Quick temperature rise air intake heater

1 . A quick temperature rise air intake heater and control system for use in an internal combustion engine having an intake defining a passage, the air intake heater comprising:

a heating element coupled to a frame, the frame being adapted to be coupled to the intake, the heating element being adapted to be positioned in a heat transfer relationship with the passage; and

a capacitor electrically coupled to the heating element, the capacitor being operable to selectively increase the power supplied to the heating element to increase the output of the heater.

2 . The air intake heater of claim 1 further including a controller operable to selectively control the supply of power from the capacitor to the heating element.

3 . The air intake heater of claim 2 wherein the heating element is positioned within 5-20 cm of an intake port opening of an engine head.

4 . The air intake heater of claim 3 wherein the heater is operable to output 2000-5000 watts when the capacitor is electrically discharging into the heating element.

5 . A quick temperature rise air intake heater for use in an internal combustion engine having an intake defining a passage, the air intake heater comprising:

a heating element adapted to be positioned in a heat transfer relationship with the passage, the heating element having portions movable between first and second positions, said portions relatively restricting more air flow when in the first position than in the second position.

6 . The air intake heater of claim 5 wherein the portions are positioned substantially parallel to the direction of air flow when in the second position.

7 . The air intake heater of claim 6 wherein during engine starting the portions are in the first position to transfer a maximum amount of energy to the air passing through the air heater, the portions not restricting the very low air flows experienced during engine cranking.

8 . The air intake heater of claim 5 wherein the movable portions of the heating elements may be positioned at positions between the first and second positions to vary the heat transfer to the air and the air flow restriction caused by the movable portions.

9 . A quick temperature rise air intake heater for use in an internal combustion engine having an intake defining a passage, the air intake heater comprising:

a heating element adapted to be positioned in a heat transfer relationship with the passage, wherein the heating element includes a surface having a plurality of indentations formed thereon, wherein the indentations cause an air flow traveling across the heating element to become turbulent to increase heat transfer from the heating element to the air.

10 . The air intake heater of claim 9 wherein the heating element has a serpentine shape.

11 . A quick temperature rise air intake heater for use in an internal combustion engine having an intake defining a passage, the air intake heater comprising:

a heating element adapted to be positioned in a heat transfer relationship with the passage, wherein the heating element includes a surface having a plurality of indentations formed thereon, wherein the indentations cause an air flow traveling across the heating element to contact additional heating element surface area and increase heat transfer from the heating element to the air.

12 . The air intake heater of claim 11 wherein the heating element has a serpentine shape.

13 . A quick temperature rise air intake heater for use in an internal combustion engine having an intake defining a passage, the air intake heater comprising:

a heating element adapted to be positioned in a heat transfer relationship with the passage, wherein the heating element includes a surface having a plurality of protrusions formed thereon, wherein the protrusions cause an air flow traveling across the heating element to become turbulent to increase heat transfer from the heating element to the air.

14 . The air intake heater of claim 13 wherein the protrusions include webs of heating element material partially separated from adjacent heating element material, wherein the webs are deformed to protrude from a surface of the adjacent heating element material.

15 . The air intake heater of claim 14 wherein the webs are defined by two substantially parallel slits extending through the heating element.

16 . The air intake heater of claim 13 wherein current flows through the protrusions during energization of the heating element.

17 . A quick temperature rise air intake heater for use in an internal combustion engine having an intake defining a passage having a direction of air flow, the air intake heater comprising:

first and second heating elements coupled to a frame, the frame being adapted to be coupled to the intake, the heating elements being adapted to be positioned in a heat transfer relationship with the passage, the first heating element having substantially planar portions aligned with one another, at least two of the planar portions being positioned at an angle to the direction of air flow, the second heating element having substantially planar portions aligned with one another, at least two of the planar portions of the second heating element being positioned at a second angle to the direction of air flow.

18 . The air intake heater of claim 17 wherein the first heating element portions are positioned at an angle to deflect the flow in a first direction substantially perpendicular to the direction of air flow.

19 . The air intake heater of claim 18 wherein the second heating element portions are positioned at an angle to deflect the flow in a direction opposite the first direction.

20 . The air intake heater of claim 19 wherein the first and second heating elements are serpentine in shape.

21 . The air intake heater of claim 17 wherein at least one planar portion of the first heating element forms an angle with at least one planar portion of the second heating element ranging between thirty and one hundred and twenty degrees.

22 . A quick temperature rise air intake heater for use in an internal combustion engine having an intake defining a passage having a direction of air flow, the air intake heater comprising:

a heating element adapted to be positioned in a heat transfer relationship with the passage, the heating element having first substantially planar spaced apart portions, each first portion having a leading edge aligned along a first plane, the heating element having second substantially planar spaced apart portions, each second portion having a leading edge aligned along a second plane spaced apart from and substantially parallel to the first plane, each portion of the heating element being aligned with a gap formed between the first portions.

23 . The air intake heater of claim 22 wherein the first and second heating element portions are oriented substantially parallel to one another and parallel to the direction of air flow.

24 . The air intake heater of claim 23 wherein the heating element is serpentine in shape.

25 . A method of cold starting a diesel fueled internal combustion engine having a quick temperature rise air intake heater, the method comprising:

determining the ambient air temperature;

simultaneously energizing the quick temperature rise air intake heater and cranking the engine if the ambient air temperature is below a predetermined value; and

heating intake air as it passes over the quick temperature rise air intake heater until the engine starts.

26 . The method of claim 25 further including electrically connecting a capacitor to the air intake heater to selectively increase the power supplied to the heater during engine cranking.

27 . The method of claim 26 further including outputting a signal indicative of the ambient air temperature to a controller and selectively controlling the output of the capacitor during engine cranking.

28 . The method of claim 25 further including outputting at least 2000 watts from the heater during engine cranking.

29 . The method of claim 25 further including positioning the air intake heater at the entrance to the intake port.

30 . The method of claim 25 further including electrically connecting a plurality of heating elements in parallel.

31 . The method of claim 25 further including positioning a cylindrically shaped outer surface of the air heater within a cylindrically shaped aperture upstream of the intake valves of the engine.

32 . The method of claim 25 wherein the predetermined ambient air temperature is 10° F.

33 . The method of claim 25 further including spacing apart a plurality of indentations on a surface of a heating element to cause turbulent air flow and increase the heat transfer from the heating element to the air passing over the heating element.

34 . The method of claim 25 further including positioning a first heating element at a first position and a second heating element at a position downstream from said first position, said second heating element being spaced apart from said first heating element a distance great enough to place said second heating element in a substantially turbulent flow.

35 . A method of cold starting a diesel fueled internal combustion engine having a quick temperature rise air intake heater, the method comprising:

determining the ambient air temperature;

energizing the quick temperature rise air intake heater if the ambient air temperature is below a predetermined value;

starting the engine within 5 seconds of heater initial energization; and

heating intake air as it passes over the quick temperature rise air intake heater to achieve a start.

36 . The method of claim 35 further including outputting at least 2000 watts from the heater during engine cranking.

37 . The method of claim 35 continuing to energize the quick temperature rise air intake heater after the engine has started.