PTC Heater Supporting Frame for Mechanical Stability and Sealing
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Solution Overview
Problem
Conventional PTC heaters for air conditioning systems in vehicles face challenges with high fabrication costs and leakage issues due to complex clip connections, which compromise the mechanical stability and tightness of the heating system.
Innovation Solution
An integrally injection-molded plastic supporting frame surrounds the PTC heater, eliminating the need for clip connections and providing a permanently stable and cost-effective mounting solution, enhancing mechanical strength and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clip connections or latching connections are used to mount the PTC heater, then the PTC heater can be attached to air conditioning system components, but the fabrication costs increase and the tightness is reduced
Solution Approach 1:
The patent merges the mounting function into the duct structure itself by providing attachment protrusions that directly engage with the PTC heater assembly. This eliminates the need for separate clip connections or latching mechanisms, thereby reducing device complexity while maintaining reliable attachment and tightness.
2Ease of manufacture
If clip connections or latching connections are used to mount the PTC heater, then the PTC heater can be attached to air conditioning system components, but the manufacturing costs increase
Solution Approach 1:
The mounting functionality is integrated directly into the duct structure through attachment protrusions, eliminating the need for separate clip connections or latching components. This merger reduces the number of parts and assembly steps, thereby lowering manufacturing costs while simplifying the overall mounting structure.
3Reliability
If conventional mounting methods are used, then the PTC heater can be installed, but air leakage occurs through the mounting region
Solution Approach 1:
The attachment protrusions are integrated into the duct structure itself, creating a seamless connection between the duct and PTC heater assembly. This integration eliminates gaps and openings that would otherwise allow air leakage, thereby improving sealing reliability while avoiding the need for additional sealing components or complex mounting structures.
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 solution reduces manufacturing costs, ensures mechanical stability, and prevents air leakage, effectively transmitting heating power to the air flowing through the PTC heater.
Implementation Method 1
PTC heating elements have the property that their electric resistance increases with an increasing temperature of the element
Implementation Method 2
effective transmission of the heating power generated by the PTC heating elements
Implementation Method 3
effective transmission of the heating power generated by the PTC heating elements, via the carrier plates and the fin structures onto the air flowing through the PTC heater
Data Source
Figure 1
AI summary
The invention relates to a PTC heater (1) for an air conditioning system, in particular of a motor vehicle, - having a plurality of heating devices (2) which are arranged in a stack-like fashion one on top of the other in a stacking direction (S), - wherein each heating device (2) comprises a plurality of electric PTC heating elements (3) which are arranged in a sandwich-like fashion in the stacking direction (S) between a first carrier (4a) and a second carrier (14a, 14b), wherein a fin structure (5) is arranged between every two heating devices (2) which are adjacent in the stacking direction (S), on which fin structure (5) a first carrier (14a) of a heating device (2) and a second carrier (14b) of a heating device (2) which is adjacent in the stacking direction (S) are supported, - having a supporting frame (8) which is made of a plastic, surrounds the plurality of heating devices (2) and is embodied as a single-piece injection moulded part.