Helical Flow Heater Core for Uniform Heating in Compact Tubes
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Solution Overview
Problem
Existing fluid heaters face challenges in achieving high heat output in compact designs with limited space, particularly in household appliances, due to the large ratio of heated interface area to fluid volume, leading to cold core flow and longer fluid ducts for thermal energy introduction.
Innovation Solution
A compact fluid heater design featuring a metal tube with a plastic fluid guide core having a helically circumferential groove, increasing the hydraulic length of the heated fluid channel, reducing the cross-sectional area, and enhancing heat transfer through tubular heating elements with a thermally conductive connection, utilizing materials like stainless steel and copper for efficient heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a round cross-section fluid guide is used, then the manufacturing is simple, but the ratio between heated interface area and fluid volume is too large causing cold core flow
Solution Approach 1:
The fluid guide cross-section is segmented into multiple flow channels separated by partition walls. This segmentation divides the large round cross-section into smaller channels, ensuring that all fluid portions are close to the heated surface, eliminating cold core flow while maintaining manufacturing simplicity through extrusion processes.
Solution Approach 2:
The invention transitions from a simple round cross-section to a multi-chamber cross-section with partition walls creating multiple flow paths. This dimensional complexity in the cross-section allows better heat distribution across the fluid volume without increasing the overall heater length.
2Manufacturing precision
If the fluid guide cross-section is reduced to improve heating efficiency, then the heated interface area to fluid volume ratio improves, but the fluid duct length must be increased
Solution Approach 1:
By segmenting the fluid guide into multiple channels with partition walls, the effective heated surface area is increased within the same fluid volume. This allows adequate heating without extending the duct length, as each segment provides its own heated interface.
Solution Approach 2:
The invention utilizes the cross-sectional dimension by creating multi-chamber structures with partition walls, effectively increasing the heated interface area without extending the longitudinal dimension (duct length). This resolves the contradiction between heating efficiency and compactness.
3Reliability
If stainless steel is used for the metal tube, then food safety is ensured, but heat conduction property is significantly poorer compared to aluminum
Solution Approach 1:
The invention uses a composite structure where a stainless steel tube (for food safety and pressure resistance) is combined with a plastic fluid guide core (for structural integrity and flow control). This composite approach allows the stainless steel to provide safety benefits while the overall design compensates for its lower thermal conductivity through optimized fluid channel geometry.
4Manufacturing precision
If the fluid guide is deformed during manufacture to reduce cross-section, then the heated area is reduced, but a reshaping step is required during production
Solution Approach 1:
The fluid guide is designed with integrated partition walls that create multiple flow channels. This segmented structure is manufactured as a single extruded piece, achieving the desired cross-sectional geometry without requiring post-manufacturing deformation or reshaping steps.
Solution Approach 2:
The plastic fluid guide core serves multiple functions: it provides structural support, defines the flow channel geometry, and eliminates the need for additional reshaping steps. This multi-functional design simplifies the manufacturing process while achieving the desired heated area characteristics.
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 design achieves more intensive and uniform heating, reduces the heat capacity and dead time of the fluid heater, improving temperature control and dynamic behavior, while maintaining compactness and efficiency.
Implementation Method 1
a heating device consisting of at least two tubular heating elements which are thermally conductively connected to the liquid-carrying pipe
Implementation Method 2
the fluid guide core has a helically circumferential groove, the base and side flanks of which, in interaction with the inside of the metal pipe, form a first fluid channel section for guiding fluid
Implementation Method 3
uses electrical energy to generate a hot fluid or steam from a cold fluid
Data Source
Figure 1
Figure 2A~2B
Figure 3~4
AI summary
A fluid heater of the flow-heater type with a fluid channel having a first fluid channel section (35), at least one substantially cylindrical metal pipe (2), a heating device (6) having preferably two tubular heating bodies (6a, 6b) spaced apart from each other over equidistant circumferential sections of the metal pipe, and a heat-conducting means for the heat-conducting connection to the metal pipe (2), wherein a fluid-guiding core (30) which is made from plastic is arranged in the metal pipe (2), the fluid-guiding core forming the first fluid channel section (35) between the metal pipe and the fluid-guiding core (30), wherein the first fluid channel section (35) runs substantially helically in the form of a groove in an outer surface of the fluid-guiding core, and wherein the fluid channel has a first fluid connection for fluid supply means and a second fluid connection for fluid removal means, wherein the fluid-guiding core (30) furthermore has a second fluid channel section (34) which is arranged, substantially coaxially, in the interior thereof and is connected in series with the first fluid channel section (35). A fluid connection subassembly can be provided in the region of a first end of the metal pipe (2), said fluid connection subassembly having both the first fluid connection (24a) and the second fluid connection (24b), and therefore fluid is supplied and fluid is removed in the region of the same end sides of the metal pipe (2). A closure stopper (50) is then provided in the region of the second end of the metal pipe (2).