High-Voltage Heater with Welded Flat Tubes for Modular Heat Transfer
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Solution Overview
Problem
Existing high-voltage heaters for motor vehicles face complications in construction, particularly with soldered stacked discs and arranging heating elements, which complicates the heat transfer and adaptation to desired heating capacities.
Innovation Solution
Replacing soldered stacked discs with flat tubes and connecting them to heating elements in a heat-transferring manner, allowing for a modular and simplified design with adaptable tube and heating element configurations, enhanced heat exchange through ribbed tubes, and integration of a housing for protection and EMC improvement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stacked discs soldered to one another are used, then heating elements can be arranged between them, but the construction becomes complicated and manufacturing is difficult
Solution Approach 1:
The heater is divided into multiple modular heating modules, each consisting of a heating element and associated flat tubes. These modules can be independently manufactured and then assembled by stacking, simplifying both manufacturing and assembly processes while maintaining functional complexity.
Solution Approach 2:
Multiple flat tubes are merged into a single integrated heating module with a common heating element, reducing the number of separate components and simplifying the overall construction compared to using multiple separate disc assemblies.
2Adaptability or versatility
If multiple stacked discs are used, then heating capacity can be increased, but the arrangement of heating elements becomes complicated
Solution Approach 1:
The heating system is segmented into standardized modules that can be stacked in varying quantities depending on the desired heating capacity. Each module contains a heating element positioned to heat adjacent flat tubes, allowing flexible configuration without complex arrangements.
Solution Approach 2:
Each heating module is designed as a universal unit that can be replicated and stacked to achieve different heating capacities. The standardized design allows the same module to serve multiple functions across different applications by simply varying the number of modules stacked.
3Device complexity
If flat tubes are used instead of stacked discs, then construction is simplified, but heat transfer efficiency must be maintained
Solution Approach 1:
The flat tubes are equipped with internal ribs or corrugations that create turbulent flow patterns, enhancing heat transfer efficiency. The curved or ribbed surfaces increase the effective heat exchange area and improve thermal contact between the coolant and tube walls.
Solution Approach 2:
The flat tubes incorporate internal rib structures that create a porous-like flow path, increasing the surface area for heat transfer and improving the thermal exchange efficiency between the heating element and the coolant flowing through the tubes.
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 provides a simplified, modular, and efficient high-voltage heater with improved heat exchange capabilities, adaptable to various heating capacities, and enhanced electromagnetic compatibility, while maintaining a compact and protective design.
Implementation Method 1
The respective heating element is connected to at least one of the adjacent flat tubes in a heat-transferring manner. The heating element can be crimped to the respective flat tube in a heat-transferring manner or glued to the respective flat tube in a heat-transferring manner by means of a heat-conductive adhesive.
Implementation Method 2
The respective flat tube can comprise rips and/or structures on the inside for guiding the coolant through the flat tube. Because of this, the heat exchange between the heating element and the coolant in the flat tube can be intensified in particular.
Data Source
AI summary
A high-voltage heater for a motor vehicle for heating a coolant is disclosed. The high-voltage heater includes at least two flat tubes that are flowable through by the coolant and at least one heating element. The at leas two flat tubes and the at least one heating element are alternatingly stacked on top of one another in a stacking direction to form a stack. The at least one heating element is connected at least to one of the adjacent flat tubes in the stack in a heat-transferring manner.