PTC Heating Assembly Insulation Frame for High-Voltage EV Heating
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Solution Overview
Problem
Conventional electric heating systems in hybrid and pure electric vehicles lack sufficient waste heat for heating and defrosting, and PTC heating elements are sensitive to temperature and voltage, leading to reduced performance and increased volume due to arc discharge concerns.
Innovation Solution
A PTC electric heating assembly with an insulation fixing frame that stabilizes and isolates PTC heating elements, reducing interference and enhancing heating performance, and an electric heating device with thermal conducting grooves for efficient heat transfer, adapted for high voltage conditions using materials with high temperature and voltage resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the distance between electrode plates is increased to avoid arc discharge under high voltage, then safety is improved, but the volume and occupied space of the PTC heating element increase
Solution Approach 1:
The patent introduces an insulation plate as an intermediary component between the two electrode plates. This insulation plate with through-holes provides both electrical insulation to prevent arc discharge and mechanical support to hold PTC heating elements, thereby maintaining safety while reducing the required distance between electrode plates and minimizing overall volume.
2Power
If multiple PTC heating elements are arranged closely to improve heating performance, then heating power is improved, but the elements may contact each other causing performance degradation
Solution Approach 1:
The insulation plate serves as a mediator that physically separates and electrically insulates adjacent PTC heating elements. The through-holes in the insulation plate hold each PTC element in place while maintaining appropriate spacing, enabling dense arrangement for high heating power without contact-induced performance degradation.
Solution Approach 2:
The insulation plate performs multiple functions simultaneously: it provides electrical insulation between electrode plates and PTC elements, mechanically supports and positions multiple PTC heating elements, and maintains proper spacing between elements. This multi-functionality enables close arrangement of elements for high power output while preventing contact issues.
3Device complexity
If conventional clamping method is used to fix PTC heating elements, then structure is simple, but elements with different thicknesses or improper positioning cannot be firmly fixed
Solution Approach 1:
The insulation plate acts as an intermediary fixing structure that replaces conventional clamping methods. PTC heating elements are inserted through the through-holes of the insulation plate, which provides precise positioning and firm fixation. This approach maintains structural simplicity while achieving high positioning precision for elements with varying thicknesses.
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 improves the stability and heating performance of PTC heating elements, increases heating power, and ensures safe operation under high voltage conditions, providing effective heating, defrosting, and defogging capabilities for electric vehicles.
Implementation Method 1
a PTC electric heating assembly comprising two electrode plates; and a PTC heating module disposed between the two electrode plates
Implementation Method 2
an electric heating device, comprising a casing defining a plurality of thermal conducting grooves and a medium circulating cavity
Data Source
AI summary
A PTC electric heating assembly, an electric heating device and an electric vehicle are provided. The PTC electric heating assembly (2) comprises two electrode plates (23) and a PTC heating module (20) disposed between the two electrode plates (23), and comprising an insulation fixing frame (22) and a plurality of PTC heating elements (21), the insulation fixing frame (22) defining a plurality of fixing units (220) and the PTC heating elements (21) being disposed into the fixing units (220) respectively.