EP4339528A1 - Electric fluid heater - Google Patents
Electric fluid heater Download PDFInfo
- Publication number
- EP4339528A1 EP4339528A1 EP22195491.0A EP22195491A EP4339528A1 EP 4339528 A1 EP4339528 A1 EP 4339528A1 EP 22195491 A EP22195491 A EP 22195491A EP 4339528 A1 EP4339528 A1 EP 4339528A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- plate
- intermediate plate
- section
- fluid
- heater
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000012530 fluid Substances 0.000 title claims abstract description 123
- 238000010438 heat treatment Methods 0.000 claims abstract description 74
- 238000003466 welding Methods 0.000 claims abstract description 14
- 238000004891 communication Methods 0.000 claims description 17
- 238000000034 method Methods 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 9
- 239000000853 adhesive Substances 0.000 claims description 8
- 230000001070 adhesive effect Effects 0.000 claims description 8
- 230000000295 complement effect Effects 0.000 claims description 4
- 239000004020 conductor Substances 0.000 claims description 4
- 239000011796 hollow space material Substances 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 238000012546 transfer Methods 0.000 description 8
- 239000002826 coolant Substances 0.000 description 4
- 239000012774 insulation material Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 238000006731 degradation reaction Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 239000000284 extract Substances 0.000 description 2
- 230000001965 increasing effect Effects 0.000 description 2
- 238000013021 overheating Methods 0.000 description 2
- 238000004806 packaging method and process Methods 0.000 description 2
- 230000002000 scavenging effect Effects 0.000 description 2
- 240000007643 Phytolacca americana Species 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
- F24H1/0072—Special adaptations
- F24H1/009—Special adaptations for vehicle systems
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
- F24H1/10—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium
- F24H1/12—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium in which the water is kept separate from the heating medium
- F24H1/121—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium in which the water is kept separate from the heating medium using electric energy supply
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H9/00—Details
- F24H9/0005—Details for water heaters
- F24H9/001—Guiding means
- F24H9/0015—Guiding means in water channels
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H9/00—Details
- F24H9/18—Arrangement or mounting of grates or heating means
- F24H9/1809—Arrangement or mounting of grates or heating means for water heaters
- F24H9/1818—Arrangement or mounting of electric heating means
- F24H9/1827—Positive temperature coefficient [PTC] resistor
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
- F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
- F28D1/03—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits
- F28D1/0308—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits the conduits being formed by paired plates touching each other
- F28D1/0325—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits the conduits being formed by paired plates touching each other the plates having lateral openings therein for circulation of the heat-exchange medium from one conduit to another
- F28D1/0333—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits the conduits being formed by paired plates touching each other the plates having lateral openings therein for circulation of the heat-exchange medium from one conduit to another the plates having integrated connecting members
Definitions
- the present invention generally relates to an electric fluid heater, more particularly to an electric fluid heater for vehicles.
- a vehicle generally includes a heater for heating air to be supplied to a passenger compartment.
- the heater is used to supply heated air to demist or defrost the windscreen.
- the heater is used to supply hot air or hot coolant for cold starting the engine.
- the heater is also applicable for battery thermal management.
- the heaters can be used for efficient thermal management of the batteries used for powering the electric motor, thereby drastically enhancing the service life of the batteries.
- the fluid to be heated is generally passed through a heat exchanger, which includes a heating element such as for example, heat exchange flow pipes through which a heated fluid circulates in case of thermal heater or an electrical resistive heater supplied with current.
- the fluid to be heated circulates across the heat exchanger and extracts heat from the heating element.
- the electrical heater includes a plurality of heating elements arranged with respect to fluid flow passes configured adjacent the heating elements between the fluid flowing through the fluid flow passes and the heating elements.
- Each heating element includes a tube that receives electrical core therein. Specifically, the tube together with the electrical core forms the heating element.
- Each tube may have several electrical cores, which may be arranged one after the other in a direction of the tube.
- the electrical core may include a resistive element.
- Each heating element includes electrodes on both sides for power supply through the heating element. Further, the heating elements include electrically insulating and thermally conductive material. The material being located between one of the electrodes and walls of the tube. In this way, the tube is electrically insulated from the electrodes and the electrical core but thermally in contact with them.
- the housing enclosing the heating elements placed between a pair heat exchanger plates of the heat exchanger having a plate stack.
- the plate stack are provided with an inlet port and an outlet port.
- the ports are in fluid communication with the fluid passage formed through the plate stack.
- the plates are arranged such that a fluid flow passage is formed around each pair of heat exchanger plates. The fluid entering the electrical heater flows from the inlet, and then passes through the fluid flow passage formed around each pair of plates. Simultaneously, the fluid extracts heat from the heating elements and egresses through the outlet.
- this arrangement has a potential risk of formation of air pockets between the housing of the heating element and the plates, and a risk of degradation of heating element because of the insulation material filled between the heating element and the housing. Further, in this arrangement, heat transfer need to take place through two layer of plates, which includes the housing of the heating element and the heat transfer plate above the housing of the heating element. Thus, this arrangement lacks to provide efficient heat transfer between the heating element and the fluid flowing around the heat transfer plates. Consequently, overheating at any spot in heat exchanger will become difficult to detect as the heater lacks to provide efficient heat transfer.
- some elements or parameters may be indexed, such as a first element and a second element.
- this indexation is only meant to differentiate and name elements which are similar but not identical. No idea of priority should be inferred from such indexation, as these terms may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention.
- an electric fluid heater comprising a plate stack comprising a first end plate, a second end plate, an intermediate plate stack comprising a plurality of intermediate plates arranged between the first end plate and the second end plate.
- the second end plate formed with different portions that are in fluid communication with each other.
- Each intermediate plate is divided into different sections, respectively, corresponding to the different portions of the second end plate.
- the first end plate is provided with an inlet port in fluid communication with a first fluid path formed through the section of the intermediate plates and an outlet port in fluid communication with a second fluid flow path formed through the section of the intermediate plates.
- the inlet port and the outlet port provided in a same side of the heater adapted to cause the fluid to follow a U-turn trajectory between the inlet port and the outlet port.
- the intermediate plate stack is arranged in pairs of plate. Each pair includes a first intermediate plate and a second intermediate plate. The first intermediate plate being joined to the second intermediate plate to form an interspace therebetween to accommodate at least one heating module without welding thereto.
- the interspace is a hollow space. In another embodiment, the interspace is a tubular space.
- each intermediate plate comprises a first edge portion and a second edge portion opposite to that of the first edge portion.
