Modular PTC Heater Frame Design for Scalable Heating Output
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Solution Overview
Problem
Existing electrical heating devices face challenges in achieving a compact design while maintaining high heating output, as the self-regulating properties of PTC elements reduce power output with increasing temperature, and conventional designs lead to inefficient heat transfer and flow resistance due to the arrangement of heat-generating elements and corrugated fins.
Innovation Solution
A modular frame design with interlocking elements that allows for a compact structure with layered corrugated fins and heat-generating elements, where the frame can accommodate multiple levels of corrugated fin elements offset in the flow direction, enhancing heat transfer through turbulent flow and reducing flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If heat-generating elements are arranged downstream of corrugated fin elements in the flow direction, then heating output is improved, but flow resistance increases
Solution Approach 1:
The patent transitions from a single-plane arrangement to a multi-level three-dimensional arrangement of corrugated fin elements. By stacking multiple levels of corrugated fins with heat-generating elements positioned between them, the design increases the effective heat exchange area without extending the flow path length, thereby improving heating output while maintaining acceptable flow resistance
Solution Approach 2:
The patent implements a nested structure where multiple levels of corrugated fin elements are stacked within the same flow passage space. Each level contains corrugated fins with heat-generating elements, and these levels are arranged one above another, creating a compact nested configuration that maximizes heat transfer surface area within the available volume
2Power
If multiple heating blocks are arranged one behind the other in the flow direction, then heating output is improved, but device length increases
Solution Approach 1:
The patent arranges multiple heating blocks in a multi-level vertical configuration rather than sequentially in the flow direction. By stacking heating blocks one above another with shared flow passages, the design achieves the heating output of multiple blocks while minimizing the length in the flow direction, effectively utilizing the vertical dimension to reduce overall device length
Solution Approach 2:
The patent merges multiple heating blocks into a single integrated structure where adjacent heating blocks share common flow passages and support structures. This consolidation allows multiple heating elements to operate simultaneously within a compact footprint, achieving high heating output without proportionally increasing device length
3Device complexity
If corrugated fin elements are arranged in a single plane, then device simplicity is maintained, but heat transfer efficiency is limited
Solution Approach 1:
The patent extends the single-plane arrangement into three-dimensional space by stacking multiple levels of corrugated fin elements vertically. This multi-level configuration increases the total heat exchange surface area and improves heat transfer efficiency while maintaining relatively simple individual component designs and assembly procedures
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 modular frame design increases heat transfer efficiency by at least 5% and allows for adaptable heating output without significant changes in components, enabling a scalable and economical electrical heating device with improved compactness and performance.
Implementation Method 1
the resistance of the PTC elements rises sharply with increasing temperature and heating power
Implementation Method 2
arranging two conventionally designed electrical heating devices one behind the other in the flow or passage direction of the medium to be heated
Implementation Method 3
a frame formed by the frame elements and the at least one intermediate frame element forms a receiving space that extends in the direction of passage of the medium to be heated and is adapted to receive a layered structure with several levels of corrugated fins and heat-generating elements
Data Source
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AI summary
The present invention relates to an electrical heating device with a frame (44) which forms openings (56) on opposite sides for the passage of a medium to be heated, and a layered structure (46) arranged in the frame (44) which has layers (L) of corrugated fins and heat-generating elements (66), wherein the heat-generating element (66) has at least one PTC element (80) arranged between parallel contact plates (82) and a frame (44) for this and is an electrical heating device with a indicate increased heating power, in particular a scalable electric heater, d. H. such a heating device that can be adapted to different heating outputs without great effort. To solve this problem, the electric heating device is inventively characterized in that the frame comprises two frame elements (48) forming the openings (56) and at least one intermediate frame element (190) arranged between them, which can be connected to one another via interlocking latching elements (50, 52) and that the elements forming the frame (44) are designed in such a way that a frame (44) formed solely by the frame elements (48) forms a receiving space (60) which extends in the direction of passage of the medium to be heated and which is used to receive a layered structure (46). adapted to a plane of corrugated fins and heat-generating elements (64, 66), and that a frame (44) formed by the frame elements (48) and the intermediate frame element (190) forms a receiving space (60) extending in the direction of passage of the medium to be heated , Which is used to accommodate a layer structure (46) with several levels (E) of corrugated ribs and nd heat-generating elements (64, 66) is adapted. The elements forming the frame (44) are designed in such a way that a frame (44) formed solely by the frame elements (48) forms a receiving space (60) extending in the direction of passage of the medium to be heated, which is used to receive a layered structure (46) with adapted to a plane of corrugated fins and heat-generating elements (64, 66), and that a frame (44) formed by the frame elements (48) and the intermediate frame element (190) forms a receiving space (60) extending in the direction of passage of the medium to be heated , which is adapted to accommodate a layered structure (46) with a plurality of levels (E) of corrugated fins and heat-generating elements (64, 66).