device complexity while keeping manufacturing costs low.
3Ease of manufacture
If the heating resistor is integrated into the housing, then the manufacturing cost decreases and weight decreases, but electrical insulation challenges arise
Solution Approach 1:
The deep-drawn metal housing provides inherent electrical insulation properties at the locations where the heating resistor is mounted. The metal construction itself, through its forming process, creates non-conductive pathways or barriers between different electrical components, ensuring insulation reliability without requiring additional insulating materials or complex designs.
4Productivity
If fins are added to enhance heat transfer, then the heating efficiency improves, but the device complexity and manufacturing cost increase
Solution Approach 1:
The fins are integrated directly into the deep-drawn metal housing structure, combining the heat transfer enhancement function with the existing housing construction. This integration avoids the need for separate fin components or additional assembly steps, thereby improving heating efficiency while minimizing increases in device complexity and manufacturing cost.
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 achieves cost efficiency, reduced weight, and improved heating performance by integrating the heating resistor directly into the housing and using fins for enhanced heat transfer, while maintaining electrical insulation and protection, thus addressing the need for a compact and efficient flow heater.
Implementation Method 1
The heating resistor is provided as conductive tracks arranged on the first housing part or the second housing part
Implementation Method 2
fins may be arranged in an interior of the housing in order to improve heat transfer to liquid to be heated
Implementation Method 3
fins may be arranged in an interior of the housing in order to improve heat transfer to liquid to be heated
Implementation Method 4
The area of the housing on which the conductive tracks are arranged is covered by an electrically insulating layer
Data Source
Figure 1~4
AI summary
Disclosed is a flow heater comprising a housing (1) having an inlet and an outlet, and an electrical heating resistor (13) provided as conductive tracks, wherein the housing (1) comprises a first housing part (11) made of a deep drawn sheet of metal and a second housing part (12) made of a sheet of metal, and wherein the heating resistor (13) is arranged as conductive tracks on the first housing part (11) or the second housing part (12).