Electric heating device
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Solution Overview
Problem
Existing electric heating devices for motor vehicles are not lightweight and cost-effective, particularly for applications in electromobility where liquid heating is increasingly used, and they do not adequately address electromagnetic interference (EMI) concerns.
Innovation Solution
The design features a plastic housing with a shielding mechanism for EMI protection, incorporating a ground connection and a control chamber with a cross-linking plastic housing base that forms the circulation, connection, and control chambers, allowing for efficient grouping of PTC heating elements and electronic components, and optional metal shielding for further weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metal housing is used for the electric heating device, then electromagnetic shielding is effective, but the weight increases and manufacturing cost increases
Solution Approach 1:
The patent employs a composite housing structure combining plastic and metal components. The housing consists of a plastic base body with integrated metal shielding elements or coatings, creating a composite material solution that provides electromagnetic shielding effectiveness while maintaining lightweight characteristics and cost efficiency compared to pure metal housings.
2Object-affected harmful factors
If a pure metal housing is used, then electromagnetic shielding is effective, but manufacturing cost increases
Solution Approach 1:
The patent uses composite materials combining plastic and metal in the housing structure. This allows achieving electromagnetic shielding performance at lower manufacturing cost compared to pure metal housings, as plastic components can be manufactured via cost-effective injection molding and metal shielding can be added through simpler processes like coating or integrated thin metal layers.
Solution Approach 2:
The patent optimizes the shielding approach by changing parameters such as using thin metal layers, metal coatings, or strategically placed metal components rather than thick metal walls. This parameter optimization achieves adequate electromagnetic shielding at reduced material cost and manufacturing complexity.
3Object-affected harmful factors
If heating components and electronic components are arranged in separate chambers, then electromagnetic interference is reduced, but the device complexity increases
Solution Approach 1:
The patent divides the housing into functionally separated chambers: a first chamber for heating components (PTC elements, heating fins) and a second chamber for electronic components (control electronics, connectors). This segmentation is achieved through integrated plastic housing design with internal partitions, providing EMI reduction while maintaining manufacturing simplicity through one-piece or multi-piece plastic molding techniques.
4Weight of moving object
If a plastic housing is used, then weight is reduced and manufacturing cost is reduced, but electromagnetic shielding is insufficient
Solution Approach 1:
The patent combines plastic housing base body with integrated metal shielding elements. This composite approach maintains the weight and manufacturing cost advantages of plastic while adding electromagnetic shielding capability through metal coatings, thin metal layers, or strategically positioned metal components within the plastic housing structure.
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 results in a lightweight, cost-effective electric heating device with effective EMI protection, improved manufacturing simplicity, and enhanced thermal management, suitable for motor vehicle applications.
Implementation Method 1
The PTC element is electrically conductively contacted with electrical conductor tracks of different polarities... the heat generated by the PTC element is conducted outwards to the outer surface of the heating rib and given off there to the liquid medium to be heated
Implementation Method 2
a heat-emitting surface of a PTC heating element is exposed in the circulation chamber. This heat-emitting surface is thermally conductively coupled to a PTC element
Implementation Method 3
The plastic housing is further provided with a shield. This shielding essentially encloses the entire circumference of the housing in order to provide effective EMC protection for the electrical heating device
Data Source
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Figure 2
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AI summary
The present invention relates to an electrical heating device with a housing (2), which has inlet and outlet openings (10; 12) for the fluid to be heated and a circulation chamber (14) and a connection chamber (56 ) is formed, with a heat-emitting surface of a PTC heating element (40) being exposed in the circulation chamber (14), which is thermally conductively coupled (120) to a PTC element which is electrically conductively contacted with electrical conductor tracks (128) with different polarities, which are electrically connected in the connection chamber (56), which according to the invention can be produced easily and inexpensively in that the housing (2) is a plastic housing (50, 72, 80, 82) which is provided with a shield (110, 112). .