Controller for an electric heating device and method for producing same
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Solution Overview
Problem
Existing controllers for electric heating devices in motor vehicles face challenges with thermal conduction efficiency, complexity, and cost due to long thermal conduction distances and reliance on a single busbar, which can lead to overheating and safety issues from contact resistances and power flow limitations.
Innovation Solution
A controller design featuring a stamped metal plate with separated supply and discharge elements, connected only through an SMD component, providing improved thermal conduction and power flow transmission without a separate heat sink, using a thermally conductive material like copper or aluminum and a high-grade thermoplastic support element for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single busbar is used for power transmission, then the device complexity is reduced, but the thermal conduction distance becomes long and power flow capacity is limited
Solution Approach 1:
The single busbar is segmented into multiple busbar sections (first busbar section, second busbar section, third busbar section) that are arranged in parallel. This segmentation reduces the thermal conduction distance for each section while maintaining overall power transmission capability, and allows for better heat dissipation distribution across multiple contact points with the heat sink.
2Ease of manufacture
If a single busbar is used for power transmission, then the manufacturing is simplified, but the power flow transmission capacity is limited
Solution Approach 1:
The power transmission path is divided into multiple parallel busbar sections, each carrying a portion of the total power flow. This increases the overall power transmission capacity while maintaining manufacturing simplicity through modular assembly of standardized busbar components.
Solution Approach 2:
Multiple busbar sections are combined in parallel configuration, merging their individual power transmission capabilities to achieve higher total power flow capacity. The busbars are electrically connected through the semiconductor switch and thermally connected to the heat sink, creating a combined power transmission system.
3Device complexity
If contact resistances exist in the conductive track, then the device structure is simplified, but local heating occurs leading to alloying and safety issues
Solution Approach 1:
The conductive track is segmented into multiple parallel paths through the busbar sections, distributing the current flow and reducing current density at any single contact point. This minimizes resistive heating and the risk of alloying while maintaining a relatively simple device structure.
Solution Approach 2:
The heat sink acts as an intermediary thermal management component, providing dedicated thermal contact points for each busbar section. This intermediary structure efficiently conducts heat away from the power transmission paths, preventing local overheating and alloying issues.
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 design enhances thermal conduction efficiency, reduces production complexity and costs, and ensures safe power transmission by creating two busbars from a single metal plate, effectively managing high power flows and preventing overheating, while maintaining mechanical integrity and safety standards.
Implementation Method 1
the thermal conduction distance up to the cooling ribs is relatively long
Implementation Method 2
the busbar is part of an initially single-part stamped metal plate... connected to an SMD component in an electrically conductive manner
Implementation Method 3
The SMD component usually is a power semiconductor switch producing power loss. This power loss needs to be continuously discharged.
Data Source
AI summary
A controller for an electric heating device comprising a support element and a busbar which is secured on the support element and which is connected to an SMD component in an electrically conductive manner. The busbar is part of an initially single-part stamped metal plate with a severed connecting piece, which separates the metal plate into a supply element and a discharge element, the elements being connected together in an electrically conductive manner solely via the SMD component. Also disclosed is a method of producing an electric heating device generally as described above such that the supply element and the discharge element are produced from the supply element region and the discharge element region on the stamped metal plate, respectively.