Angled PCB Layout for Compact Electric Radiator Heating Surface
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Solution Overview
Problem
Existing additional electric radiators for motor vehicles face challenges in optimizing the surface area for air heating while minimizing the transverse bulk of the casing, as the placement of control electronics either reduces the heating surface or complicates housing due to protrusions.
Innovation Solution
A printed circuit support with a longitudinal zone of partial milling and angled bending, separating high-power and low-power electronic components, ensures mechanical connection through a copper outer layer, with high-power components placed perpendicular to the heating zone and low-power components parallel to it, optimizing both heating zone height and compartment dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the printed circuit board support is located in the mid-plane of the auxiliary electric heater, then the electronic control unit is centrally positioned, but the area occupied by the printed circuit board support reduces the area available for heating the airflow by the heating elements
Solution Approach 1:
The printed circuit board support is bent into an angle (typically 90 degrees) relative to the mid-plane, transitioning from a two-dimensional planar arrangement to a three-dimensional angular configuration. This allows the control electronics to be positioned in a different spatial dimension, eliminating their occupation of the heating surface area while maintaining central positioning benefits.
2Area of stationary object
If the printed circuit board support is positioned perpendicular to the average plane of the auxiliary electric heater, then the surface area available for heating the airflow is maximized, but the casing of the auxiliary electric heater has a lateral protrusion making it more difficult to fit into the vehicle's air conditioning unit
Solution Approach 1:
The angled printed circuit board support is nested within the heater casing structure, with the angular configuration allowing the control unit to be accommodated in the depth of the casing rather than protruding laterally. This nesting approach eliminates the lateral protrusion problem while maintaining the perpendicular positioning benefits for heating surface area.
3Power
If high-power electronic components are placed on the printed circuit board support near the heating zone, then power transmission efficiency is improved, but thermal management becomes more challenging
Solution Approach 1:
High-power electronic components are extracted from the main printed circuit board support and positioned on a separate heat dissipation structure or dedicated thermal management zone. This separation extracts the thermal management challenge from the main control unit, allowing power transmission efficiency to be maintained while thermal issues are addressed independently through specialized cooling pathways.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This arrangement maximizes the air heating surface area while minimizing the radiator's transverse bulk, allowing for efficient and compact integration within the vehicle's air conditioning unit.
Implementation Method 1
the outer copper layer of the printed circuit board support provides mechanical bonding to all longitudinal areas and the partial milling area of the printed circuit board support
Implementation Method 2
the heating elements are placed within the airflow, and the electronic control unit for these elements is located on one side of the auxiliary heater
Data Source
Figure 1~3
AI summary
The invention relates to an additional electric radiator for a motor vehicle, comprising a heating area (4) and a compartment (5) housing electronic components for controlling the heating, said electronic components being arranged on a printed circuit board (6). The printed circuit board (6) has a longitudinal partially milled area (9), and is folded in the form of an angle bar along said partially milled area (9).