PTC Heater Contact Strip Layout to Prevent PCB Hot Spots
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Solution Overview
Problem
Existing heating devices for motor vehicles often experience 'hot spots' at connections between heating elements and control circuits, leading to inefficiencies and potential damage, and require separate cooling systems for control devices.
Innovation Solution
A heating device design featuring a PTC heating element with a contact strip section on a printed circuit board, where the contact strip acts as both a connection and a cooling element, reducing hot spots and eliminating the need for separate cooling devices by utilizing the contact strip's entire length for cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heating element is connected to the control circuit using conventional connection methods, then the heating function is achieved, but hot spots occur at the connection points causing inefficiency and potential damage
Solution Approach 1:
The patent merges the connection function and cooling function into a single integrated contact strip structure. The contact strip serves both as an electrical connector between the heating element and control circuit, and as a heat dissipation pathway, eliminating the need for separate cooling components and preventing hot spots at connection points.
Solution Approach 2:
The contact strip is designed to perform multiple functions simultaneously: it provides electrical connection, serves as a heat sink for dissipating heat from the control circuit, and acts as a structural support element. This multi-functionality resolves the contradiction by making the connection structure itself capable of preventing hot spots.
2Temperature
If separate cooling systems are added to cool the control device, then the control circuit can be cooled, but the device complexity and assembly complexity increase
Solution Approach 1:
The cooling function is merged into the existing contact strip structure that is already part of the heating element assembly. By integrating the heat dissipation function into the connection structure, the patent eliminates the need for separate cooling systems, thereby reducing device complexity while still achieving effective cooling of the control circuit.
Solution Approach 2:
The contact strip serves itself by utilizing its inherent thermal conductivity to dissipate heat from the control circuit. The structure that is already present for electrical connection automatically provides cooling functionality, eliminating the need for additional dedicated cooling components and simplifying the overall system.
3Temperature
If separate cooling devices are used for the control device, then cooling is achieved, but the space required and assembly complexity increase
Solution Approach 1:
The cooling function is combined with the contact strip structure, eliminating the need for separate cooling devices that would occupy additional space. The contact strip utilizes its existing volume and structure to provide heat dissipation, thereby reducing the overall device volume while achieving effective cooling.
4Ease of manufacture
If conventional connection methods are used, then the heating element can be connected, but hot spots occur leading to potential damage and reduced reliability
Solution Approach 1:
The connection structure is merged with the cooling function, creating an integrated contact strip that provides both electrical connection and heat dissipation. This integration maintains ease of manufacture while significantly improving connection reliability by preventing hot spots through active cooling at the connection points.
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 enhances heat distribution, reduces assembly complexity, saves space, and allows for the use of standardized components, effectively addressing the inefficiencies and space constraints of previous designs while minimizing the risk of hot spots.
Implementation Method 1
the contact strip acts as both a connection and a cooling element, reducing hot spots and eliminating the need for separate cooling devices by utilizing the contact strip's entire length for cooling
Implementation Method 2
The heating elements are usually designed as electrical heating resistors, in particular as PTC elements (Positive Temperature Coefficient, P positive T temperature C oefficent) trained
Data Source
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AI summary
The invention relates to a heating device, in particular for a motor vehicle, having at least one heating element (12) for heating air and a control device (22) which has a control circuit (24) arranged on a printed circuit board (20) for activating the at least one heating element (12). has, wherein the at least one heating element (12) has lamellae (14) and a contact strip (16), wherein a contact strip section (30) is arranged on the printed circuit board (20) of the control circuit (24) and a connection between the at least one heating element ( 12) and the control circuit (24).