PTC Heater Frame With Offset Corrugated Ribs for Better Heat Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical heating devices with PTC elements face reduced heating power due to increased resistance with temperature, and their compact design is compromised by the arrangement of heat generating elements, leading to reduced effectiveness and increased flow resistance.
Innovation Solution
The electrical heating device features a frame with corrugated-rib elements arranged offset in the same layer, creating a turbulent flow that enhances thermal transfer, and a modular frame design allowing for scalable heating power without significant changes in components, ensuring efficient heat exchange and compact construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heat generating elements are arranged offset in the passage direction, then the heating effectiveness is improved, but the flow resistance increases
Solution Approach 1:
The patent transitions from arranging heating elements in a single plane to a three-dimensional offset arrangement where corrugated-rib elements are positioned at different longitudinal positions (front, middle, rear) relative to the heat generating elements. This spatial dimensionality change allows the medium to access multiple heating zones sequentially, improving heating effectiveness while maintaining flow paths that avoid excessive resistance.
2Power
If multiple heating blocks are arranged one behind the other, then the heating power is increased, but the device compactness is compromised
Solution Approach 1:
The patent merges multiple heating blocks into a single integrated structure where corrugated-rib elements and heat generating elements are combined within one housing. The offset arrangement of corrugated-rib elements at different positions allows multiple heating zones to occupy overlapping spatial volumes, achieving increased heating power while maintaining compact device dimensions.
3Ease of manufacture
If corrugated-rib elements are arranged in a single layer, then the manufacturing is simplified, but the thermal transfer efficiency is reduced
Solution Approach 1:
The patent introduces a longitudinal dimension to the corrugated-rib element arrangement by positioning them at different distances from the heat generating elements (front, middle, rear positions). This creates multiple thermal transfer paths through the medium as it flows past the offset corrugated structures, significantly enhancing heat exchange efficiency while maintaining a relatively simple single-layer construction that does not require complex multi-layer stacking.
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 configuration increases thermal conduction by at least 5% and allows for adaptable heating power without altering the device's compactness, improving both thermal transfer and manufacturing efficiency.
Implementation Method 1
The heat generating element here comprises at least one PTC element arranged between parallel contact plates
Implementation Method 2
the corrugated ribs of the elements are offset to one another in their longitudinal extension... A turbulent flow is produced on the transition between the two corrugated-rib elements provided offset
Implementation Method 3
which leads to an improved thermal transfer from the corrugated ribs to the medium to be heated
Data Source
AI summary
An electrical heating device includes a frame and a layer structure arranged in the frame and comprising layers of corrugated ribs and PTC-based heat generating elements. The electrical heating device includes at least two corrugated-rib elements. The frame has two frame elements forming openings and at least one frame intermediate element arranged between them. A frame, formed solely by the frame elements, forms an accommodation space extending in the passage direction of the medium to be heated, which is appropriately formed for the accommodation of a layer structure with a level of corrugated ribs and heat generating elements. A frame, formed by the frame elements and the frame intermediate element, forms an accommodation space extending in the passage direction of the medium to be heated, which is formed for the accommodation of a layer structure with several levels of corrugated ribs and heat generating elements.