PTC Heater Hook-Structure Heat Rod for Component Adhesion and Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The initial indoor heating performance of vehicle air-conditioners is degraded due to the delayed heating of the engine's heat exchange medium during vehicle startup, especially in winter, and existing PTC heaters face issues with mechanical stability and adhesion between components, leading to performance degradation.
Innovation Solution
A PTC heater design that mechanically fixes the heating element, terminal, insulating layer, and heat dissipation part using a heat rod with a hook structure and additional auxiliary fixing protrusions, enhancing adhesion and preventing height increase, thus improving assembly and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a PTC element is used as an auxiliary heater, then initial indoor heating performance is improved, but mechanical stability and adhesion between components deteriorate
Solution Approach 1:
The heat dissipation part is divided into multiple sections with fixing protrusions at different locations. Each fixing protrusion independently secures the PTC element at specific positions, distributing the mechanical constraint across multiple attachment points rather than relying on a single bonding interface.
Solution Approach 2:
The fixing protrusions are pre-formed on the heat dissipation part during manufacturing. When the PTC element is assembled, these protrusions automatically engage with corresponding positions on the PTC element, providing immediate mechanical fixation without requiring additional assembly steps or bonding operations.
2Reliability
If components are mechanically fixed using a heat rod with fixing protrusion, then adhesion between PTC element and heat dissipation part is improved, but height of heat rod increases
Solution Approach 1:
The fixing protrusions extend radially outward from the heat rod in the radial dimension rather than extending axially in the height dimension. This allows the fixing protrusions to engage with the PTC element in the radial direction while maintaining a compact axial height profile of the heat rod.
Solution Approach 2:
The fixing protrusions are integrated into the heat rod structure itself, with the protrusions forming as part of the heat rod body. This nested integration eliminates the need for separate fixing components and minimizes the overall height increase of the heat rod assembly.
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 design enhances the adhesion between the PTC element and heat dissipation part, improves assembly characteristics, and maintains a compact configuration, thereby improving the heating performance and space utilization in vehicle air-conditioners.
Implementation Method 1
a heating element 200 interposed in the insulating support 100 and generating heat by power
Implementation Method 2
The PTC element has a characteristic that resistance thereof is sharply increased when a temperature, which is rising, reaches a certain level
Implementation Method 3
a heat dissipation part 12 in contact with the heat source part 11 to dissipate heat generated by the heat source part 11
Implementation Method 4
heat of the heat dissipation part 12 may be effectively dissipated outwardly from the housing, and a temperature of air may be increased by the heat dissipation part 12 while air passes through the heat dissipation holes
Data Source
AI summary
The present invention relates to a PT heater and, more specifically, to a PTC heater which: mechanically fixes a heating element, a terminal, an insulating layer, and a heat-radiating unit, which constitute the PTC heater, by bending a fixing projection of a hook structure formed at a heat rod; and further has an auxiliary fixing protrusion capable of fixing the position of the heating element so as to increase the adhesiveness between the PTC element and the heat-radiating unit, thereby enabling performance to improve and facilitating assembly through the heat rod.