Heating device

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Solution Overview

Problem

Heating systems in hybrid and electric vehicles face challenges due to the lack of residual heat from combustion engines, leading to inefficiencies in fluid heating, high costs, and risks of fluid leakage and pressure drops, as existing solutions rely heavily on sealing gaskets that deteriorate over time and are difficult to manufacture.

Innovation Solution

A heating device with a planar configuration and a heating plate featuring a dielectric material layer and structural plate, where the heating region is oriented towards the inner chamber, reducing the need for sealing gaskets and minimizing pressure drops, while maintaining leak-tightness and efficient heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sealing gaskets are used to prevent fluid leakage, then leak-tightness is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveleak-tightnessVSAvoidnumber of sealing gaskets

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The heating plate integrates both heating function and sealing function into a single component. The heating plate directly closes the window opening and provides leak-tightness without requiring separate sealing gaskets, thereby reducing device complexity while maintaining reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heating plate performs multiple functions simultaneously: it generates heat for fluid heating, closes the window opening structurally, and provides leak-tightness sealing. This multi-functionality eliminates the need for separate sealing components

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If sealing gaskets are used to isolate heating elements, then safety is improved, but manufacturing cost and complexity increase

Engineering Contradiction:

ImprovesafetyVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heating plate combines heating element isolation and heating function in one component. The plate itself serves as both the heating element housing and the sealing barrier, eliminating multiple parts and reducing manufacturing complexity and cost

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts and eliminates the sealing gasket component from the system by integrating its sealing function directly into the heating plate structure, thereby simplifying manufacturing while maintaining safety

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If resistors are housed in cavities separated from fluid, then safety is improved, but pressure drop increases

Engineering Contradiction:

ImprovesafetyVSAvoidpressure drop

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The heating plate acts as an intermediary that enables direct thermal contact between the heating element and fluid while maintaining electrical isolation. The plate structure allows heat transfer through its material while preventing direct electrical contact, thus eliminating the need for fluid-blocking cavities

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If multiple sealing gaskets are used, then leak-tightness is improved, but the device becomes more expensive and difficult to manufacture

Engineering Contradiction:

Improveleak-tightnessVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The heating plate merges the sealing function with the heating element housing into a single integrated component, eliminating the need for multiple separate sealing gaskets and reducing manufacturing complexity while maintaining leak-tightness

Inventive Principle:

Principle #5Merging (Combining)

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 significantly reduces the use of sealing gaskets, enhances manufacturability, and achieves lower pressure drops in fluid flow, improving safety and cost-effectiveness while maintaining efficient heat transfer and leak-tightness.

Implementation Method 1

a heating element arranged on one side of the dielectric material; the heating region is located on the surface of the structural plate opposite the surface of the structural plate in contact with the layer of dielectric material

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a layer of dielectric material; the dielectric material is interposed between the structural plate and the heating element

Methodology Applied

Scientific EffectDielectric insulation: Dielectric

Data Source

PatentEP3616949B1Heating device

Publication Date: 2022.07.20 BORGWARNER LUDWIGSBURG GMBH

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AI summary

The present invention relates to a heating device (D) for use in vehicles, particularly to a device for heating a fluid, for example air, water, or liquid coolant. The device is particularly designed for vehicles the main propulsion system of which is not a combustion engine and which therefore lack residual heat from the engine. The present invention is characterized by the use of a chassis (1) with a planar configuration and an inner chamber (C) in fluid communication with an inlet port (I) and an outlet port (O) and a heating plate (2, 3). The chassis comprises at least one window (1.1.2, 1.2.2) and the heating plate (2, 3) has a heating region (R) closing the window (1.1.2, 1.2.2) of the chassis (1) for heating the fluid housed in the inner chamber.