- the first intermediate plate comprises a depression along a length of the first and second edge portions thereof and the second intermediate plate comprises an elevation complementary to the depression along a length of the first and second edge portions thereof.
- the depression of the first intermediate plate brought in contact with the elevation of the second intermediate plate and brazed at the contacting portions defined by the elevation and depression of the each intermediate plate pair, thereby forming the interspace therebetween.
- the depression of the first intermediate plate divided into a first section corresponding to the first section of the plate stack and a second section corresponding to the second section of the plate stack.
- the elevation of the second intermediate plate divided into a first section corresponding to the first section of the plate stack and a second section corresponding to the second section of the plate stack.
- the depression has at least one of a rectangular shaped cross section and a square shaped cross section.
- the elevation has at least one of a rectangular shaped cross section and a square shaped cross section.
- the present invention further discloses a method for manufacturing the electric fluid heater.
- the method comprising steps of: attaching the first intermediate plate to their adjacent second intermediate plate to form the interspace therebetween, and filling at least one heating module within the interspace without welding thereto.
- the heating module may be filled within the interspace using thermally conductive adhesive material. The adhesive material achieves a homogeneous contact between the plates the entire heating element surface, thereby avoiding hotspots.
- the method further comprises a step of welding a heater housing at each interspace of the plate stack, and accommodating at least one heating element within the heater housing and filling thermally conductive material between the heater housing and the heating element.
- the electric fluid heater comprises a plate stack having a plurality of intermediate plates.
- the plate stack provided with an inlet port and an outlet port.
- the inlet port and the outlet port in fluid communication with a fluid passage formed through the plate stack.
- the plate stack is arranged in pairs of intermediate plates. Each pair includes a first intermediate plate and a second intermediate plate. The first intermediate plate being joined to the second intermediate plate to form an interspace therebetween to accommodate at least one heating module without welding thereto.
- the present invention discloses an electric fluid heater comprising a plate stack comprising a first end plate, a second end plate, an intermediate plate stack comprising a plurality of intermediate plates arranged between the first end plate and the second end plate.
- the second end plate formed with different portions that are in fluid communication with each other.
- Each intermediate plate is divided into different sections, respectively, corresponding to the different portions of the second end plate.
- the first end plate is provided with an inlet port in fluid communication with a first fluid path formed through the section of the intermediate plates and an outlet port in fluid communication with a second fluid flow path formed through the section of the intermediate plates.
- the inlet port and the outlet port provided in a same side of the heater adapted to cause the fluid to follow a U-turn trajectory between the inlet port and the outlet port.
- the intermediate plate stack is arranged in pairs of plate. Each pair includes a first intermediate plate and a second intermediate plate. The first intermediate plate being joined to the second intermediate plate to form an interspace therebetween to accommodate at least one heating module without welding thereto.
- This arrangement address the risk of degradation of heating elements and formation of air pockets. Further, this arrangement of the heating module in contact with the intermediate plate provides efficient heat transfer between the heating module and the fluid.
- FIG. 1 illustrates an isometric view of an electric fluid heater 100, hereinafter referred to as fluid heater 100, in accordance with an embodiment of the present invention.
- the fluid heater 100 comprises a plate stack 102 having a plurality of intermediate plates.
- the plate stack 102 includes a pair of end plates 104 and 108, a plurality of heating modules 122 and a plurality of intermediate plates 112, wherein each intermediate plate 112 is formed of different sections 112A and 112B.
- FIG. 2 illustrates an exploded view of the fluid heater 100 and the sequence in which the different elements of the fluid heater 100 are arranged and assembled with respect to each other.
- the pair of end plates 104 and 108 include a first end plate 104 and a second end plate 108.
- the plurality of intermediate plates 112 are arranged in pairs of intermediate plate 114, 116.
- Each pair 114, 116 includes a first heat intermediate plate 114 and a second intermediate plate 116.
- the first intermediate plate 114 being joined to the second intermediate plate 116 to form an interspace 136 therebetween.
- a fluid flow path or fluid flow passes is defined adjacent to a pair of intermediate plates 114, 116 and a heating module 122.
- Each intermediate plate 112 is formed into different sections 112A, 112B corresponding to the different portions 106A, 106B of the first end plate 104 and the different portions 110A, 110B of the second end plate 108.
- the first sections 112A of the intermediate plates 112 defines fluidly coupled first fluid flow passes.
- the second sections 112B of intermediate plates 112 defines fluidly coupled second fluid flow passes.
- the first fluid flow passes are also referred as first fluid path and the second fluid flow passes are also referred as second fluid path throughout this document.
- the first end plate 104 is defined by the opposite longer walls 124 and 126 and the pair of opposite shorter walls 128 and 130.
- the opposite longer walls 124 and 126 are also referred to as first and second longer walls 124 and 126.
- the opposite shorter walls 128 and 130 are also referred to as first and second shorter walls 128 and 130.
- the opposite longer walls 124 and 126 and the opposite shorter walls 128 and 130 define the periphery of the first end plate 104 and at least a portion of the fluid flow passes corresponding to the first end plate 104.
- the first end plate 104 includes an inlet 118 for ingress of fluid into and an outlet 120 for egress of fluid out of the fluid heater 100 from same side of the fluid heater 100 to achieve certain advantages.
- configuring the inlet 118 and the outlet 120 on the same side of the fluid heater 100 provides compact configuration to the fluid heater 100 and addresses packaging issues. Further, such configuration also addresses routing issues associated with routing of inlet and outlet conduits connected to the inlet 118 and the outlet 120 for supplying and delivering out fluid from the fluid heater 100.
- the second end plate 108 fluidly couples the first and the second fluid flow passes formed around adjacent the heating modules 122 and in fluid communication with the inlet 118 and the outlet 120, respectively.
- the first end plate 104 includes a first portion 106A and a second portion 106B, wherein a groove 132 separates the first portion 106A from the second portion 106B.
- the first portion 106A and the second portion 106B are raised portion that inherently form the groove 132 at the interface between first portion 106A and the second portion 106B.
- the cross section of the first portion 106A is increasing from the inlet 118 towards the first fluid flow passes defined by the first sections 112A.
- the second end plate 108 includes a first and second longer wall 176, 178, and a first and second shorter wall 180, 182.
- the first and second longer wall 176, 178, and the first and second shorter wall 180, 182 defines the periphery of the end plate 108.
- the second end plate 108 formed with fluidly coupled first and second portions 110A and 110B.
- the inlet 118 and the outlet 120 on same side causes the fluid to follow a U-turn trajectory between the inlet 118 and the outlet 120.
