RELATED APPLICATIONS
This application claims priority to EP 23 181 991.3, filed Jun. 28, 2023, the entire disclosure of which is hereby incorporated herein by reference.
BACKGROUND AND SUMMARY
This disclosure relates to a flow heater for heating liquids of the type generally described in U.S. Publication No. 2022/0082297 A1.
Flow heaters are needed, for example, in automobiles to heat various liquids, in particular water and aqueous solutions. Constant goals in the development of flow heaters for automobiles are a compact design, low manufacturing costs, and a high efficiency.
This disclosure teaches a flow heater that achieves these goals to a greater extent.
A flow heater according to this disclosure comprises a channel for liquid to be heated that is arranged between a heating plate and an inner wall that has at least one section that is slanted with respect to the heating plate. Accordingly, the channel has a first wedge-shaped section adjacent to the inlet and a second wedge-shaped section adjacent to the outlet, both wedge-shaped sections tapering from an end of the heating plate adjacent to the inlet and the outlet to an opposite end. The wedge-shaped sections are connected by a middle section of the flow channel, in which the direction of flow is crosswise to the direction of flow in the wedge-shaped sections.
Along the length of the first wedge-shaped section of the channel liquid to be heated enters the middle section of the flow channel and flows in the middle section in a direction crosswise to the length of the first tapering section. Thus only a small fraction of the liquid to be heated reaches the end of the first wedge-shaped section. The rest of the liquid enters the middle section along the way. Likewise, the amount of liquid inside the second wedge-shaped section increases in a direction towards the outlet as liquid enters the second wedge-shaped section along the way. Such a channel allows very large amounts of liquid to be heated efficiently in a short time.
The compactness of design enabled by the channel arranged as explained above is further improved by arranging the printed circuit board slanted with respect to the heating plate in a wedge-shaped space defined by the inner wall section and a cover part of the housing. Thereby the length of the circuit board can be greater than the length of the housing. Moreover, by arranging small, flat components of an end section of the circuit board on an end section adjacent to the inlet and the outlet and large components, like capacitors, on an opposite end section, the volume enclosed by the housing can be used very efficiently resulting in a very compact flow heater.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned aspects of exemplary embodiments will become more apparent and will be better understood by reference to the following description of the embodiments taken in conjunction with the accompanying drawings, wherein:
FIG. 1 shows a flow heater according to this disclosure;
FIG. 2 is a sectional view of the flow heater along line AA;
FIG. 3 is a sectional view of the flow heater along line CC;
FIG. 4 is a sectional view of the flow heater along line BB with arrows indicating the direction of flow of liquid;
FIG. 5 is a sectional view of another embodiment of a flow heater outside of the attached claims; and
FIG. 6 is a sectional view of another embodiment of a flow heater outside of the attached claims.
DESCRIPTION
The embodiments described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of this disclosure.
FIG. 1 shows a flow heater. The same flow heater is shown in a sectional view along line AA in FIG. 2, in sectional view along line CC in FIG. 3 and schematically in a sectional view along line BB in FIG. 3.
The flow heater comprises a housing have a base part 1, a first cover part 2, and a second cover part 3. The housing may be cuboid shaped as shown in the figures. The base part 1 has two opposing short sides 1a, 1b and two opposing long sides 1c, 1d, said two short sides 1a, 1b and said two long sides 1c, 1d are arranged between both cover parts 2, 3.
The base part 1 is provided with an inlet 4 and an outlet 5, e.g., in one of the short sides 1a of the base part 1. Liquid to be heated flows through a channel inside the housing from the inlet 4 to the outlet 5. The sectional view of FIG. 2 shows an end section 6 of the channel, which is adjacent to the outlet 5, and the sectional view of FIG. 3 shows another section 7 of the channel, said section being downstream of the inlet 4. Sections 6 and 7 of the flow channel are arranged between and delimited by a heating plate 8 and a section of an inner wall 9 of the housing. This inner wall 9 is part of the base part 1 and may be integral with it.
