PTC Heating Module Contact Socket Layout for Creepage Distance
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Solution Overview
Problem
Conventional PTC heating modules for electric and hybrid vehicles face challenges in maintaining creepage and clearance distances as voltage increases, leading to reduced output due to the low heat conductivity of ceramic resistors, which results in increased thermistor thickness and potential overheating.
Innovation Solution
The PTC heating module design includes contact sockets with adjustable thickness and surface areas to maintain adequate creepage and clearance distances independently of thermistor thickness, allowing for effective heat dissipation and increased output by using heat- and electrically conducting materials for the contact plates and sockets, and an optional electrically conducting coating to reduce contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the PTC thermistor is increased to maintain creepage and clearance distances for higher voltages, then the electrical insulation and safety are improved, but the heat dissipation capability deteriorates due to low heat conductivity of ceramic resistors
Solution Approach 1:
The patent introduces contact sockets as intermediate components that segment the direct contact path between contact plates and the PTC thermistor. This segmentation allows the creepage and clearance distances to be distributed across multiple components (contact socket thickness + thermistor thickness) rather than relying solely on increased thermistor thickness, thereby maintaining electrical insulation without compromising heat dissipation.
Solution Approach 2:
The contact sockets serve as intermediary elements between the contact plates and the PTC thermistor. These sockets provide the necessary creepage and clearance distances while maintaining thermal contact with the thermistor through their contact surfaces, thus acting as a mediator that satisfies both electrical insulation requirements and heat dissipation needs.
2Reliability
If the thickness of the PTC thermistor is increased to maintain creepage and clearance distances, then the electrical insulation is improved, but the output of the heating module decreases due to reduced heat dissipation
Solution Approach 1:
By segmenting the insulation function across contact sockets and thermistors, the patent enables the thermistor thickness to remain optimized for heat dissipation while the contact sockets provide the additional distance needed for electrical insulation, thus maintaining heating output.
Solution Approach 2:
The contact sockets as intermediary components carry the burden of providing additional creepage and clearance distances, allowing the PTC thermistor to maintain its optimal thickness for heat generation and dissipation, thereby preserving the heating module's output.
3Reliability
If the distance between contact electrodes is increased to maintain clearance distances for higher voltages, then the safety is improved, but the geometric contact surface area decreases leading to higher contact resistance
Solution Approach 1:
The patent segments the electrical contact path into multiple contact interfaces (contact plate to contact socket, contact socket to thermistor). This segmentation allows the total creepage and clearance distance to be distributed across these interfaces while maintaining adequate contact surface areas at each interface, thus balancing safety requirements with low contact resistance.
Solution Approach 2:
The contact sockets are designed with specific contact surface geometries that ensure adequate local contact quality. The contact surfaces are dimensioned to provide both the necessary creepage and clearance distances and sufficient contact area for low contact resistance, applying local quality optimization at the contact interfaces.
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 design allows for adaptable creepage and clearance distances and enhanced heat dissipation, preventing overheating and increasing the output of the PTC heating module, ensuring safe operation across varying voltages without the need for increased thermistor thickness.
Implementation Method 1
PTC: positive temperature coefficient... The resistors have a temperature-dependent electric resistance, which increases as the temperature increases. As a result, independently of marginal conditions such as voltage or nominal resistance, the temperature developing at the PTC thermistor is a temperature which varies very little.
Implementation Method 2
the electrical insulation is heat-conducting in order to dissipate the heat right through the insulation... the contact plates and the at least one contact socket in the PTC heating module according to the invention are both heat- and electrically conducting, so that the specified voltage can be applied to the respective PTC thermistor through the contact plates and the at least one contact socket, and the heat generated in the respective PTC thermistor can be effectively dissipated to outside.
Data Source
Figure 1~5
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Figure 11~15
AI summary
The invention relates to a PTC heating module (1) for heating a fluid. The PTC heating module (1) comprises at least one PTC thermistor (2) with two main sides (3a, 3b) opposite each other, which are spaced apart and define a thermistor thickness (DPTC) of the PTC thermistor (2). The PTC heating module (1) further comprises two contact plates (4a, 4b), between which the respective PTC thermistor (2) is arranged and with which the PTC thermistor (2) is electrically contacted. According to the invention the PTC heating module (1) comprises at least one contact socket (5a, 5b) with a contact side (6a, 6b), the contact socket (5a, 5b) resting on one side electrically conductively with its contact side (6a, 6b) against the one main side (3a, 3b) of the respective PTC thermistor (2) and on the other side resting electrically conductively against the one contact plate (4a, 4b). Due to a thickness (DS,A, DS,B) of the at least one contact socket (5a, 5b) a distance between the one contact plate (4a, 4b) and the other contact plate (4a, 4b) is enlarged. A geometric contact surface (FK,A, FK,B) between the main side (3a, 3b) of the respective PTC thermistor (2) and the contact side (6a, 6b) of the at least one contact socket (5a, 5b) is also smaller than a geometric surface (FPTC) of the main side (3a, 3b) of the respective PTC thermistor (2). As a result a creapage and/or clearance distance (7a, 7b, 7c) in the PTC heating module (1) is larger than the thermistor thickness (DPTC) of the PTC thermistor (2).