Heating Rod Ceramic Substrate Thin Film
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Solution Overview
Problem
Vehicular heaters face challenges with low thermal efficiency, durability issues due to external forces, and a decreasing ventilation area ratio, leading to increased energy inefficiency and potential short-circuits.
Innovation Solution
A heating rod with a ceramic substrate and a heat-radiating element, where the ratio of the heat-radiating element's thickness to the ceramic substrate's thickness is between 1:2 to 1:50, using materials like Al, zirconia toughened alumina, and metals like Mo, Ag, and Ti, with a convex shape for improved heat radiation and resistance adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a PTC thermistor is used in the heater, then the heating function is provided, but the thermal efficiency is low
Solution Approach 1:
The patent changes the material parameter from PTC thermistor to thin-film heating element deposited on ceramic substrate, achieving higher thermal efficiency while maintaining heating function through controlled film thickness and material composition
Solution Approach 2:
The patent uses composite structure combining ceramic substrate with thin-film heating material (such as metal oxide or metal layer), leveraging the high thermal stability of ceramic and the efficient heating properties of the thin film to resolve the contradiction between thermal efficiency and reliability
2Adaptability or versatility
If the ventilation area of the air conditioning system is decreased to accommodate smart devices, then the dashboard functionality is improved, but the energy efficiency of the heater becomes insufficient
Solution Approach 1:
The patent changes the heating element parameters (thin-film structure, controlled thickness, material composition) to achieve higher energy conversion efficiency, allowing the heater to maintain high performance even with reduced ventilation area
3Ease of manufacture
If the heater structure is simplified, then the manufacturing cost is reduced, but the durability against external forces and vehicle sway is low
Solution Approach 1:
The patent employs composite structure where thin-film heating element is deposited on ceramic substrate, which provides both mechanical strength and thermal stability. This composite approach maintains durability against external forces while keeping the overall structure simple and cost-effective
Solution Approach 2:
The patent uses thin-film heating elements that can flex and adapt to structural changes, providing durability against vehicle sway and external forces while maintaining heating efficiency and keeping manufacturing costs low
4Power
If the thickness of the heat-radiating element is increased, then the heating power is improved, but the risk of short-circuit increases
Solution Approach 1:
The patent optimizes the thickness parameter of the heat-radiating element to a specific range that balances heating power generation with electrical insulation requirements, preventing short-circuits while maintaining adequate heating performance
Solution Approach 2:
The patent uses composite structure with ceramic substrate providing electrical insulation and thermal stability, allowing the heat-radiating element to achieve sufficient heating power without increasing short-circuit risk due to the insulating ceramic barrier
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 radiation efficiency, reduces short-circuit defects, and provides a lightweight, eco-friendly heater with improved temperature gradients and pressure drop performance.
Implementation Method 1
a heating rod including a ceramic substrate and a heat-radiating element disposed in the ceramic substrate
Implementation Method 2
a heat-radiating element disposed in the ceramic substrate
Implementation Method 3
a heat-radiating module disposed in the case and including a heating rod
Data Source
AI summary
An embodiment discloses a heating rod comprising: a ceramic substrate; and a heat-radiating element that is arranged in the ceramic substrate, wherein the ratio of the thickness of the ceramic substrate to the thickness of the heat-radiating element is between 1:2 and 1:50. The embodiment discloses a heater comprising: a case; a heat-radiating module that is arranged inside the case; and a power module that is electrically connected to the heat-radiating module, wherein the power module includes a substrate part, a heat sink that is connected to the substrate part, and a ventilation part through which a fluid flows in and out to/from the heat sink.