Electric Heater with Conductive Sheet for Tank Thawing
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Solution Overview
Problem
Existing electric heaters for vehicle tanks, particularly those containing water or aqueous solutions like AdBlue, face challenges in efficiently thawing frozen substances at low temperatures without excessive overheating, leading to sublimation and operational issues, and are costly and environmentally unfriendly to produce due to the need for complex elastomer layers.
Innovation Solution
An electric heater comprising a resistive wire with an insulating sheath, a thermally conductive metal sheet, and protective polymer layers, which allows for efficient heat diffusion and production without elastomer support layers, enabling quick and reliable thawing of frozen masses while being cost-effective and environmentally friendly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heating systems with excessively high power concentration are used for thawing, then thawing speed is improved, but sublimation occurs causing gas layer formation and system malfunction
Solution Approach 1:
The heating system is segmented into multiple heating zones or elements distributed throughout the tank, allowing heat to be applied at multiple locations simultaneously. This increases overall thawing productivity while maintaining appropriate power density at each location to prevent sublimation and gas layer formation.
Solution Approach 2:
The heating elements are designed with localized heat distribution characteristics, concentrating heat where needed while maintaining appropriate power density. This allows efficient thawing in specific frozen areas without causing excessive overheating and sublimation in other regions.
2Reliability
If very thin coil heaters with elastomer layers are used, then heating effectiveness is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The complex elastomer support layers and chemical etching processes are removed from the manufacturing process. Instead, the patent uses simpler heating elements such as resistive wires or heating panels that can be directly installed in the tank without requiring cross-linking or complex fabrication steps.
Solution Approach 2:
The invention employs simpler, more cost-effective heating elements that can be manufactured using basic processes. These elements are designed to be functional and reliable without requiring expensive materials or complex assembly procedures, making the overall system more economical.
3Reliability
If very thin coil heaters with elastomer layers are used, then heating effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The expensive elastomer layers and chemical etching processes are extracted from the manufacturing process. The patent replaces these with simpler, more cost-effective heating elements that can be manufactured using basic industrial processes, significantly reducing production costs while maintaining heating effectiveness.
Solution Approach 2:
The invention changes the physical parameters of the heating elements, using standard resistive wires or panels with appropriate dimensions and power ratings. This allows the use of conventional manufacturing techniques and readily available materials, reducing both material and processing costs compared to custom-made thin coil heaters.
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 thaws frozen substances in vehicle tanks by optimizing heat distribution and reducing production complexity and costs, ensuring reliable operation and environmental sustainability.
Implementation Method 1
at least one resistive wire adapted to be connected to a source of electricity to generate heat
Implementation Method 2
at least one first thermally conductive sheet made of metal fixed to the at least one resistive wire
Data Source
AI summary
An electric heater (1, 1′) for heating a substance inside a tank (100), the electric heater (1, 1′) comprising: —at least one resistive wire (4) adapted to be connected to a source of electricity, said at least one resistive wire (4) being provided with a sheath (41) made of electrically insulating material; —at least a first thermally conductive sheet (5) made of metal fixed to the at least one resistive wire (4); —at least two protective layers (2, 3) made of polymer material, fixed to each other; wherein the at least one resistive wire (4) and the at least a first sheet (5) are arranged between the at least two protective layers (2, 3).

