Heating element and fluid heater and method for heating a fluid
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Solution Overview
Problem
Existing electric fluid heaters are inefficient and lack a compact, efficient design for heating fluids.
Innovation Solution
A heating element with 3-dimensional panels arranged at an angle to the axis, electrically connected in series via lateral connectors, forming a meandering conductive path within a self-supporting structure, allowing for flexible resistance adjustment and efficient energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If heating elements are arranged in parallel along the flow path, then the heating surface area is increased, but the device complexity and energy efficiency deteriorate
Solution Approach 1:
The heating element transitions from a conventional 2D flat plate configuration to a 3D structured design with multiple layers and folded sections. This dimensional change allows the heating surface to extend through the fluid flow path in three dimensions, increasing the effective heating area while maintaining a compact overall form factor and simplifying the device structure.
Solution Approach 2:
The heating element employs a nested multi-layer structure where heating panels are arranged in successive layers along the flow path. Each layer is positioned within the flow path created by the previous layer, creating a nested configuration that maximizes heating surface area within a compact volume while simplifying the overall device architecture.
2Area of stationary object
If heating elements are arranged in parallel along the flow path, then the heating surface area is increased, but the energy efficiency deteriorates
Solution Approach 1:
The heating element is designed with a continuous meandering conductive path that ensures uninterrupted heat generation along the entire flow path. The serpentine arrangement of heating panels with electrical connectors at lateral sides maintains continuous electrical and thermal contact, ensuring that heat is generated continuously as fluid passes through each section, maximizing energy utilization efficiency.
Solution Approach 2:
The heating element features non-uniform distribution of heating panels and varying panel dimensions along the flow path. Heating panels are strategically positioned and sized to provide localized heating intensity matching the fluid flow characteristics, ensuring optimal heat transfer efficiency at different locations rather than uniform heating throughout.
3Device complexity
If the heating element structure is simplified, then the device complexity is reduced, but the temperature control precision deteriorates
Solution Approach 1:
The heating element is divided into multiple discrete heating panels arranged in layers, with each panel potentially having different dimensions and positions. This segmentation allows independent optimization of each panel's heating contribution, enabling precise temperature control through the cumulative effect of multiple simplified sections while maintaining overall structural simplicity.
Solution Approach 2:
The heating element utilizes variable panel dimensions, spacing, and arrangement configurations to achieve precise temperature control. By adjusting parameters such as panel length, width, distance between layers, and angular orientation, the heating characteristics can be fine-tuned without increasing structural complexity, allowing precise temperature regulation through geometric parameter optimization.
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 design provides a compact, efficient electric fluid heater capable of high energy transfer and temperature adjustment, suitable for industrial and domestic applications.
Implementation Method 1
electric resistance heating elements arranged for heating a fluid passing through the heater... heating effect achieved by the passage of electric current through the respective wires, strips, and tubes
Data Source
AI summary
A heating element for an electric fluid heater, the heating element having an extension along a first axis and comprising fluid permeable heating panels extending at an angle within a range of 45-90 degrees to the first axis and being arranged adjacent to each other along the first axis with an interspace between adjacent heating panels. Each heating panel comprises a 3-dimensional structure, the 3-dimensional structure comprising a multitude of members of at least one electrically conductive material. The heating element has a 3-dimensional shape which is delimited in part by a first lateral side and an opposite second lateral side. The heating panels are electrically connected in series via electrical connectors arranged at the first and second lateral sides. The 3-dimensional structure comprises at least three members arranged after each other along the first axis and connected to each other at nodes.