Convective heating module

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional HVAC units in vehicles face challenges due to their size, complexity, and reliance on coolant lines and heater cores, which are costly and difficult to fit in limited packaging spaces, especially in electric and hybrid vehicles, and sensors are prone to damage and inaccurate measurements due to waste heat interference.

Innovation Solution

A convective heating module with a housing containing discrete portions for a printed circuit board assembly and heating element, separated by a channel, where sensors are located upstream of the heating element and downstream of the blower to measure ambient air accurately, protected from waste heat and damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional HVAC units with coolant lines and heater cores are used, then heating function is provided, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvemanufacturing complexityVSAvoidcoolant line complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the coolant lines and heater core from the HVAC system, replacing them with an electric heating element. This removal of complex liquid cooling components directly reduces manufacturing complexity and device complexity while maintaining the heating function through electrical resistance heating.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical liquid-based heating system (coolant circulation through heater core) with an electrical heating system. The electric heating element converts electrical energy directly to thermal energy, eliminating the need for mechanical pumps, coolant lines, and complex thermal exchange mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Power

If larger HVAC units are used to provide sufficient heating, then heating capability is improved, but packaging space requirements increase

Engineering Contradiction:

Improveheating capabilityVSAvoidpackaging space

Core Design Contradiction:

PowerVSArea of stationary object

Solution Approach 1:

The replacement of the bulky mechanical heater core with a compact electric heating element significantly reduces the space required to achieve the same heating capability. Electric heating elements have high power density and can be integrated into compact housings, allowing sufficient heating power in a minimal footprint suitable for modern vehicle packaging constraints.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If sensors are placed near heating elements for temperature control, then control accuracy is improved, but sensor reliability deteriorates due to waste heat

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidsensor reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent segments the HVAC housing into distinct portions: a first portion containing the heating element and a second portion containing the sensor. This spatial segmentation physically separates the sensor from the waste heat generated by the heating element, allowing the sensor to accurately measure ambient temperature without being influenced by thermal radiation or conduction from the heater, thereby maintaining both measurement precision and sensor reliability.

Inventive Principle:

Principle #1Segmentation

4Measurement precision

If sensors are exposed to ambient air for accurate measurement, then measurement accuracy is improved, but sensor vulnerability to damage increases

Engineering Contradiction:

Improveambient temperature measurementVSAvoidsensor damage risk

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces the housing structure as an intermediary between the sensor and the external environment. The sensor is positioned within the housing that provides protection from physical damage, moisture, and contaminants, while still allowing the sensor to exposure to ambient air through controlled openings or positioning for accurate temperature measurement. This intermediary structure reconciles the need for both protection and measurement accuracy.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 module provides efficient airflow for occupant heating or cooling, fits in compact spaces, and ensures accurate temperature sensing by isolating sensors from waste heat, reducing manufacturing complexity and assembly errors.

Implementation Method 1

a heating element in a second portion

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Implementation Method 2

a blower to move air from the first portion to the second portion

Methodology Applied

Scientific EffectForced convection: Forced Convection

Data Source

PatentUS20260008321A1Convective heating module

Publication Date: 2026.01.08 GENTHERM GMBH

AI summary

A heating module comprising a housing and a sensor. The housing comprises a first portion in which a printed circuit board assembly is located, a second portion in which a heating element is located, and a channel extending from the first portion toward the second portion. The sensor is connected to the printed circuit board assembly via a wire extending through the channel and is exposed at an end of the channel.