Fluid Heating Device With Integrated TRIAC Heat Dissipation Fitting
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Solution Overview
Problem
Existing fluid heating devices for applications like radiators and towel warmers face issues with inefficient heat dissipation from power circuit breakers like TRIAC, bulky structures, complex electrical connections, and lack of mechanical stability, leading to excessive heating and reduced service life.
Innovation Solution
A fluid heating device design that incorporates a thermally conductive fitting to house the power electronic switch (TRIAC) with a diffuser for enhanced heat dissipation and mechanical protection, along with a mechanical fixing system to ensure stable contact and efficient heat transfer, allowing for compact and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the power circuit breaker (TRIAC) is placed within the end flange of the heating device, then the structure allows heat dissipation through the flange walls, but the flange must be specially designed with sufficient thickness, making the whole structure extremely bulky
Solution Approach 1:
The device is divided into separate functional modules: the heating element assembly with integrated heat sink, the end flange for mounting, and the housing. This segmentation allows the heat dissipation function to be concentrated in the heating element assembly without requiring the entire device structure to be bulky.
Solution Approach 2:
A dedicated heat sink structure acts as an intermediary between the TRIAC and the end flange. The heat sink receives heat from the TRIAC and dissipates it through its own optimized surface area and thermal pathways, eliminating the need for the end flange to be excessively thick for heat dissipation purposes.
2Measurement precision
If the temperature sensor is placed within the insulating material close to the resistor, then the sensor can detect temperature accurately, but there is no need to dissipate power and heat in the proximity of the sensor element
Solution Approach 1:
The temperature sensor is extracted from the insulating material and relocated to a position on the heat sink structure. This allows the sensor to measure the temperature of the heat sink (which reflects the TRIAC temperature) without being exposed to the high heat density near the resistor, improving both accuracy and reliability.
Solution Approach 2:
The heat sink serves as an intermediary thermal mass between the resistor and the temperature sensor. The sensor measures the heat sink temperature, which is a reliable indicator of TRIAC temperature without requiring the sensor to be in direct proximity to the high-heat resistor area.
3Loss of energy
If heat transfer between the power circuit breaker or TRIAC and the metal fitting is improved, then heat dissipation efficiency increases, but complex mechanical fasteners or stable mechanical coupling systems are needed
Solution Approach 1:
The mounting bracket and heat dissipation structure are merged into a single integrated component. The bracket that mechanically couples the TRIAC to the end flange also serves as the heat transfer pathway, eliminating the need for separate mechanical fasteners and complex coupling systems.
Solution Approach 2:
The mounting bracket performs multiple functions simultaneously: it provides mechanical support for the TRIAC, establishes thermal contact between the TRIAC and the end flange, and serves as part of the heat dissipation structure. This multi-functionality reduces overall device complexity.
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 enables effective power and heat dissipation, increases the service life of the power electronic switch, simplifies electrical connections, and provides a compact, reliable, and economical heating device with improved mechanical and electrical insulation.
Implementation Method 1
a thermally conductive fitting to house the power electronic switch (TRIAC) with a diffuser for enhanced heat dissipation
Implementation Method 2
Such a heating device normally includes a resistor or resistive element
Data Source
Figure 1~2B
Figure 3~4
Figure 5~6B
AI summary
The present invention is relative to a fluid heating device, suitable for heating at least one fluid circulating inside a heating structure, comprising at least one enclosure (10) made of a conductive material, inside which at least one resistive element is inserted, having respective terminals connected to relative electrical conductors connected to a power electronic circuit, the power electronic circuit is provided with at least one power switch (3), which is connected in turn, to at least one resistive element and to the power circuit; the electrical conductors emerge from said enclosure (10) passing through a fitting (1), which is placed coaxially with respect to the enclosure (10) and which is made of thermally conductive material; the power switch (3), made internally to said fitting (1), comprises a power dissipating element or diffuser (2), fixed and interposed between the power switch (3) and at least a portion of the inner walls (13) of the fitting (1) or the enclosure or pipe (10)