Heating plate for a flow heater

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Solution Overview

Problem

Existing heating plates for flow heaters in vehicles face challenges in achieving high efficiency while maintaining a compact design and low manufacturing costs, particularly in effectively transferring heat away from the substrate.

Innovation Solution

The use of compressed fins made of corrugated sheet metal with increased contact area between the fins and the substrate, along with cuts across the ridges to enhance flexibility and reduce thermal strains during brazing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the fins are made from corrugated sheet metal with increased contact area to the substrate, then heat transfer efficiency is improved, but the thermal expansion during brazing causes substrate bending

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidsubstrate bending

Core Design Contradiction:

Loss of energyVSStability of the object's composition

Solution Approach 1:

The fin structure is segmented by introducing cuts across the ridges of the corrugated sheet metal. These cuts divide the continuous fin into sections, allowing each segment to independently accommodate thermal expansion during brazing while maintaining overall structural integrity and heat transfer efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flexibility parameter of the fins is changed by introducing cuts across the ridges. This modifies the mechanical properties of the fin structure, enabling it to accommodate thermal expansion stresses without causing substrate bending, while still maintaining sufficient rigidity for effective heat transfer.

Inventive Principle:

Principle #35Parameter changes

2Loss of energy

If the ridges are compressed to form narrow fins with thickness three times as much as the sheet metal or less, then heat transfer efficiency is improved, but cracks may form in the bend at the distal end of the fins

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidfin structure integrity

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The potential harm of crack formation during ridge compression is converted into a benefit. The cuts across the ridges provide predetermined locations where stress can be released, allowing the fin structure to accommodate compression stresses without compromising overall integrity. The cracks that form are contained within the cut sections and do not affect the functional heat transfer surfaces.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Stability of the object's composition

If cuts are made across the ridges of the corrugated sheet metal to increase flexibility, then the risk of substrate bending during brazing is reduced, but the structural strength of the fins may be compromised

Engineering Contradiction:

Improvesubstrate bending preventionVSAvoidfin structural strength

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The fin structure is segmented by cuts that divide it into multiple sections along the ridge. This segmentation provides flexibility to accommodate thermal expansion while the remaining continuous portions of the fin maintain structural strength for effective heat transfer. The cuts are positioned to optimize both flexibility and strength.

Inventive Principle:

Principle #1Segmentation

4Loss of energy

If the fins are arranged at a distance larger than their thickness (e.g., at least 1.4 times as large) to increase contact area, then heat transfer efficiency is improved, but the compactness of the heating plate design is reduced

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidheating plate compactness

Core Design Contradiction:

Loss of energyVSVolume of moving object

Solution Approach 1:

The corrugated structure of the fins provides a curved, three-dimensional surface that increases the contact area between the fin and substrate without proportionally increasing the overall volume. The compressed ridges create an efficient heat transfer geometry that maximizes surface area within a compact form factor.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 significantly enhances heat transfer efficiency from the substrate, allowing for more effective heating of liquids while minimizing the risk of substrate bending and maintaining a stable fin structure.

Implementation Method 1

heating resistors provided as resistive tracks on a dielectric layer

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

heat is more efficiently transferred away from the plate in areas of metal substrate that are contacted by the corrugated sheet metal

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

The fins are brazed to the substrate

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentEP4496430A1Heating plate for a flow heater

Publication Date: 2025.01.22 BORGWARNER EMISSIONS EYSTEMS SPAIN SLU

Figure 1~3

AI summary

Disclosed is a heating plate for a flow heater, comprising a substrate (1) made of metal, a heating resistor arranged on one side of the substrate (1) and fins (5) arranged on an opposite side of the substrate (1), wherein the fins (5) are brazed to the substrate (1), made of corrugated sheet metal and provided with a series of cuts (6) across ridges of the corrugated sheet metal. According to the invention the ridges are compressed such that opposing surfaces on the inside of the ridges contact each other.