- the inlet 118 is disposed at the centre of the first portion 106A and proximal to the longer walls 124 of the first end plate 104. Such strategic placement of the inlet 118 ensures even distribution of the coolant to the portion of the fluid flow passes defined by the first sections 112A.
- the second portion 106B corresponding to the second sections 112B of the intermediate plates 112 and is converging from the second sections 112B to the outlet 120 in the fluid flow direction.
- the cross section of the second portion 106B is decreasing from the second fluid flow passes defined by the second sections 112B towards the outlet 120.
- the outlet 120 is also disposed at the centre of the second portion 106B and proximal to the longer walls 124 of the first end plate 104.
- the outlet 120 is disposed at the corner of the first end plate 104 defined at the intersection of the first longer wall 124 and the first shorter wall 128. Specifically, the outlet 120 is farthest from the groove 124. Such strategic placement of the outlet 120 ensures that the portion of the fluid flow passes defined by the second sections 112B of the intermediate plates 112 is filled before the fluid egresses through the outlet 120.
- outlet 120 ensures even distribution of the coolant in the fluid flow passes defined by the second sections 112B before egressing through the outlet 120.
- Such configuration of the outlet 120 avoids trapping air in the area beneath the second portion and the fluid flow passes defined by the second sections 112B by scavenging the fluid evenly underneath the second portion 106B of the first end plate 104.
- the outlet 120 can be disposed horizontally instead of being disposed vertically to reduce back-pressure and improve flow path.
- the present invention is not limited to any particular configuration of the first end plate 102 with the inlet 118 and the outlet 120 in any particular position.
- the inlet and the outlet can be positioned on the first and the second portions so as to avoid air trapping by scavenging the fluid evenly underneath the first and second portions 106A and 106B respectively based on multiple fluid deflecting walls 134, shown in FIG.4 , formed on surface of the second end plate 108.
- the first portion 110A and the second portion 110B of the second end plate 108 is corresponding to the first sections 112A and the second sections 112B of the intermediate plates 112 and the first portion 106A and the second portion 106B of the first end plate 104.
- the first and the second portions 110A and 110B of the second end plates 108 are in fluid communication with each other unlike the first and second portions 106A and 106B of the first end plate 104.
- the first fluid flow passes receive a heat exchange fluid distributed thereto by the first portion 106A of the first end plate 104 from the inlet 118 for heat exchange with at least a portion of the heating module 122 sandwiched between the intermediate plates 112.
- the second end plate 108 fluidly couples the first fluid passes to the second fluid passes.
- the second flow passes deliver fluid to the second portion 106B of the first end plate 104 for egress through the outlet 120 after heat exchange with the heating module 122 in the assembled configuration of the intermediate plates 112.
- each intermediate plate 112 includes a first edge portion 140A and a second edge portion 140B opposite to that of the first edge portion 140A.
- Each intermediate plate 112 further includes a first side portion 142A and a second side portion 142B opposite to that of the first side portion 142A.
- the first edge portion 140A and the second edge portion 140B are the longer sidewalls of the intermediate plate 112.
- the first side portion 142A and the second side portion 142B are the shorter sidewalls of the intermediate plate 112.
- the longer sidewalls and the shorter sidewalls defines the periphery of the intermediate plate 112 that defines at least a portion of the fluid flow passes defined by the adjacent intermediate plates 112.
- the first intermediate plate 114 comprises a depression 146 along a length of the first and second edge portions 140A, 140B.
- the second intermediate plate 116 comprises an elevation 148 complementary to the depression 146 along a length of the first and second edge portions 140A, 140B thereof.
- the depression 146 of the first intermediate plate 114 brought in contact with the elevation 148 of the second intermediate plate 116 and joined at the contacting portions defined by the elevation 148 and depression 146 of each pair of intermediate plate plates 112 to form an interspace 136 therebetween.
- At least one heating module 122 is accommodated at the interspace 136 of each pair of intermediate plates 112.
- the heating module 122 may include at least two sections, which corresponds to the different sections 112A, 112B of the intermediate plate 112.
- the interspace 136 comprises a profile complementary to the profile of the heating module 122.
- the heating module 122 is slid into the interspace 136, which accommodates the heating module 122 therein without welding.
- the heating module 122 is slid into the interspace 136 and thermally conductive type adhesive material may be filled between the heating module 122 and the plates 112.
- the adhesive material achieves a homogeneous contact between the plates 112 the entire heating module surface, thereby avoiding hotspots.
- the depression 146 has at least one of a rectangular shaped cross section and a square shaped cross section.
- the elevation 148 has at least one of a rectangular shaped cross section and a square shaped cross section.
- the interspace 136 is a hollow space. In another embodiment, the interspace 136 is a tubular space.
- the heating module 122 comprises a tube 166 that receives an electrical core or heating element 164 therein.
- the electrical core 164 is for example, PTC (Positive Temperature Coefficient) resistors.
- Each tube 166 may have several electrical cores 164, which may be arranged one after the other in a direction of the tube 166.
- Each heating module 122 includes electrodes 168 on both sides for power supply through the heating module 122. Alternatively, the electrodes 168 may be on the same side of the heating module 122, which may reduce the number of components and packaging size.
- the heating module 122 includes electrically insulating and thermally conductive material 170. The material 170 being located between one of the electrodes 168 and walls 172 of the tube 166. In this way, the tube 166 is electrically insulated from the electrodes 168 and the electrical core 164 but thermally in contact with them.
- the depression 146 of the first intermediate plate 114 is divided into a first section 150A corresponding to the first section 112A of the intermediate plate 112 and a second section 150B corresponding to the second section 112B of the intermediate plate 112.
- the elevation 148 of the second intermediate plate 116 is divided into a first section 152A corresponding to the first section 112A of the intermediate plate 112 and a second section 152B corresponding to the second section 112B of the intermediate plate 112.
- the first edge portion 140A and the second edge portion 140B of the intermediate plates 112 are formed with slots or openings 154, 156 for either one of ingress and egress of fluid from the fluid pass defined by the adjacent pair of intermediate plates 112.
- the openings or slots 154, 156 are formed alternately on the opposite longer walls or edge portions 140A, 140B of each pair of the adjacent intermediate plates 112 to define zig-zag fluid flow path between the inlet 118 and the outlet 120 and permit fluid communication between the fluid flow passes defined by the adjacent intermediate plates 112.
- the zig-zag fluid flow path between the inlet 118 and the outlet 120 increases the length of the fluid flow path and accordingly enhances the contact area and contact time between the fluid flowing through the fluid flow passes and the heating element 122, thereby improving the efficiency and performance of the fluid heater 100
- the openings or slots 154 are formed on the first intermediate plates 114 at portions thereof proximal to the edge portions 140A, 140B, then, the corresponding openings or slots 156 are formed on the subsequent adjacent intermediate plates 112 or the second intermediate plate 116 at edge portions 140A, 140B.
