Heat Exchanger with Electrical Heating Coating for Fluid Preheating

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Solution Overview

Problem

Existing oil-water heat exchangers face challenges in effectively preheating engine oil, especially when it is not at operating temperature, and their production is complex and tailored to specific applications.

Innovation Solution

A heat exchanger design featuring electrical heating coatings applied to fluid receiving volumes connected to fluid channels, allowing for simple and effective heating of fluids, with a modular approach that can upgrade existing heat exchangers and reduce manufacturing costs by using a single module for different types and sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If electrical heating elements are integrated into existing heat exchangers, then preheating capability is improved, but device complexity increases

Engineering Contradiction:

Improvepreheating capabilityVSAvoidstructural complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical heating elements with an electrical heating coating applied directly to the heat exchanger surface. This substitution eliminates the need for separate heating components, connections, and control mechanisms, thereby improving preheating capability while avoiding increased device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The heating element is implemented as a thin electrical heating coating applied directly to the heat exchanger surface. This thin-film approach integrates the heating function into the existing structure without adding bulky components, maintaining structural simplicity while enabling effective preheating.

Inventive Principle:

Principle #30Flexible shells and thin films

2Temperature

If complex heating systems are designed for specific applications, then heating effectiveness is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improveheating effectivenessVSAvoidmanufacturing simplicity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The electrical heating coating can be applied to various heat exchanger types and configurations using a standardized process. This universal approach allows the same heating technology to serve multiple applications (different fluids, geometries, and scales) without requiring custom-designed heating systems, thereby maintaining manufacturing simplicity while achieving effective heating.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The heating effectiveness is optimized by adjusting parameters of the electrical heating coating (such as power density, thickness, and material composition) rather than changing the fundamental heating mechanism. This allows tailored heating performance for different applications while maintaining the same simple manufacturing process.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If traditional heating methods are used in heat exchangers, then structural simplicity is maintained, but preheating effectiveness deteriorates

Engineering Contradiction:

Improvestructural simplicityVSAvoidpreheating effectiveness

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

Traditional mechanical heating methods (such as external heaters or heat exchanger sections) are replaced with an electrical heating coating that can be directly applied to the heat exchanger surface. This substitution maintains structural simplicity by eliminating separate heating components while dramatically improving preheating effectiveness through direct electrical heating.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electrical heating coating is integrated directly into the heat exchanger structure, allowing the heat exchanger to perform both heat exchange and heating functions simultaneously. This self-service approach eliminates the need for separate heating systems while maintaining structural simplicity and improving preheating effectiveness.

Inventive Principle:

Principle #25Self-service

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

Enables efficient preheating of fluids, such as engine oil, with a simple and cost-effective solution that can be applied to various heat exchanger types, improving pollutant reduction and operational efficiency.

Implementation Method 1

the fluid receiving volume is equipped with an electrical heating coating

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a heat exchanger which is in thermally conductive contact with the at least one pipe and which carries the first Medium

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3417227B1Heat exchanger, in particular water-air heat exchanger or oil-water heat exchanger

Publication Date: 2021.06.23 WEBASTO AG

Figure 1~2
Figure 3

AI summary

The invention relates to a heat exchanger, in particular an water-air heat exchanger or oil-water heat exchanger, comprising at least one first fluid channel for guiding a first fluid, and at least one second fluid channel for guiding a second fluid, the at least one first fluid channel being joined to a fluid receiving volume, in particular on the outlet side, said fluid receiving volume being equipped with an electric heating coating (13).