As can be seen in FIGS. 2 and 3, a section of the inner wall 9 is slanted with respect to the heating plate 8. The end section 6 of the channel is wedge-shaped. The channel section 6 is tapering in a direction away from the outlet 5 and the channel section 7 is tapering away from the inlet 4.
In FIG. 4, the course of the channel is illustrated schematically with arrows. Liquid to be heated flows from the inlet 4 to the left in FIG. 3 and then along a wedge-shaped section which is not shown in the figures, but formed like end section 6. Flow through this wedge-shaped section is indicated in FIG. 4 with a downward arrow 10. Liquid flows from this wedge-shaped section into a middle section 14 of the channel that is delimited on one side by the heating plate 8 and on an opposite side by a section 11 of inner wall 9. Flow in this section is illustrated in FIG. 3 by arrow 12. Note that arrow 12 is shown outside of the housing for reasons of space, but that the middle section of the flow channel is of course inside the housing. The middle section 14 of the channel leads to the end section 6 of the flow channel shown in FIG. 2 and depicted by arrow 13 in FIG. 3.
FIG. 4 is limited to details essential for understanding the course of the channel. Hence, printed circuit board 16 and other details shown in FIG. 2 are not shown in FIG. 4.
The wedge-shaped section 7 downstream of the inlet 4 is also called the first wedge-shaped section and the wedge-shaped section 6 leading to outlet 5 is also called the second wedge-shaped section. Both wedge-shaped sections are connected by middle section 14 which may have a constant height as measured perpendicular to the heating plate 8. The direction of flow in the wedge-shaped sections 6 is crosswise, e.g., perpendicular, to the direction of flow in the middle section 14. Fins 20 that are in contact with the heating plate 8 are arranged in the channel, especially in the middle section 14 of the channel.
The fins 20 may be corrugated sheet metal connected to the heating plate 8, e.g., by brazing. The heating plate 8 is provided with heating resistors, e.g., resistive tracks, arranged on a substrate. The substrate may be a metal plate covered by a dielectric layer on which resistive tracks are arranged as heating resistors, especially on a side of the substrate facing away from fins 20.
The inner wall 9 delimiting the heating channel may have a middle section 11 parallel to the heating plate 8 and on both sides of this middle section 11 a slanted section as shown in FIG. 2. Then the middle section 14 of the channel has a constant height, while the sections 6, 7 on both sides of the middle section, are wedge-shaped. These wedge-shaped sections 6, 7 of the flow channel taper towards the end of the heating plate 8 facing away from the inlet 4 and the outlet 5.
Both cover parts 2, 3 and the heating plate 8 are parallel to each other. Parallel here means that any deviation from a geometrical perfect parallel orientation is within manufacturing tolerances.
As FIG. 2 shows, the slanted section 9 of the inner wall and the first cover part 2 of the housing define a wedge-shaped space 15 that tapers in a direction that is opposite to the direction in which the first and second wedge-shaped section 6 of the channel taper. Inside this wedge-shaped space 15 is a printed circuit board 16 with control electronics. This printed circuit board 16 is slanted with respect to the heating plate 8 and also slanted with respect to the cover parts 2, 3. Thereby, a longer printed circuit board 16 can be arranged in the housing as would be possible if it were oriented in parallel to the heating plate 8 and the cover parts 2, 3. Moreover, by the slanted arrangement of the printed circuit board 16 in the wedge-shaped space the distance from the printed circuit board 16 to the first cover 2 increases from an end of the printed circuit board 16 adjacent to the inlet 4 and the outlet 5 to an opposite end of the printed circuit board 16. At the end of the printed circuit board 16 there is therefore enough space for mounting large components, like e.g., capacitors 18, on the printed circuit board 16, whereas the other end may be used for smaller components of the control electronics.
The printed circuit board 16 and the heating plate 8 enclose an acute angle which may be 3° to 10°, for example. As can be seen in FIG. 2, there may be wedge-shaped gap 19 between the printed circuit board 16 and the slanted section of the inner wall 9. This wedge-shaped gap 19 may taper in a direction opposite to the direction of tapering of the wedge-shaped space 15, in which the printed circuit board 16 is arranged. Thus the gap 19 tapers towards the inlet 4 and the outlet 5.