- each intermediate plate 112 specifically, the first intermediate plate 114 includes at least one of first positioning elements 158A, 158B in the form of guiding pins 158A, 158B and corresponding second positioning elements 160A, 160B in the form of guiding holes 160A, 160B.
- the guiding pins 158A, 158B formed on the first intermediate plate 146 engages with the corresponding guiding holes 160A, 160B of the adjacent intermediate plate 116 to position and assemble the intermediate plate 112 with respect to the adjacent intermediate plate112.
- each guiding pin 158B there are two guiding pins 158B along the portion of the second intermediate plate 116 proximal to the second edge portion 140B.
- Each guiding pin 158A, 158B disposed on the respective portions of the intermediate plate 114 corresponding to the two sections 112A, 112B of the intermediate plate 114.
- each guiding hole 160A disposed on the respective portions of the second intermediate plate 116 corresponding to the two sections 112A, 112B of the intermediate plate 116.
- Each guiding hole 160B disposed on the respective portions of the second intermediate plate 116 corresponding to the two sections 112A, 112B of the intermediate plate 116.
- each intermediate plate 112 includes at least one rib 162.
- the at least one rib 162 defines the different sections 112A, 112B of the intermediate plate 112.
- the ribs 162 of the adjacent intermediate plates 112 acts as poke - yoke feature and facilitates in correct assembly between the adjacent intermediate plates 112.
- the present invention further discloses a method for manufacturing the electric fluid heater 100.
- the method comprising steps of: attaching the first intermediate plate 114 to their adjacent second intermediate plate 116 to form the interspace 136 therebetween, and filling at least one heating module 122 within the interspace 136 without welding thereto.
- the method further comprises a step of: filling at least one heating module 122 within the interspace 136 with thermally conductive type adhesive material.
- the adhesive material achieves a homogeneous contact between the plates 112 the entire heating module surface, thereby avoiding hotspots.
- the method further comprises a step of welding a heater housing 166 (also referred as tube 166 throughout the document) at each interspace 136 of the plate stack 102, and accommodating at least one heating element 164 (also referred as electrical core 164) within the heater housing 166 and filling thermally conductive insulation material between the heater housing 166 and the heating element 164.
- a heater housing 166 also referred as tube 166 throughout the document
- at least one heating element 164 also referred as electrical core 164
- the electric fluid heater 100 comprises a plate stack 102 having a plurality of intermediate plates.
- the plate stack 102 provided with an inlet port 118 and an outlet port 120.
- the inlet port 118 and the outlet port 120 in fluid communication with a fluid passage formed through the plate stack 102.
- the plate stack 102 is arranged in pairs of intermediate plates 102. Each pair includes a first intermediate plate 114 and a second intermediate plate 116.
- the first intermediate plate 114 being joined to the second intermediate plate 116 to form an interspace 136 therebetween to accommodate at least one heating module 122 without welding thereto.
- the heating modules are assembled to the heater by brazing at high temperature, which may affect the heating element insulation material. Therefore, the present invention facilitates the arrangement of heating module 122 by sliding the heating module 122 between plates 112.
- the heating module 122 may be slid in between plates 112 and thermally conductive type of adhesive may be filled between the plates 112 and the heating module 122.
- the heater 100 further facilitates early overheating detection due to the short heat transfer path offered by the multiple plates 112 in contact with the heating module 122. Further, the heater 100 design may be reduced or increased on all three axis based on customer power demands. Furthermore, the heater 100 further provides efficient heat transfer due to the large contact area between the heating element and the coolant and long flow path between the inlet 118 and the outlet 120.
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- General Engineering & Computer Science (AREA)
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- Instantaneous Water Boilers, Portable Hot-Water Supply Apparatuses, And Control Of Portable Hot-Water Supply Apparatuses (AREA)
Abstract
A fluid heater (100) includes a first end plate (104), a second end plate (108) and plurality of intermediate plates (112). The first end plate (104) includes an inlet (118) and an outlet (120) for ingress and egress of fluid into and out of the fluid heater (100) to cause the fluid to follow a U-turn trajectory. The intermediate plates (112) are arranged in pairs of plates (114, 116). Each pair (114, 116) includes a first intermediate plate (114) and a second intermediate plate (116). The first intermediate plate (114) being joined to the second intermediate plate (116) to form an interspace (136) therebetween to accommodate at least one heating module (138) without welding thereto. The adjacent intermediate plates (112) define fluid flow passes adjacent to the corresponding heating element (138) to permit heat exchange between the fluid and the at least one corresponding heating module (138).
Description
- The present invention generally relates to an electric fluid heater, more particularly to an electric fluid heater for vehicles.
- A vehicle generally includes a heater for heating air to be supplied to a passenger compartment. Alternatively, the heater is used to supply heated air to demist or defrost the windscreen. In some cases, the heater is used to supply hot air or hot coolant for cold starting the engine. With the emergence of the electric vehicles, the heater is also applicable for battery thermal management. The heaters can be used for efficient thermal management of the batteries used for powering the electric motor, thereby drastically enhancing the service life of the batteries. The fluid to be heated is generally passed through a heat exchanger, which includes a heating element such as for example, heat exchange flow pipes through which a heated fluid circulates in case of thermal heater or an electrical resistive heater supplied with current. Particularly, the fluid to be heated circulates across the heat exchanger and extracts heat from the heating element.
- The electrical heater includes a plurality of heating elements arranged with respect to fluid flow passes configured adjacent the heating elements between the fluid flowing through the fluid flow passes and the heating elements. Each heating element includes a tube that receives electrical core therein. Specifically, the tube together with the electrical core forms the heating element. Each tube may have several electrical cores, which may be arranged one after the other in a direction of the tube. The electrical core may include a resistive element. Each heating element includes electrodes on both sides for power supply through the heating element. Further, the heating elements include electrically insulating and thermally conductive material. The material being located between one of the electrodes and walls of the tube. In this way, the tube is electrically insulated from the electrodes and the electrical core but thermally in contact with them.
- Generally, the housing enclosing the heating elements placed between a pair heat exchanger plates of the heat exchanger having a plate stack. The plate stack are provided with an inlet port and an outlet port. The ports are in fluid communication with the fluid passage formed through the plate stack. The plates are arranged such that a fluid flow passage is formed around each pair of heat exchanger plates. The fluid entering the electrical heater flows from the inlet, and then passes through the fluid flow passage formed around each pair of plates. Simultaneously, the fluid extracts heat from the heating elements and egresses through the outlet.
