Electric PTC Heating Device With Resilient Tolerance Compensation
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Solution Overview
Problem
Existing electric heating devices face issues with manufacturing tolerances and dimensional fluctuations of PTC elements, leading to poor heat extraction and inefficient power current uptake due to stress peaks and insufficient coverage of heat extraction surfaces.
Innovation Solution
A tongue and groove connection between the PTC heating device and the receiving pocket, with a profile member providing tolerance compensation through resilient deformation, ensuring consistent heat extraction and secure fitting despite manufacturing variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a wedge-shaped pressure element is used to brace the PTC element in the receiving pocket, then good heat extraction is achieved, but stress peaks occur that can fracture the PTC element or ceramic insulating layer
Solution Approach 1:
The profile member is designed with a resilient section that can deform elastically to absorb and distribute the bracing forces. This cushioning effect prevents stress peaks from being transmitted directly to the PTC element and ceramic insulating layer, thereby preventing fractures while maintaining adequate heat extraction pressure
Solution Approach 2:
The profile member changes its physical state from rigid to resilient by incorporating a section made of elastomeric material or by designing a geometric configuration that provides elastic deformation capability. This parameter change allows the structure to adapt to manufacturing tolerances while distributing forces uniformly
2Strength
If the wedge element is made thicker to ensure adequate bracing, then stress peaks are reduced, but the free space before the wedge element is reduced, resulting in insufficient coverage of the heat extraction surface
Solution Approach 1:
The profile member transitions from a rigid structure to one with resilient properties, allowing it to deform and extend further into the receiving pocket without requiring increased thickness. This enables adequate heat extraction surface coverage while maintaining proper bracing forces through elastic deformation rather than geometric thickness
3Ease of manufacture
If the receiving pocket is designed with a conical tapering shape for production, then manufacturing is simplified, but manufacturing tolerances cause misalignment between the PTC element and receiving pocket, leading to poor heat extraction
Solution Approach 1:
The profile member incorporates a resilient section that can elastically deform to compensate for dimensional variations and misalignments caused by manufacturing tolerances. This allows the system to maintain proper contact and heat extraction despite variations in the conical receiving pocket geometry
Solution Approach 2:
The profile member transitions from a static rigid structure to a dynamic resilient structure that can adapt its shape and position in response to manufacturing variations. This dynamic capability allows the system to self-adjust and maintain optimal heat extraction contact despite tolerances in the conical receiving pocket
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 effectively compensates for manufacturing tolerances, maintaining efficient heat extraction and preventing stress peaks, thereby enhancing the performance and reliability of the PTC heating device.
Implementation Method 1
PTC heating device which comprises at least one PTC element and conductor tracks which are electrically connected in the connection chamber for energizing the PTC element
Implementation Method 2
A profile member is provided between the PTC heating device and an inner side of the receiving pocket and is connected to the receiving pocket by way of a tongue and groove connection which extends in a direction of insertion of the receiving pocket
Data Source
AI summary
An electric heating device comprises a housing with a partition wall which separates a connection chamber from a heating chamber for dissipating heat and from which at least one heating rib protrudes in the direction toward the heating chamber and forms a receiving pocket. A PTC heating device is received in the receiving pocket and includes at least one PTC element and conductor tracks which are electrically connected in the connection chamber for energizing the PTC element with different polarities and which are connected to PTC element r in an electrically conductive manner. A profile member is provided between the PTC heating device and an inner side of the receiving pocket and is connected to the receiving pocket by way of a tongue and groove connection which extends in the direction of insertion of the receiving pocket.