PTC Heating Element Frame for Heat Dissipation and Sealing
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Solution Overview
Problem
Existing PTC heating elements for the motor vehicle industry are space-consuming, complex, and inefficient in heat dissipation, requiring improved production methods and thermal extraction for electromobility applications.
Innovation Solution
A PTC heating element design where a plastic frame is materially connected to the insulation layer and the PTC element, using elastomeric plastic for the frame to ensure a tight seal and efficient heat dissipation, with the frame forming the housing and plug-in connections, and the insulating layer covering the PTC element's main side surfaces for enhanced thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional PTC heating element design with separate contact plates and insulating layers is used, then the manufacturing process becomes complex and the structure becomes bulky, but the heating element can provide sufficient electrical insulation and contact surfaces
Solution Approach 1:
The patent combines the contact plate and insulating layer into a single integrated component made of elastomeric plastic. This merging eliminates the need for separate assembly steps and reduces structural complexity while maintaining both electrical insulation and contact functions through the material's inherent properties
Solution Approach 2:
The patent changes the material parameter from rigid plastic to elastomeric plastic, which provides both electrical insulation and mechanical compliance. This parameter change allows the single component to achieve both insulation reliability and simplified structure by conforming to the PTC element surface
2Loss of energy
If traditional rigid plastic housing is used for the PTC heating element, then manufacturing is simpler, but heat dissipation efficiency is reduced
Solution Approach 1:
The patent changes the material from rigid plastic to elastomeric plastic, which has superior thermal conductivity. This parameter change improves heat dissipation efficiency while the elastomeric material can still be molded in a single piece, maintaining manufacturing simplicity
Solution Approach 2:
The patent uses elastomeric plastic that combines the benefits of both rigid materials (structural integrity, moldability) and thermally conductive materials (heat dissipation). This composite material approach achieves improved heat dissipation without sacrificing ease of manufacture
3Loss of energy
If the plastic frame completely covers the PTC element for better protection, then sealing is improved, but heat dissipation from the PTC element surface is reduced
Solution Approach 1:
The elastomeric plastic frame provides localized sealing at the edges and perimeter areas where protection is most needed, while leaving the central PTC element surface exposed for heat dissipation. This local quality approach achieves sealing reliability without compromising thermal performance
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 design results in a lightweight, economically produced PTC heating element with improved heat dissipation and sealing, addressing the inefficiencies of previous designs by using elastomeric plastic for the frame and insulating layer to enhance thermal conductivity and sealing.
Implementation Method 1
using elastomeric plastic for the frame to ensure a tight seal and efficient heat dissipation
Implementation Method 2
PTC heating element design where a plastic frame is materially connected to the insulation layer and the PTC element
Data Source
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AI summary
The present invention relates to a PTC heating element (40) with a heating element housing (134), which has at least one PTC element (120) and contact plates (128) that energize the PTC element (120) and form contact tongues (42) for an electrical plug connection. for the electrical connection of electrodes (130) electrically connected to the PTC element (120) as a structural unit, wherein the PTC element (120) is covered with an insulating layer (124) at least on one of its two main side surfaces (122) and wants to specify such a heating element housing that can be produced inexpensively and is designed to be lightweight. For this purpose, the present invention proposes that the PTC heating element has an injection-molded plastic frame (134) which only encloses the insulating layer (124) at the edge and defines opposite frame openings (136), behind which the PTC element (120) with its main side surfaces ( 122) lies.