- However, this arrangement has a potential risk of formation of air pockets between the housing of the heating element and the plates, and a risk of degradation of heating element because of the insulation material filled between the heating element and the housing. Further, in this arrangement, heat transfer need to take place through two layer of plates, which includes the housing of the heating element and the heat transfer plate above the housing of the heating element. Thus, this arrangement lacks to provide efficient heat transfer between the heating element and the fluid flowing around the heat transfer plates. Consequently, overheating at any spot in heat exchanger will become difficult to detect as the heater lacks to provide efficient heat transfer.
- Accordingly, there is a need for an electric fluid heater that optimizes thermal efficiency, while addressing the aforementioned issues.
- In the present description, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements which are similar but not identical. No idea of priority should be inferred from such indexation, as these terms may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention.
- In view of forgoing, the present invention discloses an electric fluid heater comprising a plate stack comprising a first end plate, a second end plate, an intermediate plate stack comprising a plurality of intermediate plates arranged between the first end plate and the second end plate. The second end plate formed with different portions that are in fluid communication with each other. Each intermediate plate is divided into different sections, respectively, corresponding to the different portions of the second end plate. The first end plate is provided with an inlet port in fluid communication with a first fluid path formed through the section of the intermediate plates and an outlet port in fluid communication with a second fluid flow path formed through the section of the intermediate plates. The inlet port and the outlet port provided in a same side of the heater adapted to cause the fluid to follow a U-turn trajectory between the inlet port and the outlet port.
- Further, the intermediate plate stack is arranged in pairs of plate. Each pair includes a first intermediate plate and a second intermediate plate. The first intermediate plate being joined to the second intermediate plate to form an interspace therebetween to accommodate at least one heating module without welding thereto. In one embodiment, the interspace is a hollow space. In another embodiment, the interspace is a tubular space.
- Further, each intermediate plate comprises a first edge portion and a second edge portion opposite to that of the first edge portion. The first intermediate plate comprises a depression along a length of the first and second edge portions thereof and the second intermediate plate comprises an elevation complementary to the depression along a length of the first and second edge portions thereof.
- The depression of the first intermediate plate brought in contact with the elevation of the second intermediate plate and brazed at the contacting portions defined by the elevation and depression of the each intermediate plate pair, thereby forming the interspace therebetween. The depression of the first intermediate plate divided into a first section corresponding to the first section of the plate stack and a second section corresponding to the second section of the plate stack. The elevation of the second intermediate plate divided into a first section corresponding to the first section of the plate stack and a second section corresponding to the second section of the plate stack.
- In one example, the depression has at least one of a rectangular shaped cross section and a square shaped cross section. In another example, the elevation has at least one of a rectangular shaped cross section and a square shaped cross section.
- The present invention further discloses a method for manufacturing the electric fluid heater. The method comprising steps of: attaching the first intermediate plate to their adjacent second intermediate plate to form the interspace therebetween, and filling at least one heating module within the interspace without welding thereto. In another embodiment, the heating module may be filled within the interspace using thermally conductive adhesive material. The adhesive material achieves a homogeneous contact between the plates the entire heating element surface, thereby avoiding hotspots.
- The method further comprises a step of welding a heater housing at each interspace of the plate stack, and accommodating at least one heating element within the heater housing and filling thermally conductive material between the heater housing and the heating element.
- In another embodiment, the electric fluid heater comprises a plate stack having a plurality of intermediate plates. The plate stack provided with an inlet port and an outlet port. The inlet port and the outlet port in fluid communication with a fluid passage formed through the plate stack. The plate stack is arranged in pairs of intermediate plates. Each pair includes a first intermediate plate and a second intermediate plate. The first intermediate plate being joined to the second intermediate plate to form an interspace therebetween to accommodate at least one heating module without welding thereto.
- Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein:
-
FIG. 1 illustrates an isometric view of an electrical fluid heater in accordance with an embodiment of the present invention; -
FIG. 2 illustrates an exploded view of the electrical fluid heater ofFIG. 1 ; -
FIG. 3 illustrates a perspective view of a first end plate ofFIG. 1 ; -
FIG. 4 illustrates a perspective view of a second end plate ofFIG. 1 ; -
FIG. 5 illustrates a perspective view of a pair of intermediate plates forming an interspace ofFIG. 1 ; -
FIG. 6 illustrates a perspective view of a first intermediate plate ofFIG. 1 ; -
FIG. 7 illustrates a perspective view of a second intermediate plate ofFIG. 1 , and -
FIG. 8 illustrates a perspective view of a heating module ofFIG. 1 . - It must be noted that the figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention if needs be. The invention should however not be limited to the embodiment disclosed in the description.
- The present invention discloses an electric fluid heater comprising a plate stack comprising a first end plate, a second end plate, an intermediate plate stack comprising a plurality of intermediate plates arranged between the first end plate and the second end plate. The second end plate formed with different portions that are in fluid communication with each other. Each intermediate plate is divided into different sections, respectively, corresponding to the different portions of the second end plate. The first end plate is provided with an inlet port in fluid communication with a first fluid path formed through the section of the intermediate plates and an outlet port in fluid communication with a second fluid flow path formed through the section of the intermediate plates. The inlet port and the outlet port provided in a same side of the heater adapted to cause the fluid to follow a U-turn trajectory between the inlet port and the outlet port.
- Further, the intermediate plate stack is arranged in pairs of plate. Each pair includes a first intermediate plate and a second intermediate plate. The first intermediate plate being joined to the second intermediate plate to form an interspace therebetween to accommodate at least one heating module without welding thereto. This arrangement address the risk of degradation of heating elements and formation of air pockets. Further, this arrangement of the heating module in contact with the intermediate plate provides efficient heat transfer between the heating module and the fluid.
