Heating element
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Solution Overview
Problem
Existing heat-generating elements for motor vehicle electric heating devices face challenges in providing adequate insulation for PTC elements, leading to potential electrical conductivity issues and increased risk of leakage currents at high currents.
Innovation Solution
The introduction of support points around the receptacle's circumference, which protrude beyond the flat surface and form punctiform support positions, increases the creepage distance between the PTC elements and the positioning frame, along with a sheet metal cover for enhanced EMC protection and a sealing insulating layer to prevent direct contact with the positioning frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the PTC element is directly supported on the flat inner peripheral surface of the positioning frame, then the manufacturing is simple, but the insulation is insufficient and leakage currents increase at high currents
Solution Approach 1:
The inner peripheral surface of the positioning frame is segmented into multiple flat surface sections by introducing support points. These support points divide the originally continuous flat surface into discrete sections, creating punctiform support positions that increase creepage distance while maintaining structural integrity and insulation quality.
Solution Approach 2:
Support points are introduced as intermediary elements between the PTC element and the positioning frame. These support points serve as mediators that provide mechanical support while simultaneously increasing the electrical creepage distance, preventing direct contact and reducing leakage currents without requiring complex additional insulating structures.
2Reliability
If the creepage distance between PTC element and positioning frame is increased, then insulation improves, but the device complexity increases
Solution Approach 1:
The support points serve multiple functions simultaneously: they provide mechanical support for the PTC element, increase the creepage distance for electrical insulation, and create punctiform support positions that maintain flat surface sections. This multi-functionality achieves improved insulation without proportionally increasing structural complexity.
Solution Approach 2:
Instead of increasing the creepage distance uniformly across the entire receptacle structure, the invention applies partial action by introducing discrete support points at specific locations. This creates sufficient insulation where needed while minimizing overall structural changes and maintaining manufacturing simplicity.
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 enhances insulation, reduces the risk of leakage currents, and provides better electromagnetic compatibility (EMC) protection, ensuring safer operation at high currents.
Implementation Method 1
The support points regularly form punctiform support positions by which the PTC element is kept at a distance from the surface sections of the peripheral surface that are formed by the positioning frame. This increases the creepage distance between the contact surfaces of different polarity for the contact plates.
Implementation Method 2
corrugated fin elements in the layered structure usually lying on opposite sides of the heat-generating element in a heat-conducting manner in order to regularly transmit the heat generated by the heat-generating elements to the medium to be heated
Implementation Method 3
heat-generating element... transmit the heat generated by the heat-generating elements... PTC element is accommodated
Data Source
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AI summary
The device has a layer structure (46) arranged in a frame (44) and comprising layers of waving ribs and heat generating elements. One of the heat generating elements include positive temperature co-efficient (PTC) elements, which are arranged between parallel contact plates. Waving rib elements are arranged one behind the other in a passage direction of medium e.g. water. The ribs are arranged transverse to the passage direction of the medium. A cooling body (32) is sealingly inserted into a connector housing, and a sealing element bridges a gap between the body and contours of the housing. An independent claim is also included for a frame.