Heating device

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Solution Overview

Problem

Existing heating devices for motor vehicles, particularly those with electrical heating elements, face challenges in ensuring safe separation between fluid channels and electrical components, especially in high-voltage applications, as they are not adequately insulated for liquid media, risking electrical hazards in case of leaks.

Innovation Solution

A heating device design featuring stacked disk packages with fluid-tight channels on either side of the electrical heating element, where the element is sealed and electrically insulated, with inlet and outlet connections on one disk package, allowing for parallel or serial fluid flow and enhanced insulation using ceramic materials and turbulence-inducing inserts for improved heat transfer and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If electrical heating elements are used in high-voltage applications, then heating efficiency is improved, but electrical safety deteriorates due to risk of fluid contact with live parts

Engineering Contradiction:

Improveheating efficiencyVSAvoidelectrical safety

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The device is divided into separate functional zones: a first disk package containing fluid channels, a second disk package containing electrical heating elements, and intermediate disks providing isolation. This segmentation physically separates electrical high-voltage components from fluid channels, preventing fluid contact with live parts while maintaining heating efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Intermediate disks act as intermediary elements between the fluid channel disk package and the electrical heating element disk package. These intermediate disks provide both mechanical support and electrical insulation, serving as a mediator that allows heat transfer while preventing direct contact between fluid and electrical components

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If fluid channels are placed close to electrical heating elements for efficient heat transfer, then heat transfer efficiency is improved, but electrical insulation deteriorates

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidelectrical insulation

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

Different regions of the disk structure have different properties: outer regions provide structural support and sealing, intermediate regions provide electrical insulation, and specific localized areas provide thermal conduction paths. This local differentiation allows the structure to simultaneously achieve good thermal coupling where needed while maintaining electrical insulation in critical zones

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The disk structure employs composite construction with materials having different properties: electrically insulating materials in regions contacting both fluid and electrical components, while thermally conductive paths are provided through designated contact areas. This composite approach allows simultaneous achievement of electrical insulation and thermal efficiency

Inventive Principle:

Principle #40Composite materials

3Reliability

If connection devices protrude through windows in disks for electrical contacting, then electrical connectivity is improved, but fluid leakage risk increases

Engineering Contradiction:

Improveelectrical connectivityVSAvoidfluid leakage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Connection devices for electrical contacting are extracted and positioned on the outer peripheral region of the disk package, separate from the fluid channel windows. This extraction removes the electrical connection points from the fluid pathway, eliminating the risk of fluid leakage through connection points while maintaining reliable electrical connectivity

Inventive Principle:

Principle #2Taking out (Extraction)

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 effectively isolates electrical heating elements from fluid channels, preventing electrical hazards and enabling efficient heat transfer, making it suitable for high-voltage applications while ensuring safety and efficiency.

Implementation Method 1

electrical heating element

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

ceramic cover element being provided that is arranged on a passivation layer and tightly sealed

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

turbulence-increasing inserts, so-called turbulence inserts

Methodology Applied

Scientific EffectTurbulence: Turbulence

Data Source

PatentEP2689945B1Heating device

Publication Date: 2017.05.31 BEHRN-HELLA THERMOCONTROL GMBH

Figure 1~2
Figure 3~5
Figure 6~7

AI summary

The device has a plate stack (30) that is formed of a fluid passage in a fluid-tight manner between a pair of plate (5,6). An electric heater element is sealed in the plates, and electrically isolated from the inlet side and the outlet-side fluid ports (11,12) of the fluid passage in the plate . The electric heater element comprises a connecting device (32) for electrical contact, which is connected to the electric heating element and projected through a window (31) between the plates. A fluid connector and the windows are located adjacent to opposite side edges of the plates.