-
FIG. 1 illustrates an isometric view of anelectric fluid heater 100, hereinafter referred to asfluid heater 100, in accordance with an embodiment of the present invention. Thefluid heater 100 comprises aplate stack 102 having a plurality of intermediate plates. Theplate stack 102 includes a pair ofend plates heating modules 122 and a plurality ofintermediate plates 112, wherein eachintermediate plate 112 is formed ofdifferent sections FIG. 2 illustrates an exploded view of thefluid heater 100 and the sequence in which the different elements of thefluid heater 100 are arranged and assembled with respect to each other. The pair ofend plates first end plate 104 and asecond end plate 108. - Referring to
FIG. 1 to FIG. 3 , the plurality ofintermediate plates 112 are arranged in pairs ofintermediate plate pair intermediate plate 114 and a secondintermediate plate 116. The firstintermediate plate 114 being joined to the secondintermediate plate 116 to form aninterspace 136 therebetween. A fluid flow path or fluid flow passes is defined adjacent to a pair ofintermediate plates heating module 122. Eachintermediate plate 112 is formed intodifferent sections different portions first end plate 104 and thedifferent portions second end plate 108. Thefirst sections 112A of theintermediate plates 112 defines fluidly coupled first fluid flow passes. Thesecond sections 112B ofintermediate plates 112 defines fluidly coupled second fluid flow passes. The first fluid flow passes are also referred as first fluid path and the second fluid flow passes are also referred as second fluid path throughout this document. - Referring to
FIG. 3 , thefirst end plate 104 is defined by the oppositelonger walls shorter walls longer walls longer walls shorter walls shorter walls longer walls shorter walls first end plate 104 and at least a portion of the fluid flow passes corresponding to thefirst end plate 104. Thefirst end plate 104 includes aninlet 118 for ingress of fluid into and anoutlet 120 for egress of fluid out of thefluid heater 100 from same side of thefluid heater 100 to achieve certain advantages. For example, configuring theinlet 118 and theoutlet 120 on the same side of thefluid heater 100 provides compact configuration to thefluid heater 100 and addresses packaging issues. Further, such configuration also addresses routing issues associated with routing of inlet and outlet conduits connected to theinlet 118 and theoutlet 120 for supplying and delivering out fluid from thefluid heater 100. Thesecond end plate 108 fluidly couples the first and the second fluid flow passes formed around adjacent theheating modules 122 and in fluid communication with theinlet 118 and theoutlet 120, respectively. - The
first end plate 104 includes afirst portion 106A and asecond portion 106B, wherein agroove 132 separates thefirst portion 106A from thesecond portion 106B. Thefirst portion 106A and thesecond portion 106B are raised portion that inherently form thegroove 132 at the interface betweenfirst portion 106A and thesecond portion 106B. The cross section of thefirst portion 106A is increasing from theinlet 118 towards the first fluid flow passes defined by thefirst sections 112A. - Referring to
FIG. 4 , thesecond end plate 108 includes a first and secondlonger wall shorter wall longer wall shorter wall end plate 108. Thesecond end plate 108 formed with fluidly coupled first andsecond portions inlet 118 and theoutlet 120 on same side causes the fluid to follow a U-turn trajectory between theinlet 118 and theoutlet 120. - Further as illustrated in
FIG. 1 - FIG. 3 , theinlet 118 is disposed at the centre of thefirst portion 106A and proximal to thelonger walls 124 of thefirst end plate 104. Such strategic placement of theinlet 118 ensures even distribution of the coolant to the portion of the fluid flow passes defined by thefirst sections 112A. Similarly, thesecond portion 106B corresponding to thesecond sections 112B of theintermediate plates 112 and is converging from thesecond sections 112B to theoutlet 120 in the fluid flow direction. Specifically, the cross section of thesecond portion 106B is decreasing from the second fluid flow passes defined by thesecond sections 112B towards theoutlet 120. - Further, again referring to the
FIG. 1 - FIG. 3 , theoutlet 120 is also disposed at the centre of thesecond portion 106B and proximal to thelonger walls 124 of thefirst end plate 104. In accordance with another embodiment of the present invention, theoutlet 120 is disposed at the corner of thefirst end plate 104 defined at the intersection of the firstlonger wall 124 and the firstshorter wall 128. Specifically, theoutlet 120 is farthest from thegroove 124. Such strategic placement of theoutlet 120 ensures that the portion of the fluid flow passes defined by thesecond sections 112B of theintermediate plates 112 is filled before the fluid egresses through theoutlet 120. More specifically, such strategic placement of theoutlet 120 ensures even distribution of the coolant in the fluid flow passes defined by thesecond sections 112B before egressing through theoutlet 120. Such configuration of theoutlet 120 avoids trapping air in the area beneath the second portion and the fluid flow passes defined by thesecond sections 112B by scavenging the fluid evenly underneath thesecond portion 106B of thefirst end plate 104. In another embodiment, theoutlet 120 can be disposed horizontally instead of being disposed vertically to reduce back-pressure and improve flow path. - However, the present invention is not limited to any particular configuration of the
first end plate 102 with theinlet 118 and theoutlet 120 in any particular position. The inlet and the outlet can be positioned on the first and the second portions so as to avoid air trapping by scavenging the fluid evenly underneath the first andsecond portions fluid deflecting walls 134, shown inFIG.4 , formed on surface of thesecond end plate 108. Thefirst portion 110A and thesecond portion 110B of thesecond end plate 108 is corresponding to thefirst sections 112A and thesecond sections 112B of theintermediate plates 112 and thefirst portion 106A and thesecond portion 106B of thefirst end plate 104. However, the first and thesecond portions second end plates 108 are in fluid communication with each other unlike the first andsecond portions first end plate 104. - Referring to
FIG. 1 to 3 , in the assembled configuration of theintermediate plates 112, the first fluid flow passes receive a heat exchange fluid distributed thereto by thefirst portion 106A of thefirst end plate 104 from theinlet 118 for heat exchange with at least a portion of theheating module 122 sandwiched between theintermediate plates 112. Thesecond end plate 108 fluidly couples the first fluid passes to the second fluid passes. The second flow passes deliver fluid to thesecond portion 106B of thefirst end plate 104 for egress through theoutlet 120 after heat exchange with theheating module 122 in the assembled configuration of theintermediate plates 112. - Referring to
FIG. 5 , eachintermediate plate 112 includes afirst edge portion 140A and asecond edge portion 140B opposite to that of thefirst edge portion 140A. Eachintermediate plate 112 further includes afirst side portion 142A and asecond side portion 142B opposite to that of thefirst side portion 142A. Thefirst edge portion 140A and thesecond edge portion 140B are the longer sidewalls of theintermediate plate 112. Thefirst side portion 142A and thesecond side portion 142B are the shorter sidewalls of theintermediate plate 112. The longer sidewalls and the shorter sidewalls defines the periphery of theintermediate plate 112 that defines at least a portion of the fluid flow passes defined by the adjacentintermediate plates 112. - The first
intermediate plate 114 comprises adepression 146 along a length of the first andsecond edge portions intermediate plate 116 comprises anelevation 148 complementary to thedepression 146 along a length of the first andsecond edge portions - The
