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

VSEngineering 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

Engineering Contradiction:
Improvethawing speedVSAvoidsystem operation reliability
Core Design Contradiction:
ProductivityVSReliability

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.

Inventive Principle:
Principle #1Segmentation

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.

Inventive Principle:
Principle #3Local quality

2Reliability

If very thin coil heaters with elastomer layers are used, then heating effectiveness is improved, but manufacturing complexity and cost increase

Engineering Contradiction:
Improveheating effectivenessVSAvoidmanufacturing complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

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.

Inventive Principle:
Principle #2Taking out (Extraction)

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.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Reliability

If very thin coil heaters with elastomer layers are used, then heating effectiveness is improved, but manufacturing cost increases

Engineering Contradiction:
Improveheating effectivenessVSAvoidmanufacturing cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

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.

Inventive Principle:
Principle #2Taking out (Extraction)

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.

Inventive Principle:
Principle #35Parameter changes

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

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Implementation Method 2

at least one first thermally conductive sheet made of metal fixed to the at least one resistive wire

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11956866B2Electric heater for tank
Publication Date: 2024.04.09 I R C A S P A IND RESISTENZE CORAZZATE E AFFINI
  • US11956866B2 patent drawing
  • US11956866B2 patent drawing

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).