Ceramic Heating Module With Integrated Transistor Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric heating systems in hybrid and electric vehicles face increased design complexity due to high power losses in power transistors, which are not efficiently managed in 12 V on-board electrical systems, and require higher heat output with reduced current load in higher voltage systems, necessitating hermetically sealed, moisture-resistant heating elements.
Innovation Solution
An electric heating system utilizing an electrically insulating, heat conducting ceramic substrate with separate heating and control zones, featuring a resistance heating element and a transistor for current control, coupled with a cooling element to manage heat dissipation and ensure operational safety, and a ceramic cover for protection, allowing for efficient heat conductivity and reduced overheating risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high voltage on-board electrical systems (400 V) are used, then current strength is reduced and heat output is increased, but heating elements require hermetic sealing with high electric strength which increases design complexity
Solution Approach 1:
The patent combines the heating element with the ceramic substrate to form an integrated module. The ceramic substrate serves multiple functions: it provides electrical insulation, thermal management, and structural support for the hermetically sealed heating element, thereby reducing overall design complexity while maintaining high voltage compatibility and heat output performance
2Ease of operation
If PTC heating elements are used in 12 V systems, then heating function is achieved, but power transistors generate high power losses requiring cooling which increases design complexity
Solution Approach 1:
The patent extracts the power loss issue from the heating system by using a resistance heating conductor with much lower current requirements enabled by high voltage operation. This eliminates the need for high-power transistors and their associated cooling systems, thereby reducing design complexity while maintaining the heating function
3Productivity
If conventional PTC heating systems are used, then selective heat input (hot spot) occurs, but homogeneous allover heat generation is not achieved
Solution Approach 1:
The patent applies local quality by designing the resistance heating conductor with varying resistance characteristics in different zones. The conductor has lower resistance in peripheral areas and higher resistance in the center, creating localized heat distribution patterns that result in homogeneous overall heat generation across the ceramic substrate surface
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
The solution provides a scoop-proof, moisture-resistant, and high-electric-strength heating module with homogeneous heat generation, reducing design complexity and ensuring the operational safety of electrical components by effectively dissipating heat and monitoring temperature for redundancy and safety.
Implementation Method 1
an electrical resistance heating element (22) which is arranged on the ceramic substrate, in the heating zone (16) thereof, and which is embodied as a resistance heating conductor (24)
Implementation Method 2
an electrically insulating, heat conducting ceramic substrate (14) which has a heating zone (16) and a control zone (18) which are spaced apart from one another
Implementation Method 3
a first cooling element (42) which is thermally coupled to the heating zone (16) of the ceramic substrate (14)
Data Source
AI summary
The electric heating system, in particular for a hybrid vehicle or electric vehicle, is provided with a heating module. The heating module is provided with an electrically insulating, heat conducting ceramic substrate which has a heating zone and a control zone which are spaced apart from one another. The heating module comprises an electrical resistance heating element which is arranged on the ceramic substrate, in the heating zone thereof, and which is embodied as a resistance heating conductor which is mounted on the ceramic substrate. Further, the heating module comprises a transistor for controlling the current through the resistance heating conductor, wherein the transistor and other optionally present electrical components and conductor tracks are arranged in the control zone on the ceramic substrate. The heating module is provided with a first cooling element which is thermally coupled to the heating zone of the ceramic substrate.