depression 146 of the firstintermediate plate 114 brought in contact with theelevation 148 of the secondintermediate plate 116 and joined at the contacting portions defined by theelevation 148 anddepression 146 of each pair ofintermediate plate plates 112 to form aninterspace 136 therebetween. At least oneheating module 122 is accommodated at theinterspace 136 of each pair ofintermediate plates 112. In one embodiment, theheating module 122 may include at least two sections, which corresponds to thedifferent sections intermediate plate 112. Theinterspace 136 comprises a profile complementary to the profile of theheating module 122. Theheating module 122 is slid into theinterspace 136, which accommodates theheating module 122 therein without welding. In one embodiment, theheating module 122 is slid into theinterspace 136 and thermally conductive type adhesive material may be filled between theheating module 122 and theplates 112. The adhesive material achieves a homogeneous contact between theplates 112 the entire heating module surface, thereby avoiding hotspots. In one embodiment, thedepression 146 has at least one of a rectangular shaped cross section and a square shaped cross section. In one embodiment, theelevation 148 has at least one of a rectangular shaped cross section and a square shaped cross section. In one embodiment, theinterspace 136 is a hollow space. In another embodiment, theinterspace 136 is a tubular space. - Referring to
FIG. 8 , in an example, theheating module 122 comprises atube 166 that receives an electrical core orheating element 164 therein. Theelectrical core 164, is for example, PTC (Positive Temperature Coefficient) resistors. Eachtube 166 may have severalelectrical cores 164, which may be arranged one after the other in a direction of thetube 166. Eachheating module 122 includeselectrodes 168 on both sides for power supply through theheating module 122. Alternatively, theelectrodes 168 may be on the same side of theheating module 122, which may reduce the number of components and packaging size. Further, theheating module 122 includes electrically insulating and thermallyconductive material 170. Thematerial 170 being located between one of theelectrodes 168 andwalls 172 of thetube 166. In this way, thetube 166 is electrically insulated from theelectrodes 168 and theelectrical core 164 but thermally in contact with them. - Referring to
FIG. 6 , thedepression 146 of the firstintermediate plate 114 is divided into afirst section 150A corresponding to thefirst section 112A of theintermediate plate 112 and asecond section 150B corresponding to thesecond section 112B of theintermediate plate 112. Referring toFIG. 7 , theelevation 148 of the secondintermediate plate 116 is divided into afirst section 152A corresponding to thefirst section 112A of theintermediate plate 112 and asecond section 152B corresponding to thesecond section 112B of theintermediate plate 112. Thefirst edge portion 140A and thesecond edge portion 140B of theintermediate plates 112 are formed with slots oropenings intermediate plates 112. - The openings or
slots edge portions intermediate plates 112 to define zig-zag fluid flow path between theinlet 118 and theoutlet 120 and permit fluid communication between the fluid flow passes defined by the adjacentintermediate plates 112. The zig-zag fluid flow path between theinlet 118 and theoutlet 120 increases the length of the fluid flow path and accordingly enhances the contact area and contact time between the fluid flowing through the fluid flow passes and theheating element 122, thereby improving the efficiency and performance of thefluid heater 100 - In accordance with an embodiment, if the openings or
slots 154 are formed on the firstintermediate plates 114 at portions thereof proximal to theedge portions slots 156 are formed on the subsequent adjacentintermediate plates 112 or the secondintermediate plate 116 atedge portions - Referring to
FIG. 6 andFIG. 7 , eachintermediate plate 112, specifically, the firstintermediate plate 114 includes at least one offirst positioning elements pins second positioning elements holes intermediate plate 146 engages with the corresponding guidingholes intermediate plate 116 to position and assemble theintermediate plate 112 with respect to the adjacent intermediate plate112. Referring to theFIG. 5 , there are two guidingpins 158A along the portion of the firstintermediate plate 114 proximal to thefirst edge portion 140A. Further, there are two guidingpins 158B along the portion of the secondintermediate plate 116 proximal to thesecond edge portion 140B. Each guidingpin intermediate plate 114 corresponding to the twosections intermediate plate 114. - Referring to the
FIG. 7 , there are two guidingholes 160A along the portion of the secondintermediate plate 116 proximal to thefirst edge portion 140A, each guidinghole 160A disposed on the respective portions of the secondintermediate plate 116 corresponding to the twosections intermediate plate 116. Further, there are two guidingholes 160B along the portion of theintermediate plate 116 proximal to thesecond edge portion 140B. Each guidinghole 160B disposed on the respective portions of the secondintermediate plate 116 corresponding to the twosections intermediate plate 116. - However, the present invention is not limited to any particular number, placement and configuration of the openings / slots formed on the
edge portions intermediate plates 112 as far as the slots / openings define zig-zag fluid flow path between theinlet 118 and theoutlet 120 and permit fluid communication between the fluid flow passes defined by the adjacentintermediate plates 112. Further, eachintermediate plate 112 includes at least onerib 162. The at least onerib 162 defines thedifferent sections intermediate plate 112. Theribs 162 of the adjacentintermediate plates 112 acts as poke - yoke feature and facilitates in correct assembly between the adjacentintermediate plates 112. - The present invention further discloses a method for manufacturing the
electric fluid heater 100. The method comprising steps of: attaching the firstintermediate plate 114 to their adjacent secondintermediate plate 116 to form theinterspace 136 therebetween, and filling at least oneheating module 122 within theinterspace 136 without welding thereto. The method further comprises a step of: filling at least oneheating module 122 within theinterspace 136 with thermally conductive type adhesive material. The adhesive material achieves a homogeneous contact between theplates 112 the entire heating module surface, thereby avoiding hotspots. The method further comprises a step of welding a heater housing 166 (also referred astube 166 throughout the document) at eachinterspace 136 of theplate stack 102, and accommodating at least one heating element 164 (also referred as electrical core 164) within theheater housing 166 and filling thermally conductive insulation material between theheater housing 166 and theheating element 164. - In another embodiment, the
electric fluid heater 100 comprises aplate stack 102 having a plurality of intermediate plates. Theplate stack 102 provided with aninlet port 118 and anoutlet port 120. Theinlet port 118 and theoutlet port 120 in fluid communication with a fluid passage formed through theplate stack 102. Theplate stack 102 is arranged in pairs ofintermediate plates 102. Each pair includes a firstintermediate plate 114 and a secondintermediate plate 116. The firstintermediate plate 114 being joined to the secondintermediate plate 116 to form aninterspace 136 therebetween to accommodate at least oneheating module 122 without welding thereto. - In conventional heater arrangements, the heating modules are assembled to the heater by brazing at high temperature, which may affect the heating element insulation material. Therefore, the present invention facilitates the arrangement of
heating module 122 by sliding theheating module 122 betweenplates 112. Optionally, theheating module 122 may be slid in betweenplates 112 and thermally conductive type of adhesive may be filled between theplates 112 and theheating module 122. Theheater 100 further facilitates early overheating detection due to the short heat transfer path offered by themultiple plates 112 in contact with theheating module 122. Further, theheater 100 design may be reduced or increased on all three axis based on customer power demands. Furthermore, theheater 100 further provides efficient heat transfer due to the large contact area between the heating element and the coolant and long flow path between theinlet 118 and theoutlet 120. - In any case, the invention cannot and should not be limited to the embodiments specifically described in this document, as other embodiments might exist. The invention shall spread to any equivalent means and any technically operating combination of means.
