Four-Zone PTC Electric Heater Using Overlapping Radiating Layers
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Solution Overview
Problem
Existing air-conditioning units in electric vehicles are limited to single-zone or dual-zone configurations using high-voltage electric heaters, which are not feasible for providing more than two zones without increasing component count, size, cost, and complexity.
Innovation Solution
A single, integrated high-voltage PTC electric heater with two superimposed radiating layers, each with independently controllable heating zones, where the thermal power generation is imbalanced between sections, allowing for four separate thermal zones by controlling each layer and sector independently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two separate dual-zone heaters are used to provide more than two zones, then the number of controllable thermal zones increases, but the component count, dimensions, costs and installation complexity double
Solution Approach 1:
The patent merges two separate dual-zone heaters into a single integrated heater component. The first and second radiating layers are combined in one device, with each layer having two sectors that can be independently controlled. This integration reduces component count while maintaining the capability to provide multiple controllable thermal zones through the four independent heating regions (two layers × two sectors each).
Solution Approach 2:
The single heater is segmented into four independently controllable heating regions through the combination of two radiating layers and two sectors per layer. Each sector can be controlled separately via the control circuitry, enabling multi-zone temperature control without requiring multiple separate heater units. This segmentation allows flexible thermal zone configuration while keeping the overall device compact.
2Ease of manufacture
If heating rods have uniform thermal power distribution, then manufacturing is simpler, but the heater cannot provide differentiated thermal output in different sections
Solution Approach 1:
The heating rods are designed with non-uniform thermal power distribution, where different sections of the same heating rod generate different amounts of heat. This local quality variation allows the heater to provide differentiated thermal output in different sections, enabling more flexible temperature control across the heating area while maintaining a single integrated structure.
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
Enables the creation of multi-zone air-conditioning units with reduced component count, smaller dimensions, lower costs, and improved serviceability by integrating two radiating bodies into a single component with parallel control.
Implementation Method 1
Each heating rod (15, 15') comprises a string of positive temperature coefficient (PTC) elements or thermistors connected in parallel
Implementation Method 2
Each heating rod (15, 15') comprises a string of positive temperature coefficient (PTC) elements or thermistors connected in parallel
Data Source
Figure 1~2
Figure 3~4
AI summary
Electric PTC heater for a vehicle, comprising a support part (101) and control circuitry (102), and a first and a second radiating layer (110, 120) that overlap one another, each radiating layer (110, 120) comprising a plurality of heating rods (115, 115'; 125, 125') extending from the support part (101) and connected in parallel with the control circuitry (102). Each radiating layer (110, 120) comprises a first layer sector (A1, C1; A2, C2) and a second layer sector (B1, Dl; B2, D2) that can be controlled independently of one another. The radiating layers (110, 120) can be controlled independently of one another. In the first radiating layer (110), the second section (115b, 115b') of the heating rods (115, 115') is capable of generating greater thermal power than the first section (115a, 115a') of the heating rods (115, 115') and, in the second radiating layer (120), the first section (125a, 125a') of the heating rods (125, 125') is capable of generating greater thermal power than the second section (125b, 125b') of the heating rods (125, 125').