PTC Grid Heat Exchanger Assembly for Low-Cost Fluid Heating
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Solution Overview
Problem
Existing heating devices are costly to manufacture, have high power consumption, and use materials that contribute to environmental pollution, failing to meet the demand for environmentally friendly and efficient solutions.
Innovation Solution
The use of grid elements as heat exchanger plates with openings to enhance turbulence of the medium flowing through, combined with PTC heating elements and a tensioning system that allows for efficient heat transfer without additional connection measures, enabling higher temperature use and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional heating devices are used, then heating function is provided, but power consumption is high and manufacturing costs are high
Solution Approach 1:
The heating device is divided into multiple heating arrangements, each consisting of heating elements positioned between grid elements. This segmentation allows for optimized heat distribution and reduced energy consumption while maintaining effective heating coverage.
Solution Approach 2:
Grid elements with openings are used as heat exchanger plates. The porous structure increases turbulence of the medium flowing through, enhancing heat transfer efficiency and reducing the power required to achieve the same heating effect.
2Ease of manufacture
If conventional heating devices are used, then heating function is provided, but manufacturing complexity is high
Solution Approach 1:
The device is divided into modular heating arrangements that can be independently assembled. Each arrangement consists of heating elements between grid elements, simplifying the manufacturing process and reducing production complexity.
Solution Approach 2:
Multiple functions are merged into the grid elements, which serve as both structural support and heat exchanger plates. The tensioning elements also serve dual purposes of mechanical assembly and electrical connection, reducing the number of separate components needed.
3Loss of energy
If conventional heating devices are used, then heating function is provided, but heat transfer efficiency is low
Solution Approach 1:
Grid elements with openings create turbulence in the medium flowing through the heat exchanger plates. This turbulence significantly enhances heat transfer efficiency, allowing more effective heat output from the heating elements.
Solution Approach 2:
Heating elements are positioned between grid elements in a sandwich-like arrangement, creating multiple heat transfer surfaces. This multi-dimensional arrangement increases the effective heat exchange area and improves overall heat transfer efficiency.
4Strength
If adhesive bonds are used to join grid elements and heating elements, then connection is achieved, but temperature resistance is limited and material usage increases
Solution Approach 1:
Adhesive bonds are replaced with a tensioning element system that uses mechanical tension to join grid elements and heating elements. This mechanical connection system provides superior temperature resistance and eliminates the need for additional adhesive materials.
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 design significantly increases heat output and efficiency, reduces production costs, and minimizes environmental impact by promoting turbulence and laminar flow, while ensuring optimal heat transfer and power utilization.
Implementation Method 1
Due to its openings a high degree of turbulence of the medium flowing through, z. As air to achieve
Implementation Method 2
the grid elements are used as heat exchanger plates
Implementation Method 3
there is optimum heat transfer from the heating element to the grid elements
Implementation Method 4
The at least one tensioning element allows grid elements and heating element(s) to be joined together easily
Data Source
Figure 1~4
Figure 2~3
Figure 5~6
AI summary
The invention relates to a heating device having a heating arrangement in a housing through which in a longitudinal direction a fluid medium can flow, wherein the at least one heating arrangement comprises at least two lattice elements as heat exchanger plates with openings, through which the medium flows. The lattice planes thereof are designed for the exchange of thermal energy between the plate and the fluid medium. The invention further comprises at least one heating element, particularly a PTC- element, which is arranged between the lattice elements. The at least one heating arrangement is arranged in the housing such that the lattice planes of the lattice elements are disposed substantially perpendicular to the longitudinal direction and the media flow is substantially perpendicular to the lattice planes. The lattice elements and the at least one heating element are arranged such that they are tensioned with respect to one another by means of at least one tensioning element for the contact with one another, and the lattice elements comprise at least one contact region and are arranged such that they absorb the thermal energy from the at least one heating element substantially via the contact region. The heating device can be produced with low costs and simplified production, wherein environmental aspects are considered even during the operation of the heating device.