Ceramic PTC Heating Element Housing for Thermal Management
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Solution Overview
Problem
Existing PTC heating elements in the motor vehicle industry are space-consuming, complex, and inefficient in heat dissipation, requiring lighter and more economical designs that can effectively extract heat generated by PTC elements.
Innovation Solution
A PTC heating element with a housing formed from two ceramic housing elements that directly contact each other, forming a sealed unit with the PTC element and conductor tracks, using ceramic laser welding for sealing and thermal conductivity, and incorporating contact tongues for electrical connection, which are designed to be lightweight and efficient in heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional PTC heating elements are designed with separate housing components and multiple sealing elements, then reliability is improved, but device complexity and weight increase
Solution Approach 1:
The patent merges the housing and counter-element into a single integrated housing structure formed by ceramic laser welding. This integration eliminates the need for separate sealing elements and multiple housing components, reducing structural complexity while maintaining sealing reliability through the continuous ceramic material structure.
Solution Approach 2:
The patent employs ceramic laser welding to join housing components, creating a composite structure with enhanced thermal conductivity and sealing properties. The ceramic material provides both structural integrity and thermal management capabilities, reducing the need for additional sealing components.
2Strength
If traditional PTC heating elements use heavy metal housing components, then structural strength is improved, but weight increases
Solution Approach 1:
The patent changes the material parameter from traditional metal to ceramic housing elements. Ceramic materials provide sufficient structural strength for the housing while significantly reducing weight compared to metal alternatives, achieving weight optimization without compromising structural integrity.
Solution Approach 2:
The patent uses ceramic materials for the housing and counter-element, creating a lightweight yet strong composite structure. The ceramic material's high strength-to-weight ratio enables weight reduction while maintaining the necessary mechanical strength for housing the PTC element and conducting heat.
3Ease of manufacture
If PTC heating elements are designed with poor heat dissipation structures, then manufacturing simplicity is improved, but thermal efficiency deteriorates
Solution Approach 1:
The patent integrates heat dissipation functionality into the housing structure itself through the ceramic material's thermal conductivity. The housing and counter-element serve dual purposes as both structural enclosures and heat dissipation pathways, eliminating the need for separate heat sinks or fins while maintaining thermal efficiency.
Solution Approach 2:
The patent leverages the high thermal conductivity of ceramic materials to create an efficient heat dissipation system. The ceramic housing structure conducts heat away from the PTC element effectively, improving thermal efficiency without adding complex heat dissipation components that would increase manufacturing complexity.
4Ease of manufacture
If contact plates are snapped to positioning frames, then ease of assembly is improved, but contact pressure and electrical connection reliability worsen
Solution Approach 1:
The patent replaces the mechanical snap-fit connection system with a ceramic laser-welded joint. This substitution eliminates the need for separate fastening elements and provides more reliable electrical contact through the continuous ceramic material, while the modular housing design maintains ease of assembly through standardized welding processes.
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 lightweight, cost-effective PTC heating element with enhanced thermal conductivity and efficient heat extraction, ensuring reliable operation over long periods under alternating thermal loads.
Implementation Method 1
The heating element housing is formed from a housing element and a housing counter-element, wherein the housing element and the housing counter-element are joined by ceramic laser welding
Implementation Method 2
the housing element and the housing counter-element are joined by ceramic laser welding
Implementation Method 3
PTC heating elements are increasingly used in motor vehicles, especially in the field of electromobility
Data Source
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Figure 3
AI summary
The present invention relates to a PTC heating element (2) for an electric heating device, comprising a heating element housing (28) which integrates at least one PTC element (4) and contact tongues (16) supplying current to the PTC element (4) for the electrical connection of conductors electrically connected to the PTC element (4) as a single structural unit, and to an electric heating device with such a PTC heating element (2). A PTC heating element (2) according to the invention, which is weight-reduced and allows for good thermal coupling, is characterized in that the heating element housing (28) comprises a housing element (6) and a counter-housing element (12) made of ceramic, wherein the two housing elements (6, 12) abut each other in a sealing manner and enclose the PTC element (4) between them in a sealed manner and are projected by the contact tongues (16).