Sealed Electric Heater Layout for High-Voltage Vehicle Insulation
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Solution Overview
Problem
Existing electric heaters for vehicles, particularly those using high electrical voltages, face challenges in mechanical stability, safety, and voltage insulation, especially in modern vehicles with alternative drives, where conventional systems are not adapted for high voltages and are prone to electrical breakdown.
Innovation Solution
A compact electric heater design featuring a helical heating element with a tubular outer body and insulating material, where the heating element is embedded in an electronics housing with sealed connections, and supported by holding elements for mechanical stability, and power electronics for temperature-controlled modulation, ensuring safe operation and high breakdown voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electric heaters are used in modern vehicles with high voltage systems, then heating function is provided, but electrical safety and breakdown voltage are insufficient
Solution Approach 1:
The heater is specifically designed for high voltage operation with increased creepage and clearance distances between electrical contacts, reinforced insulation layers, and elevated breakdown voltage ratings. These parameter changes enable the heater to safely operate in modern vehicle electrical systems while maintaining electrical safety through enhanced insulation geometry and material selection.
Solution Approach 2:
The heater employs composite construction combining highly insulating materials with mechanical strength components. The housing uses material combinations that provide both structural integrity and electrical insulation, while sealing elements incorporate materials with high dielectric strength to prevent voltage breakdown across fluid interfaces. This composite approach simultaneously achieves adaptability to high voltage and maintains electrical safety.
2Temperature
If heating elements are exposed to high vibration loads in vehicles, then heating function is maintained, but mechanical stability deteriorates
Solution Approach 1:
The heating element is constructed as a segmented helical spring structure rather than a rigid continuous form. This segmentation allows the heating element to flex and absorb vibration loads while maintaining its heating function. The spring segments can independently deform under vibration, preventing stress concentration and maintaining mechanical stability throughout the heating element during vehicle operation.
Solution Approach 2:
The heating element uses a helical curved geometry instead of straight rigid sections. This curvature provides inherent flexibility and shock absorption capabilities, allowing the heating element to withstand high vibration loads while maintaining structural integrity. The curved spring structure can elastically deform under vibration and return to its original shape, preserving both mechanical stability and heating function.
3Ease of operation
If end sections of heating element are led out at angle for electrical connection, then electrical contact is achieved, but mechanical stability and safety deteriorate
Solution Approach 1:
The heating element passes through a sealed bearing or bushing structure that acts as an intermediary between the heated fluid environment and the external electrical connection. This intermediate component provides both mechanical support for the angled heating element and electrical insulation to prevent voltage breakdown. The sealed bearing maintains fluid tightness while allowing the angled passage of the heating element, and its insulating properties prevent electrical breakdown paths to the housing.
Solution Approach 2:
The sealing and insulation structure at the heating element exit uses composite materials combining mechanical strength for sealing with high dielectric strength for voltage insulation. This composite construction allows the heating element to be led out at an angle for electrical connection while maintaining both mechanical stability and electrical safety through the insulating properties of the composite sealing structure.
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 design provides enhanced mechanical stability, safety, and efficient temperature control, preventing electrical breakdown and ensuring safe operation even in high-voltage environments, while allowing for cost-effective temperature monitoring and power modulation.
Implementation Method 1
at least one heating element is accommodated... which has at least one heating stage, each of which has at least one heating element (e.g. designed as a heating resistor) for generating a specific heating output
Implementation Method 2
an annular space is formed between the outer body and the heating element, which is filled with an insulator
Data Source
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AI summary
The invention relates to an electric heater comprising a fluid-conducting housing, in which at least one, preferably helical, heating unit, preferably a wire resistance heating element, is accommodated. The heating unit can have a tubular outer body, in which a heating element electrically contacted with a control circuit accommodated in an electronics housing is embedded. According to the invention, end sections of the heating unit extend in a sealed manner through the fluid-conducting housing to, and preferably into, an electronics housing. The invention further discloses a method for actuating an electric heater and to a heater that can be operated according to such a method, wherein said heater is designed with at least one resistance heating element, which acts as a temperature sensor, so that the temperature thereof can be used for actuating the heater.