Vehicle Electric Heater Layout for Heat Flow and Voltage Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric heaters in motor vehicle heating systems face reduced heat flow due to contact sheets located between heating and radiator elements, leading to suboptimal heat transfer and voltage control issues.
Innovation Solution
The electric heater features a heater core with heating elements having a central portion for thermal contact and lateral portions for electrical contact, separated from radiator elements by insulating layers, allowing independent heat and electric transfer and enhancing stability with metallic contact elements and overmolded plastic insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact sheets are located between heating means and radiator elements to provide electrical contact, then electrical connection is ensured, but heat flow from heating means to radiator elements is reduced
Solution Approach 1:
The heating means is divided into central portion and lateral portions, with radiator elements contacting the central portion and contact elements contacting the lateral portions. This segmentation separates thermal and electrical contact areas, allowing heat to flow efficiently through the central portion while electrical connection is maintained through the lateral portions without interfering with the heat path.
Solution Approach 2:
An electrically insulating layer is introduced as an intermediary between the heating means and the radiator elements in certain areas. This insulating layer prevents direct electrical contact where it would create unwanted thermal resistance, while still allowing thermal contact through non-insulated areas. The insulating layer mediates between the need for electrical isolation and thermal conduction.
2Reliability
If contact sheets are arranged between heating means and radiator elements, then electrical contact is provided, but heating potential of ceramic heating means is reduced
Solution Approach 1:
The heating means is segmented into central portion (for thermal contact) and lateral portions (for electrical contact). This allows the ceramic heating means to maintain its full heating potential by providing dedicated areas for each function, preventing the contact sheets from reducing the overall heating capability.
Solution Approach 2:
The contact elements are positioned at the lateral portions of the heating means, which are arranged in a different spatial dimension relative to the central portion. This dimensional separation allows electrical contact to occur at the sides while thermal contact occurs at the center, eliminating the interference between electrical and thermal functions.
3Reliability
If contact sheets are placed between heating means and radiator elements, then electrical connection is achieved, but voltage control of heating means becomes problematic
Solution Approach 1:
By segmenting the heating means into central and lateral portions with distinct functions, the electrical connection path is separated from the thermal path. This allows for better voltage control as the contact elements at the lateral portions provide stable electrical connection without interfering with the thermal gradient and heat flow control in the central portion.
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
This configuration improves heat performance by maintaining thermal contact while ensuring electrical insulation, making the heater suitable for high-voltage applications and enhancing mechanical stability against external loads.
Implementation Method 1
electric heating elements comprising heating means and contact means to electrically contacting the heating means
Implementation Method 2
radiator elements which are thermally contacting the heating elements
Implementation Method 3
heat dissipating radiator elements which abut against the contact sheets of the electric heating elements
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to an electric heater (1) in particular for a heating or an air-conditioning system of a motor vehicle, with a heater core (2) comprising a plurality of electric heating elements (3) comprising heating means (6) and contact elements (7) to electrically contacting the heating means (6), said heater core (2) further comprising a plurality of radiator elements (4) which are thermally contacting the heating elements (3), wherein the heating means (6) comprises a central portion (8) and two lateral portions (9), wherein the central portion (8) is arranged between the two lateral portions (9), wherein the radiator elements (4) are thermally contacting the heating means (6) in a central portion (8) and the contact elements (7) are electrically contacting the heating means (6) in the lateral portions (9).