Electric heating device and PTC heating element for same
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical heating devices with PTC heating elements are complex, space-consuming, and inefficient in heat dissipation, particularly in the motor vehicle industry where weight optimization and economical manufacturability are crucial, and there is a need for improved thermal extraction and sealing to handle high system pressures.
Innovation Solution
A PTC heating device with a plug-in connection between the PTC heating element and partition wall, utilizing a flexible elastomer sealing collar for fluid-tight sealing and frictional retention, and a lightweight, cross-linked elastomer housing that allows for efficient heat dissipation and reduced weight, with a design that minimizes the thickness of the sealing collar to accommodate multiple elements closely within the circulation chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional PTC heating elements with overmolded contact sheets and insulating layers are used, then electrical connection is achieved, but the structure becomes space-consuming and complex
Solution Approach 1:
The contact sheet and insulating layer are extracted from the overmolding process and implemented as separate components. The contact sheet is inserted into a recess in the heating element housing, and the insulating layer is placed over the contact sheet, eliminating the need for complex overmolding while achieving the same electrical connection and insulation functions
Solution Approach 2:
The heating element housing is divided into segments with recesses that accommodate the contact sheet and insulating layer separately. This segmentation allows for simpler manufacturing and assembly while reducing overall structural complexity and space requirements compared to a monolithic overmolded design
2Loss of energy
If sufficient heat dissipation is not achieved, then PTC elements can be operated with poor efficiency, but improving heat dissipation increases device complexity
Solution Approach 1:
The heating element housing is designed with localized thermal management features, including recesses that facilitate heat extraction from specific areas of the PTC element. The partition wall includes openings that allow heat to be conducted from the PTC element to the housing, providing targeted heat dissipation without requiring complex thermal management systems
Solution Approach 2:
The housing material acts as an intermediary for heat transfer from the PTC element to the surrounding environment. The partition wall serves as a thermal conduit, conducting heat from the PTC element through the housing structure, enabling efficient heat dissipation through the housing itself rather than requiring separate cooling mechanisms
3Weight of stationary object
If a lightweight housing material is used, then weight is reduced, but sealing capability under high pressure may be compromised
Solution Approach 1:
The heating element housing is made from a composite material consisting of a thermoplastic matrix reinforced with glass fibers. This composite provides both the lightweight property of thermoplastics and the enhanced mechanical strength and sealing capability provided by the glass fiber reinforcement, allowing the housing to withstand high system pressures while maintaining reduced weight
Solution Approach 2:
The material properties of the housing are optimized by adjusting the glass fiber content and distribution within the thermoplastic matrix. This parameter change enables the housing to achieve the necessary pressure resistance for sealing while maintaining the weight advantages of lightweight materials, balancing both requirements simultaneously
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 provides a cost-effective, lightweight, and efficient heat dissipation system that maintains fluid-tight sealing under high pressures, enabling reliable operation in motor vehicles with reduced material usage and improved thermal management.
Implementation Method 1
PTC heating elements arranged in a circulation chamber (14)... PTC elements (120)... contact plates (128) that energize the PTC element
Implementation Method 2
flexible elastomer sealing collar (48) for fluid-tight sealing and frictional retention
Implementation Method 3
flexible elastomer sealing collar (48) for fluid-tight sealing... cross-linked elastomer housing
Implementation Method 4
efficient heat dissipation... improved thermal management... partition wall (54), which separates the circulation chamber from a connection chamber
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to an electrical heating device with a plurality of PTC heating elements (40) arranged in a circulation chamber (62) with a heating element housing (134), which has at least one PTC element (120) and contact tongues (42) that energize the PTC element contact plates (128) forming an electrical plug connection as a structural unit, and with a partition (54) which separates the circulation chamber (62) from a connection chamber (56) in which the contact tongues (42) of the PTC projecting through the partition (54). -Heating element (40) are exposed and electrically connected and a PTC element and a housing of such an electrical heating device. For economical production, the invention proposes a plug-in connection formed between the partition (54) and the PTC heating element (40), via which the PTC heating element (40) is frictionally and/or positively held on the partition (54) in the plugging direction .