Segmented Electric Heater Layout for Safe High-Voltage Fluid Heating
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Solution Overview
Problem
Existing electrical heating devices for motor vehicles, particularly those with high-voltage applications, face challenges in efficiency, safety, and cost-effectiveness, especially in hybrid and electric vehicles where high power density is required without the waste heat from internal combustion engines.
Innovation Solution
The design of an electrical heating device with a housing that includes heating elements arranged to allow fluid flow on both sides, optimized for heat transfer through a zigzag or meandering path, and sealed connections to ensure efficient heat transfer and safety, using a combination of heating elements and flow control elements to direct fluid flow effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electrical heating devices are used in high-voltage applications for hybrid and electric vehicles, then heating power and efficiency are improved, but safety hazards and construction complexity increase
Solution Approach 1:
The heating device is divided into multiple independent heating elements arranged in series within the housing. Each heating element operates at a lower voltage level while the series configuration achieves the required high-voltage power output. This segmentation reduces safety hazards by isolating high-voltage connections and simplifying the overall system architecture.
Solution Approach 2:
The patent introduces a specialized housing structure that serves as an intermediary between the heating elements and the external environment. The housing provides electrical insulation, mechanical protection, and thermal management functions, thereby reducing safety hazards associated with high-voltage components while maintaining heating efficiency.
2Use of energy by moving object
If heating elements are arranged to allow fluid flow on both sides, then heat transfer efficiency is improved, but device complexity increases
Solution Approach 1:
The heating elements are arranged in a zigzag or meandering pattern within the housing, allowing coolant to flow on both sides of each heating element. This spatial arrangement maximizes the heat transfer surface area without requiring additional external components, thereby improving heat transfer efficiency while maintaining relatively simple construction.
Solution Approach 2:
The patent combines multiple heating elements into a single integrated assembly housed within a single housing structure. The housing simultaneously provides structural support, electrical insulation, and fluid distribution functions. This merging of functions improves heat transfer efficiency while avoiding the complexity of multiple separate components.
3Reliability
If sealed connections are used for heating elements, then safety and heat transfer efficiency are improved, but manufacturing complexity increases
Solution Approach 1:
The heating elements are pre-assembled with their electrical connections and sealing structures before being installed in the housing. This preliminary assembly ensures proper sealing and electrical insulation are achieved without requiring complex manufacturing processes for the entire device. The pre-assembled units can be manufactured separately and then integrated into the final product.
Solution Approach 2:
The patent employs flexible sealing elements and thin-film electrical insulation materials to create sealed connections between heating elements and the housing. These flexible sealing structures achieve reliable safety performance while being relatively simple to manufacture and install compared to rigid sealed connections.
4Power
If high power density is required for hybrid and electric vehicles, then heating performance is improved, but safety hazards and system complexity increase
Solution Approach 1:
The high-power heating device is segmented into multiple heating elements connected in series, allowing the system to achieve high power density while maintaining manageable voltage and current levels for each individual element. This segmentation simplifies the overall system architecture by distributing the power load across multiple smaller components.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides electrical insulation for high-voltage safety, mechanical support for the heating elements, thermal management through coolant flow channels, and protection against environmental factors. This multi-functionality achieves high heating performance while reducing system complexity by eliminating the need for separate components for each function.
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 heat transfer efficiency while maintaining safety and reducing production costs, making it suitable for high-voltage applications in vehicles with improved performance and reliability.
Implementation Method 1
electrical heating device (100) with a number of heating elements (102) which protrude into an interior (107) of the housing (101), with a heating element (102) in a heating element housing (11) having at least one heating means (19)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to an electrical heating device (1, 100, 200, 300) with a housing (2, 101, 201, 301, 303) with a fluid inlet (3, 103, 203, 304) and with a fluid outlet (4, 104, 204, 305), wherein a fluid can flow through the housing (2, 101, 201, 301, 303) and wherein a number of heating elements (9, 50, 102, 202, 302) are placed in the interior (13, 107, 207 ) of the housing (2, 101, 201, 301, 303), the heating elements (9, 50, 102, 202, 302) having a heating element housing (11, 51) and a heating element (9, 50, 102, 202 , 302) in the heating element housing (11, 51) at least one heating means (19, 56, 320) and contact elements (12, 55, 314) making contact with the at least one heating means (19, 56, 320) and electrical insulation (20, 57 , 315) for insulating the contact elements (12, 55, 314) from the heating element housing (11, 51), the contact elements (12, 55, 314) protruding from the heating element (9, 50, 102, 202, 302) and wherein the heating elements (9, 50, 102, 202, 302) are sealingly connected with their heating element housing (11, 51) to the housing (2, 101, 201, 301, 303), the heating elements (9, 50, 102, 202, 302) being arranged in such a way that the fluid can flow around them on one or both sides in a flow direction of the fluid from the fluid inlet (3, 103, 203, 304) to the fluid outlet (4, 104, 204, 305).