Heating block
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Solution Overview
Problem
Existing heating blocks in calorifiers face issues with high flow pressure loss and material accumulation due to friction welding, leading to contamination and distortion, which affects the flow characteristics and usability of the heating block.
Innovation Solution
A heating block design using two partial shells with non-planar joining surfaces welded via a heat-mediated, abrasion-free process, allowing for a three-dimensional connection and preventing material accumulation, while maintaining a uniform wall thickness and reducing pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction welding is used to join the two halves of the heating block body, then the joining strength is improved, but abrasion debris is generated that contaminates the flowing medium and increases pressure loss
Solution Approach 1:
The patent replaces the mechanical friction welding process with a chemical bonding process using adhesive material. The adhesive is applied to the joining surfaces of the two partial shells, which are then bonded together without mechanical friction, thereby eliminating abrasion debris generation while maintaining joining strength.
Solution Approach 2:
The patent introduces an adhesive material as an intermediary substance between the two partial shells. This adhesive mediator enables the joining of the components without direct mechanical contact and friction, thus preventing the generation of abrasion debris that would otherwise contaminate the water flow.
2Strength
If friction welding is used to join the two halves of the heating block body, then the joining strength is improved, but the pressure loss increases due to abrasion debris
Solution Approach 1:
The patent replaces the mechanical friction welding process with a chemical bonding process using adhesive material. The adhesive is applied to the joining surfaces of the two partial shells, which are then bonded together without mechanical friction, thereby eliminating abrasion debris generation and the associated pressure loss increases.
Solution Approach 2:
The patent introduces an adhesive material as an intermediary substance between the two partial shells. This adhesive mediator enables the joining of the components without direct mechanical contact and friction, thus preventing the generation of abrasion debris that would otherwise increase pressure loss.
3Productivity
If injection molding is used to produce the heating block body, then the manufacturing efficiency is improved, but material accumulations occur causing distortion and cracks
Solution Approach 1:
The patent divides the heating block body into two separate partial shells that are manufactured independently through injection molding. By segmenting the component, the mold design can optimize material flow and cooling for each shell separately, preventing material accumulations and the resulting distortion and cracks that occur in monolithic designs.
Solution Approach 2:
The patent transitions from a monolithic three-dimensional injection molded part to two separate two-dimensional shell components that are subsequently joined. This dimensional simplification allows for optimized mold designs that prevent material accumulations during injection molding, while the final three-dimensional structure is achieved through assembly of the two shells.
4Ease of manufacture
If the joining surfaces are designed in a two-dimensional plane for friction welding, then the manufacturing simplicity is improved, but the design flexibility is limited
Solution Approach 1:
The patent transitions from two-dimensional planar joining surfaces to three-dimensional curved joining surfaces. The partial shells are designed with three-dimensional geometry that allows for complex shapes and configurations, providing greater design flexibility while still maintaining manufacturing simplicity through the use of standard injection molding techniques and adhesive bonding.
Solution Approach 2:
The patent changes the geometric parameters of the joining surfaces from flat two-dimensional planes to curved three-dimensional surfaces. This parameter change enables greater design flexibility for the heating block body shape and configuration, while the adhesive bonding process maintains manufacturing simplicity by not requiring precise planar alignment.
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 maintains a consistent water flow rate, reduces pressure loss, and prevents material accumulation, resulting in a more efficient and durable heating block with improved flow characteristics and reduced contamination.
Implementation Method 1
a heating block body which is composed of an electrically insulating material and which can accommodate at least one heating element with a conductor through which electrical current passes
Implementation Method 2
the first and the second partial shell are welded to one another by means of a medium through the supply of heat
Data Source
AI summary
A heating block for use in a water heater for heating water, having a heating block body, in particular made of plastic, for forming a cavity for conducting the water and for receiving at least one heating element. The heating block body includes a first partial shell having a first sub-cavity and a second partial shell having a second sub-cavity. The first and the second partial shells are assembled in a joining region and form between them the cavity from the two sub-cavities. The joining region is not formed, at least partially, in a joining plane and/or the first and the second partial shells are welded together by the supply of heat via a medium, in particular, an essentially abrasion-free and/or vibration-free welding process, and/or the first partial cavity has a greater depth than the second partial cavity or vice versa.