Integrated Fluid Heater Assembly for Fast Vehicle Cabin Heating
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Solution Overview
Problem
Existing heating systems in motor vehicles, particularly electric vehicles, face challenges in rapidly and effectively heating the passenger compartment, especially in cold environments, and rely on inefficient methods such as air conditioning loops in heat pump mode or additional electric heating devices that are not always sufficient.
Innovation Solution
An electric fluid heating device with a compact and robust design, featuring cylindrical heating elements, a control module with temperature sensors, and a mechanical holding mechanism that simplifies assembly and electrical connections, allowing for efficient heating of fluids before they enter a water circuit or air conditioning loop, thereby enhancing heating performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an additional electric heating device is added to the heat exchanger or water circuit, then heating performance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the heating element with the fluid inlet housing to create an integrated assembly. The heating element is positioned to extend through the housing, with electrical connections made directly to the housing structure, eliminating the need for separate mounting brackets, insulation layers, and intermediate connection components. This merging of functions maintains high heating performance while reducing overall device complexity.
2Speed
If traditional heating methods are used, then device structure is simple, but heating speed and effectiveness are insufficient
Solution Approach 1:
The patent replaces conventional thermal heating methods (which rely on fluid circulation through heat exchangers) with direct electric heating elements immersed in the fluid pathway. This substitution of heating mechanism dramatically increases heating speed and effectiveness, as electrical resistance heating provides immediate heat generation without requiring thermal transfer through multiple components.
3Reliability
If heating elements are connected with multiple components, then connection is secure, but assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the electrical connection structure directly into the fluid inlet housing. Electrical terminals are formed as integral parts of the housing or are directly mounted to it, eliminating the need for separate mounting brackets, insulation layers, and intermediate connection components. This reduces the number of parts while maintaining secure electrical and mechanical connections.
4Stability of the object's composition
If intermediate components are used in the heating device, then assembly is stable, but device bulk and manufacturing cost increase
Solution Approach 1:
The patent removes intermediate components such as separate mounting brackets, insulation layers, and connection adapters from the heating device assembly. The heating element is positioned and connected directly to the fluid inlet housing, which serves as both the structural support and electrical connection point. This extraction of unnecessary intermediate parts reduces device bulk while maintaining assembly stability through direct integration.
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 rapid and effective heating of the passenger compartment, reducing manufacturing costs and improving the robustness and compactness of the heating device, while eliminating the need for intermediate components and ensuring reliable electrical connections.
Implementation Method 1
an additional electric heating device... comprises a heating element in contact with the fluid to be heated
Data Source
AI summary
The invention relates to an electrical fluid heating device for a motor vehicle, characterised in that it comprises: at least one heating element (7a, 7b); a means (3) for controlling the heating element (7a, 7b), comprising an electrical card support (13); and a connection means comprising an electrical connector (22; 16; 23; 24) that electrically connects the heating element (7a, 7b) to the electrical card support (13), and at least one mechanical holding means designed so as to mechanically hold said electrical connector (22; 16; 23, 24) against the heating element (7a, 7b).