Printed PTC Heater Rods Without Pellet Frame Assembly
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Solution Overview
Problem
Existing heater rods for automotive applications are inefficient in manufacturing due to the need for individual PTC pellets and polymeric frames, which increases costs and complexity.
Innovation Solution
The use of a PTC heating resistor printed onto a substrate, such as a sheet metal or ceramic strip, eliminates the need for individual pellets and frames, allowing for multiple layers of resistors to be printed and deposited using methods like screen printing, with improved thermal contact through compression into a metal tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual PTC pellets are positioned on a strip of sheet metal by a polymeric frame, then the heater rod structure is maintained, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent merges the PTC heating elements into a continuous printed resistor layer directly on the substrate, eliminating the need for separate pellets and polymeric frames. This integration simplifies both manufacturing and structural complexity while maintaining the heating function.
Solution Approach 2:
The patent replaces the mechanical assembly of individual pellets held by a polymeric frame with a printed circuit board-style resistor layer created through printing and firing processes. This substitution eliminates complex mechanical positioning and assembly steps.
2Productivity
If a PTC heating resistor is printed onto a substrate, then manufacturing costs are reduced and process is simplified, but additional printing and firing steps are required
Solution Approach 1:
The patent enables continuous manufacturing by printing the PTC resistor layer directly onto the substrate in a continuous process, followed by firing to sinter the paste. This continuous approach eliminates the need for handling and positioning individual pellets, significantly improving productivity despite the added printing step.
3Adaptability or versatility
If multiple PTC heating resistor layers are printed on top of each other, then customizable heating power and resistance levels are achieved, but the number of printing and firing steps increases
Solution Approach 1:
The patent achieves customizable heating power and resistance by adding layers in the vertical dimension rather than varying parameters within a single layer. Multiple printed layers stacked on top of each other allow independent control of heating characteristics while maintaining a compact 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
This approach simplifies the manufacturing process, reduces costs, and enables the production of heater rods with customizable heating power and resistance levels, enhancing efficiency and flexibility.
Implementation Method 1
PTC heating resistor which is printed onto a substrate
Implementation Method 2
After such a printing step the substrate can be fired causing the newly printed layer to dry and to sinter
Implementation Method 3
The heater rods are attached to heat sinks for transferring heat to an air flow
Data Source
AI summary
Disclosed is a heater comprising a PTC heating resistor based on barium titanate. The PTC heating resistor is printed onto a substrate. Also disclosed is a method for manufacturing such a heater.