Heat dissipator, associated heating module and assembly method therefor
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Solution Overview
Problem
Existing electric heating devices for motor vehicles are costly and complex due to their multi-component structure, which includes separate resistive elements, electrodes, and heat sinks, requiring multiple materials and intricate assembly processes.
Innovation Solution
A simplified electric heating device design featuring a unitary heat sink block that serves as both a heat exchanger and a support for the heating elements, eliminating the need for separate heat sinks and support frames, and integrating resistive elements and electrodes directly within the heat sink housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate heating elements, electrodes, and heat sinks are used, then heating function is achieved, but manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The patent combines the heat sink and support frame into a single integrated component. The support frame includes support surfaces that directly contact the heating elements, eliminating the need for separate heat sink and frame components. This merging reduces the number of parts, simplifies assembly, and lowers manufacturing costs while maintaining the heating function.
Solution Approach 2:
The support frame is designed to serve multiple functions simultaneously: it provides structural support for the heating elements, acts as a heat dissipation path, and serves as a mounting structure for the housing. This multi-functionality eliminates the need for separate dedicated heat sink components while achieving both support and thermal management objectives.
2Reliability
If multiple components (resistive elements, electrodes, heat sinks, support frames) are used, then heating performance is achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the heat sink and support frame into one integrated component, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This consolidation directly reduces manufacturing costs while maintaining all necessary heating and support functions through the integrated design.
3Temperature
If separate heat sinks are provided for each row of heating elements, then heat transfer efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The integrated support frame serves as a common heat dissipation structure for all heating elements. The support surfaces are thermally conductive and provide heat transfer pathways for all heating elements simultaneously, eliminating the need for individual heat sinks for each row while maintaining effective heat transfer to the housing and surrounding air.
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 reduces manufacturing costs, simplifies assembly, and automates the process, while maintaining effective heat transfer to the air flow, thereby improving thermal comfort in vehicle compartments.
Implementation Method 1
a heating bar comprising resistive elements, for example with a positive temperature coefficient (PTC)
Implementation Method 2
The heat sink function performed by the corrugated tape consists of exchanging the heat produced by the PTC effect resistive elements with the air flow
Data Source
Figure 1~8
Figure 3~4f
Figure 5~7
AI summary
The invention relates to a heat sink of a heating module (3) for an electric heating device (1) for heating an air flow, said heating module (3) comprising at least one heating element (5). The heat sink (7) is designed to be passed through by the air flow and to transmit the heat from the heating element (5) to the air flow to be heated. According to the invention, the heat sink (7) is a single block having at least one housing (9) for receiving at least one heating element (5), said housing (9) having at least one opening in a face of the sink that is intended to be in contact with the air flow. The invention also relates to a heating module (3) comprising at least one heating element (5) and such a heat sink (7). The invention also relates to a method for assembling such a heating module (3).