Plate-Pair Electric Heater Assembly for High-Voltage Reliability
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Solution Overview
Problem
Conventional electric heating devices for motor vehicles are complex and costly to manufacture, requiring multiple components and connections, which complicates their reliability and suitability for high-voltage applications.
Innovation Solution
A method for manufacturing an electric heating device involving plate pairs with a predefined distance, where a heating unit with contact electrodes is securely positioned between them using an adhesive for thermal and electrical insulation, simplifying the assembly and reducing component count while ensuring reliability for high-voltage applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electric heating devices use multiple plate pairs with heating units arranged between them, then heating functionality is achieved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent merges multiple separate components (plates, heating units, insulating elements, contact electrodes) into an integrated plate pair assembly where heating elements are directly embedded within the plate structure itself. This consolidation reduces the total component count while maintaining the heating function through the integrated design.
Solution Approach 2:
The plate structure serves multiple functions simultaneously: it provides structural support, contains the heating element, provides electrical insulation, and facilitates fluid flow. This multi-functionality eliminates the need for separate dedicated components for each function, thereby reducing overall device complexity.
2Ease of manufacture
If multiple components are connected and attached to form the electric heating device, then the device can be assembled, but manufacturing costs and assembly complexity increase
Solution Approach 1:
The device is segmented into modular plate pair assemblies that can be manufactured independently and then assembled. Each plate pair is a self-contained unit with integrated heating elements, allowing for standardized manufacturing processes and simplified final assembly by stacking multiple identical modules.
Solution Approach 2:
Heating elements and other components are pre-integrated into the plate structure during manufacturing, creating pre-assembled plate pairs. This preliminary integration of components into modular units simplifies the final assembly process, as workers only need to stack and connect pre-prepared modules rather than assembling individual components.
3Reliability
If insulating elements are used to electrically insulate heating units from plate pairs, then electrical insulation is achieved, but the number of components and manufacturing complexity increase
Solution Approach 1:
Electrical insulation properties are applied locally at specific critical points within the plate structure where electrical isolation is needed, rather than using separate insulating components throughout. The plate material itself is designed with appropriate insulation characteristics in the regions requiring electrical isolation.
Solution Approach 2:
The insulating function is merged into the plate structure itself through material selection and design, eliminating the need for separate insulating elements. The plate serves both structural and electrical insulation functions simultaneously through its inherent material properties and geometric design.
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 method allows for the creation of a reliable and cost-effective electric heating device with improved manufacturability, secure thermal contact, and efficient electrical insulation, suitable for high-voltage applications up to 800 V.
Implementation Method 1
the attachment of the heating unit in the free space to the plate pairs is accomplished with at least one adhesive
Implementation Method 2
which heating unit has at least one heating element and contact electrodes electrically connected thereto
Implementation Method 3
soldering the stack of plates
Data Source
AI summary
An electric heating device and a method for manufacturing an electric heating device with at least two plate pairs forming a fluid passage through which fluid can flow, which plate pairs are assembled from two plates and form a fluid passage between the two, wherein the plate pairs take on a predefined distance from one another and form a free space, wherein at least one heating unit is arranged in the free space between at least two of the plate pairs, which heating unit has at least one heating element and contact electrodes electrically connected thereto for making electrical contact with the at least one heating element. The invention also relates to such an electric heating device.