Fuel Heater Flow Guide Prevents Metal Chip Shorts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical short circuits in fuel heating devices due to metal chips in diesel fuel are not effectively prevented by existing technologies, as elongated metal shavings can pass through filters and bridge between heat exchanger elements, causing electrical shorts.
Innovation Solution
A device with a tubular housing containing a PTC heating element between two heat exchanger elements, where a flow guide element divides the fuel flow into two partial flows, preventing metal chips from depositing between the heat exchanger elements and thus preventing electrical shorts. The flow guide element is designed to protrude beyond the heat exchanger elements, ensuring that metal chips cannot bridge between them, and is preferably made of a non-conductive material to prevent electrical shorts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If filters with specific mesh size are used to filter fuel, then solid particles are filtered out, but elongated metal shavings can still pass through and cause electrical shorts
Solution Approach 1:
The flow channel is segmented into a first flow channel and a second flow channel using a flow guide element. This segmentation directs fuel flows to pass on opposite sides of the heating element, preventing metal shavings from bridging between heat exchanger elements while still allowing filters to capture particulate matter.
Solution Approach 2:
The flow guide element acts as an intermediary component that physically separates the fuel paths on either side of the heating element. It prevents direct contact between metal shavings and the heating element surfaces, thereby eliminating the electrical short circuit risk while maintaining filtration effectiveness.
2Productivity
If heat exchanger elements are placed close together for efficient heat transfer, then heating efficiency improves, but metal chips can easily bridge between them causing electrical shorts
Solution Approach 1:
The flow channel is segmented into a first flow channel and a second flow channel using a flow guide element. This segmentation directs fuel flows to pass on opposite sides of the heating element, preventing metal shavings from bridging between heat exchanger elements while still allowing filters to capture particulate matter.
Solution Approach 2:
The flow guide element acts as an intermediary component that physically separates the fuel paths on either side of the heating element. It prevents direct contact between metal shavings and the heating element surfaces, thereby eliminating the electrical short circuit risk while maintaining filtration effectiveness.
3Reliability
If a flow guide element is introduced to prevent metal chip bridging, then electrical short prevention improves, but device complexity increases
Solution Approach 1:
The flow guide element serves multiple functions simultaneously: it segments the flow channel, directs fuel flow patterns, prevents metal shaving accumulation, and provides structural support. This multi-functionality prevents electrical shorts while adding minimal structural complexity to the overall device.
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 prevents metal chips from causing electrical shorts by ensuring they cannot bridge between heat exchanger elements, enhancing the reliability and safety of fuel heating devices by maintaining electrical insulation and efficient heat transfer.
Implementation Method 1
a PTC heating element is arranged between two heat exchanger profiles
Implementation Method 2
a heat transfer device which is in thermal contact with it and has two heat transfer elements
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a device (10) for heating fuel, in particular diesel fuel. The device (10) has a tubular housing (18) for guiding a fuel flow (K). The device (10) has a first heat exchanger element (14) and a second heat exchanger element (16) arranged in the housing (18). The device (10) has an electric heating element (12), in particular a PTC heating element, arranged in the housing (18) between the first heat exchanger element (14) and the second heat exchanger element (16). The first heat exchanger element (14), the electric heating element (12), and the second heat exchanger element (16) are electrically and thermally connected.The device (10) has a first flow guide element (42) which is configured to divide the fuel flow (K) upstream of the first heat exchanger element (14) and the second heat exchanger element (16) into a first partial flow (K1) which flows around the first heat exchanger element (14) and a second partial flow (K2) which flows around the second heat exchanger element (16).