Honeycomb PTC Heater With Moisture-Absorbing Electrodes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heater elements for vehicle interiors are large in size, leading to space constraints, and prone to short circuits due to condensation water, which can splash and cause electrical issues and environmental contamination.
Innovation Solution
A heater element with a honeycomb structure covered by moisture absorbent-containing layers on the electrode surfaces and partition walls, designed to absorb moisture and prevent short circuits while enhancing air purification by adsorbing components like water vapor and CO2.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a heater element with honeycomb structure is used to increase heat transfer area, then heating efficiency is improved, but the risk of short circuits due to condensation water increases
Solution Approach 1:
The patent introduces a moisture absorbent layer as an intermediary substance between the honeycomb structure and the environment. This layer absorbs condensation water before it can reach the electrode layers, thereby preventing short circuits while maintaining the heating function of the honeycomb structure.
Solution Approach 2:
The moisture absorbent layer is positioned to preemptively counteract the harmful effect of condensation water. By absorbing moisture in advance, the system prevents the potential short circuit problem before it can occur, allowing the use of efficient honeycomb heating elements without reliability concerns.
2Volume of moving object
If the heater element size is reduced to save space, then vehicle interior space is improved, but the heat transfer area is reduced
Solution Approach 1:
The patent employs a honeycomb structure with high porosity, which provides a large surface area within a compact volume. The porous walls of the honeycomb cells allow for extensive heat transfer surfaces while maintaining a small overall heater element size, thus resolving the contradiction between compactness and heat transfer area.
3Object-affected harmful factors
If ventilation is increased to improve interior air quality, then air purification is improved, but heater energy loss increases
Solution Approach 1:
The heater element is designed to perform multiple functions: heating and air purification. The moisture absorbent layer not only prevents short circuits but also adsorbs harmful substances from the air, allowing the system to improve air quality without requiring separate ventilation systems that would cause energy loss.
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 design suppresses short circuits and condensation issues, providing effective heating and air purification, thus improving vehicle interior environments and reducing energy loss.
Implementation Method 1
moisture absorbent-containing layers on the electrode surfaces and partition walls, designed to absorb moisture
Implementation Method 2
adsorbing components like water vapor and CO2
Implementation Method 3
heater element that utilizes Joule heat
Data Source
AI summary
A heater element includes: a honeycomb structure portion capable of generating heat by energization, including an outer peripheral wall, and partition walls disposed on an inner peripheral side of the outer peripheral wall, the partition walls partitioning a plurality of cells that form flow paths extending from a first end surface to a second end surface, and the partition walls including a material having a PTC characteristic; a first electrode layer covering a part or all of a surface of the partition walls forming the first end surface; a second electrode layer covering a part or all of a surface of the partition walls forming the second end surface; a first moisture absorbent-containing layer covering a part of an outer surface of the first electrode layer; and a second moisture absorbent-containing layer covering a part of an outer surface of the second electrode layer.