PTC Heater Power Tolerance Using Standardized Dual Elements
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Solution Overview
Problem
The existing electric heating systems for motor vehicles face challenges in maintaining consistent heating power due to manufacturing variations in PTC heating elements, leading to the need for storing large numbers of PTC heating elements with specific departure values, which is costly and inefficient.
Innovation Solution
The introduction of 'tolerance' PTC heating elements with a standardized lower rated heating power, which can be used in combination with primary PTC heating elements to compensate for manufacturing deviations, simplifying the manufacturing process and reducing storage needs by using only two standardized rated heating powers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If PTC heating elements with the same rated heating power are used exclusively, then the manufacturing process becomes simpler, but the actual heating power departs significantly from rated values due to manufacturing variations
Solution Approach 1:
The patent applies parameter changes by introducing a second parameter (heating power rating) in addition to the original single parameter approach. Instead of using only PTC elements with identical rated power, the invention combines PTC elements with different rated power values (first rated heating power and second rated heating power) to compensate for manufacturing variations and achieve consistent actual heating power output.
2Manufacturing precision
If PTC heating elements with compensating departures are combined, then the heating power tolerance limits are met, but the selection and storage effort increases significantly
Solution Approach 1:
The patent resolves this contradiction by changing the parameter approach from selecting individual elements with varying departures to using elements with standardized different rated power values. By combining PTC elements with first rated heating power and second rated heating power in specific configurations, the invention achieves tolerance compliance without requiring complex selection and storage of individually varied elements.
Solution Approach 2:
The invention applies universality by creating a standardized system where PTC elements with different rated powers serve multiple functions. The same types of PTC elements (with first or second rated heating power) can be used across different heating devices and configurations, reducing the need for specialized storage and selection of uniquely varied elements.
3Manufacturing precision
If large numbers of PTC heating elements with specific departure values are stored, then the heating power can be compensated, but the storage requirements and costs increase
Solution Approach 1:
The patent reduces storage requirements by changing from storing individually varied PTC elements to storing standardized elements with two distinct rated power parameters. This parameter standardization allows for smaller, more manageable inventory levels while maintaining the ability to compensate for manufacturing variations through controlled combinations of the standardized elements.
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 approach allows for simplified large-scale production and reduced storage requirements by ensuring that the actual heating power remains within predetermined tolerance ranges, eliminating the need for extensive preclassification and storage of PTC heating elements with varying departure values.
Implementation Method 1
PTC heating elements are temperature-dependent semi-conductor resistors that are heated when current is supplied, the resistance of the heating elements increasing at the same time
Implementation Method 2
PTC heating elements are temperature-dependent semi-conductor resistors that are heated when current is supplied, the resistance of the heating elements increasing at the same time. Due to the self-regulating properties of the PTC heating elements, an overheating can be securely prevented
Implementation Method 3
PTC heating elements that are in thermally conductive communication with radiator elements for dissipating the heat to the intake air
Implementation Method 4
radiator elements for dissipating the heat to the intake air
Data Source
AI summary
For avoiding the selection and storage of PTC heating elements with different departures from rated heating power, additional tolerance PTC heating elements are held ready which uniformly have a lower rated heating power, preferably one half or third of the rated heating power, compared to the standard or primary PTC heating element. By the use of a second standardized heating element, i. e. the tolerance PTC heating element, the storage of a high number of PTC heating elements with different departures can be dispensed with and a cheaper manufacture can be permitted.