Modular Induction Fluid Heater With Turbulent Heat Transfer

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Solution Overview

Problem

Conventional electric vehicle heating systems require additional components and electrical isolation, leading to inefficiencies and increased costs due to the need for a water circuit and heavy PTC ceramic elements, which also pose safety concerns.

Innovation Solution

An induction heating system where an inductor is positioned within an alternating magnetic field, generating a turbulent flow to enhance heat transfer between the inductor and fluid, eliminating the need for electrical isolation and simplifying the system design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional electrical water heaters use heating elements that project into the fluid, then heating function is achieved, but electrical isolation is required which increases cost and reduces efficiency

Engineering Contradiction:

Improveelectrical isolationVSAvoidheat transfer efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent replaces conventional electrical heating elements with an induction heating system that uses electromagnetic fields to heat the fluid directly. The induction coil generates an alternating magnetic field that induces eddy currents in the fluid, converting electromagnetic energy directly into thermal energy without requiring electrical contact or isolation barriers, thus eliminating the trade-off between electrical isolation and heat transfer efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental heating mechanism from direct electrical resistance heating to electromagnetic induction heating. By changing the energy conversion parameter from electrical-to-thermal through resistance to electromagnetic-to-thermal through induction, the system achieves heating without electrical isolation requirements while maintaining high efficiency

Inventive Principle:

Principle #35Parameter changes

2Reliability

If PTC ceramic elements are used for heating, then intrinsic safety against overheating is achieved, but the elements are heavy and increase system weight

Engineering Contradiction:

Improveoverheating protectionVSAvoidheater weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent replaces heavy PTC ceramic elements with an induction heating coil system. The induction coil generates electromagnetic fields that heat the fluid directly, eliminating the need for heavy ceramic heating elements while maintaining safety through controlled electromagnetic energy input and fluid flow management

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If a water circuit is used for heating, then waste heat utilization is simplified, but additional components such as pumps, pipes, and valves are required which increase system complexity

Engineering Contradiction:

Improvewaste heat utilizationVSAvoidwater circuit components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines the heating function directly into the fluid heating process by using induction heating coils that heat the water/glycol mixture in place, eliminating the need for separate water circuits, pumps, and associated components. The induction heating system integrates heating directly into the existing fluid loop without requiring additional mechanical components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and eliminates unnecessary water circuit components (pumps, pipes, valves) from the heating system by using direct induction heating. By taking out these intermediate components and using electromagnetic induction to heat the fluid directly, the system simplifies the overall architecture while maintaining waste heat utilization capability

Inventive Principle:

Principle #2Taking out (Extraction)

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 increases heat transfer efficiency, reduces system complexity and costs, and addresses safety concerns by eliminating the need for electrical isolation and heavy ceramic elements.

Implementation Method 1

an induction coil, which is integrated in an oscillating circuit and generates an alternating magnetic field, and at least one first inductor, which is positioned within the alternating magnetic field

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Implementation Method 3

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 4

The inductor (12) has a surface suitable for generating a turbulent surround-flow and/or through-flow

Methodology Applied

Scientific EffectTurbulence: Turbulence

Implementation Method 5

The inductor (12) has a surface suitable for generating a turbulent surround-flow and/or through-flow, thereby increasing the heat transfer to the fluid

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS9924565B2Modular induction fluid heater

Publication Date: 2018.03.20 MAHLE INT GMBH

AI summary

A device for electrically heating a fluid, in particular for use in an electrically operated motor vehicle, comprising an induction coil, which is integrated in an oscillating circuit and produces an alternating magnetic field, and at least one first inductor, which is positioned within the alternating magnetic field. The inductor can be arranged inside a module, through which a fluid to be heated can flow, and the induction coil is arranged outside the module.