Sealed Electric Heater Base Body for Coolant Bubble Protection
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Solution Overview
Problem
Existing electric heaters for internal combustion engines face issues such as resistor damage from air bubbles and calcareous deposits, sealing failures leading to fluid infiltration, and reduced reliability, especially in cold climates where a malfunction can cause engine starting failures.
Innovation Solution
The design integrates an electric resistor and temperature sensor within a thermally conductive base body, connected to a control unit, with fins for enhanced heat distribution and a sealed chamber to prevent air bubbles, and a safety sensor to prevent overheating, all within a unit that maintains fluid circulation and temperature regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the resistor is placed directly in contact with the cooling fluid, then heating efficiency is improved, but the resistor is damaged by air bubbles and calcareous deposits
Solution Approach 1:
The patent introduces a thermal conductor body as an intermediary between the resistor and the cooling fluid. The resistor is embedded in this conductor body which has high thermal conductivity, allowing heat to be transferred to the fluid without the resistor being directly exposed to harmful factors like air bubbles and calcareous deposits. This resolves the contradiction by maintaining efficient heat transfer while protecting the resistor.
2Temperature
If the resistor is placed directly in contact with the cooling fluid, then heat transfer is improved, but sealing characteristics are lost and fluid infiltration damages the resistor
Solution Approach 1:
The thermal conductor body serves as a mediator that separates the resistor from the cooling fluid while maintaining thermal contact. The resistor is embedded in the conductor body which is in turn in contact with the fluid, ensuring both efficient heat transfer and protection of the resistor from fluid infiltration through maintained sealing characteristics.
Solution Approach 2:
The resistor is nested within the thermal conductor body, which itself is positioned within the heating chamber. This nested arrangement allows the resistor to be indirectly coupled to the cooling fluid through the conductor body, maintaining both thermal efficiency and sealing integrity.
3Measurement precision
If the temperature sensor is arranged inside a receptacle, then temperature measurement is enabled, but the receptacle loses sealing characteristics and fluid infiltrates the sensor
Solution Approach 1:
The thermal conductor body acts as an intermediary structure that accommodates the temperature sensor. The sensor is positioned within this conductor body which maintains sealing characteristics, preventing fluid infiltration while still allowing accurate temperature measurement of the cooling fluid.
4Ease of manufacture
If the heater components are separate parts, then manufacturing and assembly are simplified, but reliability is reduced due to multiple sealing interfaces
Solution Approach 1:
The patent merges the thermal conductor body with the heating chamber structure, creating an integrated component that reduces the number of separate sealing interfaces. The resistor and temperature sensor are embedded within this unified structure, minimizing potential leakage points while maintaining manufacturing feasibility.
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 configuration enhances the reliability and efficiency of the heater by preventing damage from air bubbles and deposits, maintaining fluid circulation, and ensuring consistent temperature control, reducing the risk of heater failure and engine starting issues in cold climates.
Implementation Method 1
an electric resistor (400) which is embedded in the mass of material which forms the said first, base body (100), wherein the said resistor (400) heats the first, base body (100) itself by thermal conductivity
Implementation Method 2
the said first, base body (100) also comprises a plurality of fins (331, 332, 333, etc.), which are also made of a material with a high coefficient of thermal conductivity, and extend vertically inside the said inner chamber (300)
Implementation Method 3
the said fluid rises upwards and flows between the fins (331, 332, 333, etc.), with consequent heating of the fluid
Implementation Method 4
the said first, base body (100) incorporates the first sensor (500), i.e. the operating sensor, which is designed to measure the temperature of the mass of material of the first, base body (100)
Data Source
Figure 1
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AI summary
An electric heater for heating, maintaining the temperature and permitting the circulation of a fluid, comprises: >-a first, base body (100) and a second, cover body (200), which can be associated with one another and can form an inner chamber (300); >-a first mouth (210) for the intake of the fluid; >-a second mouth (220) for the discharge of the fluid; >-an electric resistor; >-a first sensor for the temperature of use; >-a second sensor for the safety temperature; >-an electronic control unit. -The said first, base body (100) incorporates the electric resistor, which heats the base body (100), which in turn heats the sensor (500), and wherein the latter measures the temperature of the base body (100) itself. -The resistor, the said first sensor and the said second sensor are connected to the control unit in order to maintain the first, base body (100) at a certain temperature of use, and in order to prevent a safety temperature from being exceeded.