Claims (14)
- An electric fluid heater (100), comprising:a plate stack (102) comprising a first end plate (104), a second end plate (108),an intermediate plate stack (112) comprising a plurality of intermediate plates (112) arranged between the first end plate (104) and the second end plate (108), the second end plate (108) formed with different portions (110A, 110B) that are in fluid communication with each other, each intermediate plate (112) is divided into different sections (112A, 112B) respectively corresponding to the different portions (110A, 110B) of the second end plate (108); the first end plate (104) is provided with an inlet port (118) in fluid communication with a first fluid path formed through the section (112A) of the intermediate plates (112) and an outlet port (120) in fluid communication with a second fluid flow path formed through the section (112B) of the intermediate plates (112), the inlet port (118) and the outlet port (120) provided in a same side of the heater (100) adapted to cause the fluid to follow a U-turn trajectory between the inlet port (118) and the outlet port (120), characterized in that,the intermediate plate stack (112) is arranged in pairs of plate (114, 116), each pair (114, 116) includes a first intermediate plate (114) and a second intermediate plate (116), the first intermediate plate (114) being joined to the second intermediate plate (116) to form an interspace (136) therebetween to accommodate at least one heating module (138) without welding thereto.
- The electric fluid heater (100) of claim 1, wherein each intermediate plate (112) comprises a first edge portion (140A) and a second edge portion (140B) opposite to that of the first edge portion (140A), and the first intermediate plate (112) comprises a depression (146) along a length of the first and second edge portions (140A, 140B) thereof and the second intermediate plate (116) comprises an elevation (148) complementary to the depression (146) along a length of the first and second edge portions (140A, 140B) thereof.
- The electric fluid heater (100) of claim 2, wherein the depression (146) of the first intermediate plate (114) brought in contact with the elevation (148) of the second intermediate plate (116) and brazed at the contacting portions defined by the elevation (148) and depression (146) of the each intermediate plate pair (114, 116), thereby forming the interspace (136) therebetween.
- The electric fluid heater (100) of claim 2, wherein the depression (146) of the first intermediate plate (114) divided into a first section (150A) corresponding to the first section (112A) of the plate stack (112) and a second section (150B) corresponding to the second section (112B) of the plate stack (102).
- The electric fluid heater (100) of claim 2, wherein the elevation (148) of the second intermediate plate (116) divided into a first section (152A) corresponding to the first section (112A) of the plate stack (112) and a second section (150B) corresponding to the second section (112A) of the plate stack (112).
- The electric fluid heater (100) of claim 2, wherein the depression (146) has at least one of a rectangular shaped cross section and a square shaped cross section.
- The electric fluid heater (100) of claim 2, wherein the elevation (148) has at least one of a rectangular shaped cross section and a square shaped cross section.
- The electric fluid heater (100) of claim 3, wherein the interspace (136) is a hollow space.
- The electric fluid heater (100) of claim 3, wherein the interspace (136) is a tubular space.
- A method for manufacturing the electric fluid heater (100) according to claim 1, the method comprising steps of: (a) attaching the first intermediate plate (114) to their adjacent second intermediate plate (116) to form the interspace (136) therebetween, and (b) filling at least one heating module (122) within the interspace (136) without welding thereto.
- The method of claim 10, further comprises a step of: filling thermally conductive type of adhesive material between the heating module (122) and the interspace (136).
- The method of claim 10, wherein the step (a) further comprises a step of: welding a heater housing at each interspace (136) of the plate stack (112).
- The method of claim 12, further comprises a step of: accommodating at least one heating element within the heater housing and filling thermally conductive material between the heater housing and the heating element.
- An electric fluid heater, comprising:a plate stack having a plurality of intermediate plates, the plate stack provided with an inlet port and an outlet port, the inlet port and the outlet port in fluid communication with a fluid passage formed through the plate stack,characterized in that, the plate stack is arranged in pairs of intermediate plates according to claims 1-12, each pair includes a first intermediate plate and a second intermediate plate, the first intermediate plate being joined to the second intermediate plate to form an interspace therebetween to accommodate at least one heating module without welding thereto.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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EP22195491.0A EP4339528A1 (en) | 2022-09-14 | 2022-09-14 | Electric fluid heater |
PCT/EP2023/075207 WO2024056769A1 (en) | 2022-09-14 | 2023-09-14 | Electric fluid heater |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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EP22195491.0A EP4339528A1 (en) | 2022-09-14 | 2022-09-14 | Electric fluid heater |
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EP4339528A1 true EP4339528A1 (en) | 2024-03-20 |
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EP22195491.0A Pending EP4339528A1 (en) | 2022-09-14 | 2022-09-14 | Electric fluid heater |
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WO (1) | WO2024056769A1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2013087671A1 (en) * | 2011-12-15 | 2013-06-20 | Behr Gmbh & Co. Kg | Electrically operable heating device |
US20140050465A1 (en) * | 2011-09-28 | 2014-02-20 | Mitsubishi Heavy Industries Automotive Thermal Systems Co., Ltd. | Heat medium heating device and vehicular air-conditioning device including the same |
US20200079180A1 (en) * | 2018-09-11 | 2020-03-12 | Mahle International Gmbh | Electric heating device |
-
2022
- 2022-09-14 EP EP22195491.0A patent/EP4339528A1/en active Pending
-
2023
- 2023-09-14 WO PCT/EP2023/075207 patent/WO2024056769A1/en unknown
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20140050465A1 (en) * | 2011-09-28 | 2014-02-20 | Mitsubishi Heavy Industries Automotive Thermal Systems Co., Ltd. | Heat medium heating device and vehicular air-conditioning device including the same |
WO2013087671A1 (en) * | 2011-12-15 | 2013-06-20 | Behr Gmbh & Co. Kg | Electrically operable heating device |
US20200079180A1 (en) * | 2018-09-11 | 2020-03-12 | Mahle International Gmbh | Electric heating device |
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