Heating device for vehicle
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Solution Overview
Problem
Conventional high-voltage PTC heaters for vehicles suffer from high thermal resistance, low efficiency, increased weight, and package size due to silicon bonding, and lack uniform temperature control across the heating area, with asymmetric PTC element arrangements leading to unbalanced temperature differences and higher manufacturing costs.
Innovation Solution
A heating device comprising a film heating unit with a heating element insulated by films on both sides and a heat dissipation unit with brazed plates and fins, where the film and heat dissipation unit are laminated, and a bonding layer made of silicon, allowing for independent temperature control and high voltage operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If silicon bonding is used to adhere PTC elements and heat dissipation structure, then assembly is achieved, but thermal resistance significantly increases and efficiency decreases
Solution Approach 1:
The patent removes the silicon bonding layer from the thermal conduction path between PTC elements and heat dissipation structure. By eliminating this high thermal resistance interface, the system achieves direct thermal contact while maintaining assembly capability through alternative bonding methods that do not impede heat flow.
Solution Approach 2:
The patent changes the bonding interface properties by using materials and methods that provide both mechanical adhesion and thermal conduction. This involves selecting bonding agents with low thermal resistance and optimizing contact pressure and surface roughness to minimize thermal interface resistance while maintaining assembly integrity.
2Reliability
If conventional PTC heater structure is used, then heating function is achieved, but weight and package size are increased
Solution Approach 1:
The patent employs thin-film heating elements and flexible substrate structures that maintain effective heating functionality while significantly reducing the overall weight and package size of the heater assembly. The thin-film approach allows for compact integration without compromising thermal output.
Solution Approach 2:
The patent integrates multiple functional components into a nested configuration where heating elements, heat dissipation structures, and support components are layered and compacted together. This nested arrangement minimizes the overall package volume and weight while ensuring all necessary heating functions are preserved.
3Ease of operation
If asymmetric arrangement of PTC elements is used, then temperature control is achieved, but unbalanced temperature difference control occurs
Solution Approach 1:
The patent deliberately employs asymmetric arrangement of PTC elements to achieve differentiated temperature control across the heating surface. This asymmetric configuration allows independent temperature regulation in different zones, enabling applications requiring non-uniform heating patterns while maintaining precise control through separate circuitry for each zone.
4Ease of operation
If multiple types of PTC elements with different Curie points are used, then independent temperature control is achieved, but manufacturing cost increases
Solution Approach 1:
The patent uses a single type of PTC element that serves multiple temperature control functions through electronic control strategies. By implementing independent circuitry and control algorithms for different zones, the system achieves multi-temperature-zone control capability without requiring multiple types of PTC elements with different Curie points, thereby reducing manufacturing costs while maintaining independent temperature control functionality.
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 enhances heat transfer efficiency, reduces weight and package size, achieves uniform temperature across the heating area, and enables independent temperature control, while maintaining high stability and durability.
Implementation Method 1
the heating element (120) has a predetermined pattern, and generates heat by electrical resistance when power is applied
Implementation Method 2
the film (110) is in a thin sheet form with a small thickness and is made of an insulator
Implementation Method 3
a heating device for a vehicle which is installed in an air passage of an air conditioner for a vehicle and exchanges heat with air passing therethrough to heat the air
Data Source
AI summary
Disclosed is a heating device for a vehicle, enabling substantially increased heat transfer efficiency, excellent rapid heating, and reduced weight and package. The heating device for a vehicle comprises: a film heating unit comprising a heating element, and a film covering both sides of the heating element in the thickness direction; and a heat dissipation unit comprising a pair of plates spaced in the thickness direction, and a heat-dissipating fin interposed between the pair of plates, wherein the film heating unit and the heat dissipation unit are sequentially laminated by attaching the plates to the film.