Closed-Housing PTC Load Resistor for Engine Warm-Up Heat Dissipation
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Solution Overview
Problem
Internal combustion engines face challenges with thermal expansion, wear, fuel condensation, and catalytic converter efficiency due to temperature variations, requiring effective heating solutions to optimize performance and reduce emissions.
Innovation Solution
An electrical load resistor with a closed housing containing PTC heating elements, where heat is absorbed and radiated externally through a well-conducting housing material, designed as a heat sink with exposed cooling fins, ensuring efficient heat dissipation and absorption without overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a closed housing with high thermal conductivity material is used to absorb and dissipate heat rapidly, then the heat absorption capacity and dissipation rate are improved, but the housing mass increases
Solution Approach 1:
The housing is divided into multiple receiving pockets, each containing PTC heating elements. The housing walls themselves serve as heat dissipation surfaces, segmented into multiple external surfaces that can radiate heat independently, increasing overall heat dissipation capacity without proportionally increasing mass
Solution Approach 2:
The invention utilizes the external surfaces of the housing walls as heat dissipation interfaces, adding a thermal radiation dimension to the heat dissipation process. By making the housing walls themselves the heat dissipation surfaces rather than relying solely on internal heat transfer media, the system achieves rapid heat absorption and dissipation with minimal mass addition
2Speed
If PTC heating elements are used to generate heat quickly, then the heating speed is improved, but the risk of overheating and damage increases
Solution Approach 1:
PTC (Positive Temperature Coefficient) heating elements inherently provide thermal feedback control. As the temperature increases, the electrical resistance of the PTC element automatically increases, reducing the current and heat generation. This self-regulating mechanism prevents overheating and damage while maintaining rapid heating capability
Solution Approach 2:
The PTC heating elements are self-regulating and do not require external temperature control systems. The material properties of PTC elements automatically adjust the heating output based on temperature conditions, providing built-in protection against overheating while maintaining efficient heating performance
3Loss of energy
If the housing is made highly thermally conductive for rapid heat dissipation, then the heat dissipation rate is improved, but the housing material selection and manufacturing complexity increase
Solution Approach 1:
The housing serves multiple functions simultaneously: it provides structural containment for the PTC heating elements, acts as a thermal management system through its heat-dissipating external surfaces, and serves as the outer casing of the device. By making the housing itself the heat dissipation component rather than adding separate heat sinks, the design simplifies manufacturing while achieving rapid heat dissipation
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 solution shortens engine start-up time, reduces wear, and improves fuel efficiency by rapidly reaching operating temperature, while preventing overheating and enhancing heat absorption and dissipation capabilities.
Implementation Method 1
a PTC heating element is received... The PTC heating element generally comprises several PTC elements, which are energized via the contact plate
Implementation Method 2
The heat generated by the PTC heating elements is therefore not transferred to a medium circulating through the housing, but rather absorbed by the housing, which is usually made of a highly thermally conductive material
Implementation Method 3
the heat generated by the PTC heating elements is radiated directly to the surroundings through the housing
Data Source
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AI summary
The present invention relates to an electrical load resistor with a housing having at least one U-shaped receiving pocket in which at least one PTC element is received. The housing comprises at least one PTC element and at least one contact plate electrically connected to the PTC element for supplying current to the PTC element. The contact plate has a terminal for plugging in the PTC element. The PTC heating element is thermally conductively in contact with at least opposite main side surfaces of the receiving pocket and projects beyond the terminal of the receiving pocket. To improve the heat absorption and heat dissipation capacity of the electrical load resistor, the housing of the electrical load resistor is closed and therefore has no inlet or outlet openings for a medium to be heated.In secondary aspects, the present invention discloses a device with an electrical load resistor for shortening the start-up time of an internal combustion engine, a method for shortening the start-up time of an internal combustion engine, and the use of a PTC heating device known per se as an electrical load resistor for shortening the start-up time of an internal combustion engine.