Vehicle Heating Module With Integrated Power Electronics
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Solution Overview
Problem
Conventional heating modules for vehicle interiors with PTC heating elements face challenges in mechanical and electrical connection complexity, leading to inefficiencies and increased costs due to the need for complex plug and solder connections between the power electronics unit and PTC heating elements.
Innovation Solution
The solution involves arranging the power electronics unit and PTC heating elements on a metal support plate with an electrically insulating oxide ceramic layer and a conductive track, eliminating the need for complex connections and allowing for efficient heat dissipation, thereby simplifying the design and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex plug and solder connections are used to connect the power electronics unit to the PTC heating elements, then reliable electrical connection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the power electronics unit and PTC heating elements onto a single circuit board, eliminating the need for separate plug and solder connections. The board serves as both the mechanical support and the electrical connection medium, integrating multiple functions into one component.
Solution Approach 2:
The circuit board performs multiple functions: it provides mechanical support for both the power electronics unit and PTC heating elements, serves as an electrical conductor for power and signal transmission, and acts as a structural element of the heating module. This multi-functionality eliminates the need for separate connection components.
2Temperature
If additional components for heat dissipation are provided, then thermal management is improved, but device complexity and production cost increase
Solution Approach 1:
The circuit board serves dual purposes: electrical connection and heat dissipation. The same conductive traces and board structure that provide electrical pathways also function as thermal pathways to conduct waste heat away from the power electronics unit and PTC heating elements, eliminating the need for separate heat sinks or thermal management components.
Solution Approach 2:
The patent combines the electrical connection function and thermal management function into a single integrated structure (the circuit board), rather than using separate components for each function. This reduces the total number of parts while maintaining both electrical and thermal performance.
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 configuration provides an improved electrical and thermal connection, enhancing the heating module's efficiency and reducing manufacturing costs by eliminating the need for intricate connection methods and additional heat dissipation components.
Implementation Method 1
electrical heating modules based on so-called PTC heating elements. Such PTC heating elements also have an electrical resistance that increases with increasing temperature of the heating element
Implementation Method 2
the metal carrier plate can be used to transport waste heat generated by the PTC heating elements during operation
Implementation Method 3
an electrically insulating insulation layer, for example made of an oxide ceramic, provided on the metal carrier plate
Data Source
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AI summary
The invention relates to a heating module (1) for heating the vehicle interior of a motor vehicle, comprising at least one PTC heating element (2), which is arranged between a first and a second carrier plate (3, 4) each composed of a metal, wherein the first carrier plate (3) has an electrically insulating insulation layer (6) on a side (5) facing the at least one PTC heating element (2), on which insulation layer an electrical conducting track (7) is formed, which is electrically connected to the at least one PTC heating element (2), wherein a power electronics unit (8) electrically connected to the electrical conducting track (7) is present on the first carrier plate (3) in order to provide electrical heating power to the at least one PTC heating element (2).