PTC Heater Grid Structure for Accurate Layer Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric heaters for vehicle air conditioning face challenges in simplifying production and ensuring proper installation of heat generating elements with standardized components, while maintaining effective thermal contact and shielding against foreign particles.
Innovation Solution
The electric heater features a planar heating block with parallel layers of heat-emitting and heat-generating elements, reinforced by a grid arrangement where first struts extend at right angles to the housing and second struts are defined by the heating block, providing shielding and support while allowing for easier installation and compensation of manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heating block is enclosed between frame openings and mounted in the housing, then the heating block is securely positioned, but the manufacturing precision and assembly complexity increase due to predetermined positioning requirements
Solution Approach 1:
The heating block is designed with an integrated grid arrangement where the struts themselves provide the positioning and support functions. The second struts extending parallel to the layers automatically define the position of the heating block elements, eliminating the need for separate positioning mechanisms and reducing assembly complexity while maintaining positioning accuracy.
Solution Approach 2:
The grid arrangement serves multiple functions simultaneously: it provides structural support, defines positioning, and shields the heating elements. The struts that extend at right angles to the layers also serve as positioning references for the heating block, combining support and positioning functions into a single structural element.
2Device complexity
If the grid arrangement is formed only by housing parts, then the housing structure is simplified, but the heating block lacks adequate shielding and positional definition
Solution Approach 1:
The grid arrangement is merged into the heating block structure itself. The second struts extending parallel to the layers are defined by the heating block, combining the shielding function with the positional definition function. This integration ensures that the heating block elements are properly positioned and shielded without requiring additional housing components.
Solution Approach 2:
The grid arrangement incorporates struts extending in two directions: first struts at right angles to the layers for support, and second struts parallel to the layers for shielding and positional definition. This two-dimensional grid structure provides comprehensive coverage and positioning in multiple dimensions.
3Ease of manufacture
If standardized components are used for the heating block layers, then manufacturing cost is reduced, but ensuring proper thermal contact and electrical connection becomes more difficult
Solution Approach 1:
The grid arrangement with its integrated struts automatically ensures proper positioning and contact between standardized heating block layers. The second struts defined by the heating block serve as built-in positioning references that guide the assembly of standardized components, ensuring consistent thermal and electrical contact without requiring complex alignment 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
This design simplifies production, ensures reliable thermal contact, and prevents short circuits by predefining the position of second struts, allowing for easier handling and installation of heat generating elements, while accommodating thermal expansions and external forces.
Implementation Method 1
The heat generating elements of the heating block normally comprise several PTC heating elements which are provided overlapping in one plane and are arranged between printed conductors which are normally formed by sheet metal bands. These printed conductors carry current with different polarities.
Implementation Method 2
The heat produced by the heat generating elements is dissipated through heat dissipating elements to the medium to be heated, i.e. the air.
Data Source
AI summary
An electric heater, comprises a heating block held in a housing and including parallel layers of heat-emitting and heat generating elements. A grid arrangement covers the respective frame apertures in the housing and reinforces the housing. First struts of the grid arrangement, extending at right angles with respect to the layers, are assigned to the housing, and second struts extending parallel with respect to the layers are defined by the heating block. Moreover, a heat generating element of an electric heater, comprises a position frame made of an insulating material and defining receptacles arranged side by side each for at least one PTC heating element. The receptacles are arranged between conductor paths against which the PTC heating elements are placed in an electrically conductive manner.