PTC Heater Control Housing With Elastic PCB Switch Pretensioning
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Solution Overview
Problem
Existing control devices for electric heating systems in motor vehicles with PTC elements face challenges in achieving effective heat transfer between the power switch and cooling surface while minimizing component count and manufacturing complexity, particularly due to issues with pretensioning mechanisms that require specific edge areas or raised edges, which are not always feasible in all structural configurations.
Innovation Solution
A control device utilizing an elongated soft elastic plastic pretensioning element with through-holes, extruded to specific dimensions, applies the power switch under pretension against a cooling surface, allowing for efficient heat transfer and reduced mechanical load, while being adaptable to various configurations and easy to manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pretensioning mechanisms with raised edges or specific edge areas are used, then the power switch can be applied under pretension against the cooling surface, but the device complexity increases and adaptability to different structural configurations decreases
Solution Approach 1:
The invention extracts the pretensioning function from complex mechanical structures (raised edges, specific edge areas) and concentrates it into a single elastic pretensioning element. This element is supported on the housing cover and applies pretension directly to the power switch, eliminating the need for specialized edge features and reducing overall device complexity while maintaining effective heat transfer.
2Reliability
If traditional pretensioning mechanisms are used, then the power switch can be secured against the cooling surface, but the manufacturing complexity and costs increase
Solution Approach 1:
The elastic pretensioning element is designed to automatically apply the necessary pretension force to the power switch based on its inherent elasticity and the geometry of the housing cover support. The element self-adjusts to maintain optimal thermal contact between the power switch and cooling surface without requiring complex assembly procedures or specialized manufacturing processes for raised edges or specific structural features.
3Temperature
If multiple separate components are used for pretensioning, then the power switch can be effectively cooled, but the component count increases and adaptability decreases
Solution Approach 1:
The invention merges the pretensioning function with the housing cover structure by supporting the single elastic pretensioning element on the housing cover. This integrated approach allows the same basic design to adapt to different structural configurations and cooling surface positions without requiring multiple separate components or complex assembly variations, while maintaining effective thermal contact for power switch cooling.
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 enables efficient heat transfer between the power switch and cooling surface with reduced component complexity, lower manufacturing costs, and improved adaptability to different structural configurations, ensuring effective thermal management and durability.
Implementation Method 1
an elastic pretensioning element which comprises an elongated piece of a soft elastic plastic part extruded with at least one through hole
Implementation Method 2
The power switch is applied against a cooling surface in a heat-conducting manner under pretension
Data Source
AI summary
A control device is disclosed for an electric heating device with a PTC element as an auxiliary heater in a motor vehicle. The control device has a control housing in which a printed circuit board, equipped with at least one power switch is provided. The power switch is applied against a cooling surface in a heat-conducting manner under pretension via an elastic pretensioning element. The pretensioning element is formed from an elongated piece of a soft-elastic plastic part extruded with at least one through-opening. Also disclosed is an electric heating device having such a control device.