PTC Heating Element Face-Side Contact for High Heat Density
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Solution Overview
Problem
Existing PTC heating elements in the automotive industry are bulky, complex, and inefficient due to inadequate heat decoupling, which hinders their use in electric mobility applications where high heat density and efficiency are required.
Innovation Solution
An electric heating device design featuring a PTC heating element with conductor tracks contacting the face sides, allowing for better heat dissipation through a circulation chamber, eliminating the need for contact plates and enabling a compact, high-density arrangement of PTC elements, with a plastic casing and elastomeric sealing to enhance heat transfer and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If contact plates are used to contact the PTC element on main side surfaces, then electrical connection is achieved, but the heating element becomes bulky and heat dissipation is inadequate
Solution Approach 1:
The patent changes the contact dimension from main side surfaces (2D plane contact) to face sides (1D edge contact). The conductor tracks contact the PTC element at the face sides, which are perpendicular to the main side surfaces. This dimensional change allows heat to be dissipated more effectively through the main side surfaces while maintaining electrical connection, thereby resolving the contradiction between heat dissipation efficiency and heating element thickness.
Solution Approach 2:
The patent extracts and eliminates the contact plates that were previously necessary for electrical connection. By providing conductor tracks that directly contact the PTC element at the face sides, the separate contact plate component is removed. This extraction reduces the overall thickness and complexity of the heating element while maintaining the electrical connection function, thus resolving the contradiction between compactness and electrical connectivity.
2Productivity
If multiple PTC elements are arranged closely to increase heat density, then space utilization improves, but heat decoupling becomes inadequate leading to reduced efficiency
Solution Approach 1:
The patent utilizes the face side contact configuration to enable effective heat decoupling even when PTC elements are closely arranged. The conductor tracks at the face sides create thermal boundaries that prevent heat interference between adjacent elements, allowing high heat density through close packing while maintaining energy efficiency through proper thermal decoupling.
3Reliability
If contact plates and insulation layers are used in traditional configuration, then electrical insulation is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the functions of contact plates and insulation layers into an integrated structure. The conductor tracks that contact the PTC element at the face sides are designed to provide both electrical connection and electrical insulation functions. This merging eliminates the need for separate contact plates and insulation layers, thereby reducing manufacturing complexity and component count while maintaining reliable electrical insulation.
Solution Approach 2:
The patent extracts and eliminates the separate contact plate component from the traditional design. By integrating the contact function directly into the conductor tracks that contact the PTC element at the face sides, the design removes unnecessary components and simplifies the manufacturing process while maintaining electrical insulation reliability.
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 design achieves high heat density and efficiency by decoupling heat via main side surfaces and introducing it directly into the insulation layer for dissipation, reducing the thickness of the heating elements and allowing for closer packing, thus improving heat dissipation and reducing manufacturing costs.
Implementation Method 1
PTC elements which are contacted on oppositely disposed main side surfaces by a contact plate
Implementation Method 2
the heat-emitting surfaces of a PTC heating element are exposed. These surfaces are coupled to a PTC element in a heat conductive manner
Implementation Method 3
The heat is typically introduced directly into the insulation layer and dissipated by way of heat conduction to the outer surface thereof
Data Source
AI summary
An electric heating device a PTC heating element, a platelet-type PTC element which has two main side surfaces and face side surfaces extending perpendicular to the main side surfaces, and a casing. The casing forms inlet and outlet openings for the fluid to be heated and forms a circulation chamber in which a heat emitting surface of the PTC heating element is exposed and is coupled in a heat conductive manner to the PTC element. The PTC element is contacted in an electrically conductive manner by way of electrical conductor tracks to different polarities. A high degree of efficiency and a high output is obtained in that the conductor tracks are contacted in an electrically conductive manner to face side surfaces of the PTC element.