Electric heating device and PTC heating element for such
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Solution Overview
Problem
Existing electric heating devices with PTC heating elements for motor vehicles are bulky, complex, and inefficient in heat dissipation, requiring cost-effective and lightweight designs that facilitate direct and symmetrical heat dissipation.
Innovation Solution
An electric heating device with a PTC heating element featuring a partition wall that forms a fluidically tight seal, using a plug connection with a frictionally engaged and positive fit to secure the PTC heating element, and an elastomeric sealing collar for effective heat dissipation and vibration resistance, allowing for efficient heat transfer and manufacturing simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the contact plate is overmolded with insulation layer during production, then production is simplified, but the heating device becomes bulky and complex
Solution Approach 1:
The patent merges the contact plate and insulation layer into a single integrated component by overmolding the insulation layer directly onto the contact plate during production. This eliminates the need for separate assembly steps and reduces the number of individual parts, thereby simplifying production while avoiding increased structural complexity.
Solution Approach 2:
The integrated contact plate with overmolded insulation layer serves multiple functions simultaneously: electrical contact, insulation, and structural support. This multi-functionality reduces the need for additional components, simplifying both production and the overall device structure.
2Ease of manufacture
If traditional heating element design is used, then manufacturing is straightforward, but heat dissipation is inadequate and efficiency is poor
Solution Approach 1:
The patent introduces a three-dimensional heat dissipation structure with heat dissipation fins extending from the heating element casing. This adds a vertical dimension to heat dissipation, increasing the surface area available for heat transfer from the PTC element to the surrounding air, thereby improving heat dissipation efficiency without complicating the manufacturing process.
Solution Approach 2:
The heating element casing is designed with localized heat dissipation features including fins and air channels in specific regions where heat needs to be dissipated most effectively. This local optimization of heat dissipation quality improves overall efficiency while maintaining simple manufacturing of the basic structure.
3Weight of moving object
If lightweight materials are used to reduce weight, then the device becomes lighter, but heat decoupling of PTC element becomes insufficient
Solution Approach 1:
The patent employs composite material construction with the heating element casing made from thermally insulating materials that provide both lightweight properties and effective heat decoupling. The casing may incorporate materials with low thermal conductivity to prevent heat transfer to surrounding components while maintaining reduced weight compared to traditional metal constructions.
Solution Approach 2:
The heating element casing acts as an intermediary thermal barrier between the PTC element and the external environment. This intermediary structure provides heat decoupling functionality while being designed with optimized thickness and material properties to achieve both weight reduction and effective thermal insulation.
4Ease of manufacture
If PTC elements are secured with simple mounting, then assembly is easy, but the device cannot withstand high vibrations in motor vehicles
Solution Approach 1:
The patent incorporates vibration damping elements and flexible mounting structures that allow the PTC element to be securely held while accommodating vibrational movements. The mounting system includes compliant features that maintain electrical contact and mechanical security under dynamic vibration conditions without requiring complex assembly procedures.
Solution Approach 2:
The heating element casing includes pre-designed vibration isolation features and cushioning elements positioned at critical mounting points. These features are built into the casing structure before assembly, providing inherent vibration resistance that protects the PTC element and maintains reliability under motor vehicle vibration conditions while keeping assembly simple.
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 enables efficient heat dissipation, reduces manufacturing costs, and ensures the heating device remains secure and functional under high vibrations, addressing the inefficiencies and bulkiness of previous designs.
Implementation Method 1
PTC heating elements which are increasingly used in motor vehicles, in particular in the field of electric mobility
Implementation Method 2
sealing sleeves made of Teflon with a labyrinth seal provided on the outer peripheral surface are drawn the connection ports
Implementation Method 3
good heat decoupling of the heat generated by the PTC element is desired, since the PTC elements have self-regulating properties and can only be operated with poor efficiency if the heat generated by the PTC element is removed only inadequately
Data Source
AI summary
An electric heating device has several PTC heating elements that are arranged in a circulation chamber. The electric heating device includes a heating element casing which fits as a structural unit at least one PTC element and contact plates that energize said PTC element and form contact strips for an electrical plug connection. A partition wall separates the circulation chamber from a connection chamber in which the contact strips of the PTC heating element penetrating the partition wall are exposed and are electrically connected. A plug connection is formed between the partition wall and the PTC heating element and via which the PTC heating element is held in a frictionally engaged and/or in positive fit manner on the partition wall in the direction of insertion.