PTC Heating Module Layout for Direct Wick Heat Transfer

Solution Overview

Problem

Current heating systems for vaporizing fluids containing aromatic substances, such as mosquito repellents, suffer from low efficiency due to the unfavorable surface-to-volume ratio of PTC ceramic heating elements and the arrangement of these elements at a distance from the heat transfer surface, leading to higher heating powers and structural compromises.

Innovation Solution

A heating module with a PTC ceramic heating element closely matched to the shape of its housing opening, allowing direct heat transfer to a liquid-conducting element, such as a wick, without additional heat conduction elements, using a clamping contact-connection without spring elements and optimized electrode configurations for efficient heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a PTC heating element is positioned at a great distance from the wick with additional heat conduction elements, then the heating element can be protected and structurally supported, but the surface-to-volume ratio becomes unfavorable and heat transfer efficiency decreases

Engineering Contradiction:

Improvestructural supportVSAvoidheat transfer efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent removes the intermediate heat conduction elements (such as metal plates or fins) from the heating system. The PTC heating element is positioned to directly contact the wick, eliminating the need for separate heat conduction components and reducing thermal resistance in the heat transfer path.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The heating element structure is merged with the wick support structure. The PTC heating element is positioned to directly contact the wick, combining the heating function with the support function into a single integrated arrangement, thereby improving surface-to-volume ratio and heat transfer efficiency.

Inventive Principle:

Principle #5Merging (Combining)

2Loss of energy

If the PTC heating element is positioned close to the wick for direct heat transfer, then heat transfer efficiency improves, but the heating element requires precise positioning and additional structural support

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidpositioning precision

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The heating element structure is merged with the wick support structure. The PTC heating element is positioned to directly contact the wick, combining the heating function with the support function into a single integrated arrangement, thereby improving surface-to-volume ratio and heat transfer efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heating element is designed to be self-supporting through its direct contact with the wick. The wick itself provides mechanical support to the heating element, eliminating the need for separate structural support components and simplifying the overall device structure.

Inventive Principle:

Principle #25Self-service

3Temperature

If additional heat conduction elements are used to transfer heat from the heating element to the wick, then heat transfer can be maintained at distance, but the surface-to-volume ratio of the heating element becomes unfavorable

Engineering Contradiction:

Improveheat transfer capabilityVSAvoidsurface-to-volume ratio

Core Design Contradiction:

TemperatureVSArea of stationary object

Solution Approach 1:

The patent removes the intermediate heat conduction elements (such as metal plates or fins) from the heating system. The PTC heating element is positioned to directly contact the wick, eliminating the need for separate heat conduction components and reducing thermal resistance in the heat transfer path.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The heating element is designed with a configuration that maximizes surface area in contact with the wick. By positioning the heating element to directly contact the wick over an extended area rather than using point contact through intermediate elements, the effective heat transfer surface area is increased.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 achieves high-efficiency heat transfer with reduced power consumption and improved structural design, ensuring effective vaporization of fluids containing active substances while minimizing mechanical stress on the ceramic heating element.

Implementation Method 1

PTC heating elements are used predominantly for heating systems that vaporize fluids containing an active substance

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

heat generated by a PTC heating element is transferred to a heat conductor, which can surround the wick and which can in turn heat the wick

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

Heating systems that vaporize fluids containing aromatic substances or active substances, for example, for repelling insects such as mosquitoes, are known

Methodology Applied

Scientific EffectVaporization: Evaporation

Data Source

PatentUS9242020B2Heating module and vaporization apparatus having a heating module

Publication Date: 2016.01.26 TDK ELECTRONICS AG

AI summary

A heating module includes a housing with an opening, and a PTC ceramic heating element arranged in the housing having an inner face facing toward the opening, an outer face facing away from the opening and two end faces connecting the inner and outer faces, wherein the inner face is at least partially matched to the opening.