Overlapping PTC Heater Layout for Four-Zone EV Cabin Heating
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Solution Overview
Problem
Existing air-conditioning units in electric vehicles are limited to single-zone or dual-zone configurations using high-voltage electric heaters, which are not feasible for multi-zone systems without increasing component count, size, cost, and complexity.
Innovation Solution
A single high-voltage PTC heater with two overlapping radiating layers, each with independently controllable heating zones, allowing for balanced and inverted thermal power generation across sections to create four distinct zones, integrated into a single component for easier installation and reduced complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two separate dual-zone heaters are used to provide more than two zones, then the air-conditioning unit can achieve multi-zone control, but the number of components doubles, increasing dimensions, costs, and installation complexity
Solution Approach 1:
The patent merges two separate dual-zone heaters into a single integrated heater component. The heater includes a first radiating body with first and second heating zones, and a second radiating body with third and fourth heating zones, all integrated into one device. This consolidation reduces the number of components from two separate heaters to one, thereby reducing dimensions, costs, and installation complexity while maintaining multi-zone control capability.
Solution Approach 2:
The single heater is segmented into four independently controllable heating zones through two radiating bodies, each with two heating zones. The control circuitry can independently control each zone, enabling multi-zone air-conditioning functionality. This segmentation allows the system to achieve versatility without requiring multiple complete heater units.
2Adaptability or versatility
If two separate dual-zone heaters are used to provide more than two zones, then the air-conditioning unit can achieve multi-zone control, but dimensions and installation complexity increase
Solution Approach 1:
The patent merges two separate dual-zone heaters into a single integrated heater component. The heater includes a first radiating body with first and second heating zones, and a second radiating body with third and fourth heating zones, all integrated into one device. This consolidation reduces the number of components from two separate heaters to one, thereby reducing dimensions, costs, and installation complexity while maintaining multi-zone control capability.
Solution Approach 2:
The two radiating bodies are arranged in an overlapping configuration where they share common space and support structures. The first radiating body and second radiating body are positioned such that they overlap, allowing them to occupy less space than if they were completely separate. This nesting-like arrangement reduces the overall dimensions of the heater while maintaining four independently controllable heating zones.
3Adaptability or versatility
If two separate dual-zone heaters are used to provide more than two zones, then the air-conditioning unit can achieve multi-zone control, but costs and serviceability worsen
Solution Approach 1:
The patent merges two separate dual-zone heaters into a single integrated heater component. The heater includes a first radiating body with first and second heating zones, and a second radiating body with third and fourth heating zones, all integrated into one device. This consolidation reduces the number of components from two separate heaters to one, thereby reducing dimensions, costs, and installation complexity while maintaining multi-zone control capability.
Solution Approach 2:
The single heater integrates multiple functions into one component: it provides four independently controllable heating zones, houses a control circuitry capable of independent control of each zone, and includes a support structure that accommodates both radiating bodies. This multi-functionality reduces the need for multiple separate components, thereby improving serviceability and reducing costs.
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
Enables a multi-zone air-conditioning system with reduced dimensions, lower costs, and improved serviceability by integrating two independent heating zones into a single component, allowing for precise thermal control and efficient air distribution.
Implementation Method 1
each heating rod (115, 125) having a first section (115a, 125a) and a second section (115b, 125b), wherein each radiating layer (110, 120) comprises a first layer sector (A1, B1, A2, B2) and a second layer sector (C1, D1, C2, D2) that may be controlled independently of one another by means of the control circuitry (102)
Data Source
AI summary
A positive temperature coefficient electric heater for a vehicle includes a support part, a control circuitry, and a first and a second radiating layers overlapping one another, each radiating layer having a plurality of heating rods extending from the support part and connected in parallel to the control circuitry. Each radiating layer has a first layer sector and a second layer sector controlled independently of one another. The radiating layers may be controlled independently of one another. In the first radiating layer, the second section of the heating rods is capable of generating greater thermal power than the first section of the heating rods and, in the second radiating layer, the first section of the heating rods is capable of generating greater thermal power than the second section of the heating rods.