Induction Heater for Electric Vehicle Thermal Management
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Solution Overview
Problem
Electric heaters in high-voltage vehicle systems face challenges in efficiently transferring heat due to thermal resistance from insulation, making it difficult to effectively warm components like batteries and vehicle cabins.
Innovation Solution
The use of induction heating, where a ferromagnetic heating element is exposed to an alternating magnetic field, inducing eddy currents and directly heating a heat transfer medium without thermal losses, and utilizing a heat exchanger to release heat to the surroundings, eliminating the need for galvanic connections and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elaborate electrical insulation is used in high-voltage heaters, then electrical safety is improved, but thermal resistance increases and heat transfer efficiency deteriorates
Solution Approach 1:
The patent replaces the conventional resistive heating element with an induction heating system that uses electromagnetic fields to generate heat directly in a ferromagnetic heating element. This substitution eliminates the need for elaborate electrical insulation between the heat source and heat sink, as the heating occurs through electromagnetic induction rather than direct electrical contact, thereby resolving the contradiction between electrical safety and heat transfer efficiency
Solution Approach 2:
The patent introduces a ferromagnetic heating element as an intermediary between the electromagnetic field and the heat transfer medium. This heating element is heated by induced eddy currents and then transfers heat to the fluid, acting as a thermal bridge that eliminates the need for electrical insulation while maintaining efficient heat transfer
2Device complexity
If induction heating is used without galvanic connection, then assembly complexity and insulation requirements are reduced, but electrical safety measures must still be ensured
Solution Approach 1:
The patent replaces galvanic (direct electrical) connections with electromagnetic induction for heating. The magnetic field generating unit heats the ferromagnetic element through induced eddy currents without requiring electrical contact, thereby simplifying assembly and eliminating the need for complex insulation while maintaining electrical safety through non-contact heating
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 solution provides efficient heating with minimal thermal resistance, simplifies insulation and assembly, and ensures safety by automatically limiting the maximum temperature through Curie temperature control, meeting electrical vehicle heating system requirements.
Implementation Method 1
Eddy currents are induced in the ferromagnetic material of the heating element of the induction heating
Implementation Method 2
Eddy currents are induced in the ferromagnetic material of the heating element of the induction heating. If additional magnetic reversal losses occur due to the use of appropriate materials, these also contribute to the heating of the heating element
Implementation Method 3
One of the advantages of induction heating is that the heat is generated directly, i.e. Without thermal losses through insulation or the like. Can be given to the heat transfer medium
Implementation Method 4
the heat sink is, for example, the heat transfer medium
Implementation Method 5
which in turn emits its thermal energy to its surroundings via a heat exchanger
Data Source
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AI summary
The electric heater for a vehicle having an electric drive or hybrid drive has a heating element (42) for heating a flowing, liquid heat-transfer medium. Furthermore, the electric heater has a heat exchanger (22, 28) for giving off heat to the surroundings thereof, the heat exchanger being arranged downstream of the heating element (42) and being in thermal contact with the heat-transfer medium, wherein the heating element (42) has a ferromagnetic material that can be wetted by the heat-transfer medium and/or through and/or around which the heat-transfer medium can flow. The electric heater is provided with a magnetic field generating unit (52) for generating an alternating magnetic field, in which the heating element (42) is arranged, wherein eddy currents can be induced in the ferromagnetic material of the heating element (42) by the magnetic field in order to heat the heating element (42). Possible core losses likewise produce heat.