In FIGS. 5 and 6, further embodiments of a flow heater are shown in a sectional view according to FIG. 2. Identical and corresponding components of the flow heaters of all embodiments are designated with identical reference numerals in the various figures. The embodiments shown in FIGS. 4 and 5 differ from the embodiment explained mostly in the printed circuit board 16. Whereas in the embodiment of FIG. 2 the printed circuit board 16 is slanted with respect to the heating plate 8, two separate, smaller circuit boards 16a, 16b are used in the embodiment of FIG. 4 which are electrically connected by means of an electrical conductor 21, e.g., a wire. In the embodiment shown in FIG. 5, a single printed circuit board 16 is used that is arranged in parallel with the heating plate 8. Large components of the control electronic, e.g., a capacitor 18, are arranged on an end of the printed circuit 16 board facing away from the inlet 4 and the outlet 5 and on a surface of the printed circuit board 16 facing away from the first cover part 2.
The embodiment shown in FIG. 5 refers to a flow heater, comprising a housing comprising a base part 1 and a cover part 2, a channel for liquid to be heated, which extends from an inlet 4 to an outlet 5, a heating plate 8 adjacent to the channel, fins 20 arranged in the channel in contact with the heating plate 8, and a printed circuit board 16 arranged between an inner wall 9 of the housing and the cover part 2, wherein the inner wall 9 has at least one section that is slanted with respect to the heating plate 8, between the heating plate 8 and the inner wall 9 the channel has a first wedge-shaped section downstream of the inlet and a second wedge-shaped section 6 leading to the outlet 5, both wedge-shaped sections tapering from an end of the heating plate 8 adjacent to the inlet 4 and the outlet 5 to an opposite end, wherein said wedge-shaped sections are connected by a middle section of the flow channel, in which the direction of flow is crosswise to the direction of flow in the wedge-shaped sections 6, and wherein a fist printed circuit board 16a and a second printed circuit board 16b are arranged in a wedge-shaped space defined by the inner wall 9 and the cover part 2, said wedge-shaped space tapering in a direction that is opposite to the direction in which the first and second channel sections taper. The first printed circuit board 16a and the second printed circuit boards 16b being arranged at different distances from the cover part 2.
The embodiment shown in FIG. 6 refers to a flow heater, comprising a housing comprising a base part 1 and a cover part 2, a channel for liquid to be heated, which extends from an inlet 4 to an outlet 5, a heating plate 8 adjacent to the channel, fins 20 arranged in the channel in contact with the heating plate 8, and a printed circuit board 16 arranged between an inner wall 9 of the housing and the cover part 2, wherein the inner wall 9 has at least one section that is slanted with respect to the heating plate 8, between the heating plate 8 and the inner wall 9 the channel has a first wedge-shaped section downstream of the inlet and a second wedge-shaped section 6 leading to the outlet 5, both wedge-shaped sections tapering from an end of the heating plate 8 adjacent to the inlet 4 and the outlet 5 to an opposite end, wherein said wedge-shaped sections are connected by a middle section of the flow channel, in which the direction of flow is crosswise to the direction of flow in the wedge-shaped sections 6, and wherein a printed circuit board 16 is arranged in a wedge-shaped space defined by the inner wall 9 and the cover part 2, said wedge-shaped space tapering in a direction that is opposite to the direction in which the first and second channel sections taper. The printed circuit board is arranged adjacent to the cover 2, in parallel with the cover 2, and provided with components, e.g., a capacitor on a surface facing away from the cover 2.
While exemplary embodiments have been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of this disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
LIST OF REFERENCE SIGNS
1 base part
1
a short side
1
b short side
1
c long side
1
d long side
2 cover part
3 cover part
4 inlet
5 outlet
6 section of channel
7 section of channel
8 heating plate
9 inner wall
10 arrow
11 section of inner wall
12 arrow
13 arrow
14 middle section of channel
15 wedge-shaped space
16 printed circuit board
16
a printed circuit board
16
b printed circuit board
18 capacitor
19 gap
20 fins
Patent Application
20250003633
