PTC Heating Module Lateral Contacting for Simplified Production
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Solution Overview
Problem
The existing PTC heating modules face significant technical and cost challenges due to the complexity of lateral electrical contacting, which limits installation space and increases production effort and costs.
Innovation Solution
The PTC heating module simplifies contacting by using a contact element that is electroconductively fixed to a lateral surface of the PTC thermistor element and a contacting track on an insulating board, allowing for secure and efficient electrical connection while maintaining mechanical stability, and incorporates insulating boards for heat transfer and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lateral contacting of PTC elements is implemented, then electrical connection is achieved, but production effort and costs increase significantly
Solution Approach 1:
The patent introduces a contacting track as an intermediary element that simplifies the electrical connection process. Instead of directly contacting the PTC element laterally which requires precise positioning and insulation, the contacting track provides a predefined path that guides the contact element, reducing manufacturing complexity while ensuring reliable electrical connection.
Solution Approach 2:
The contacting track is pre-formed on the insulating board before the PTC element is installed. This preliminary action allows the contact elements to be positioned and fixed more easily, as the electrical connection path is already established, thereby reducing the production effort required during assembly.
2Reliability
If lateral contacting is used, then electrical connection is established, but installation space is limited
Solution Approach 1:
The patent transitions from direct lateral contacting (requiring space in the thickness dimension) to a contacting track system that utilizes the surface area of the insulating board. By forming the contacting track on the board's surface, the solution moves the electrical connection problem to a different dimensional plane, effectively utilizing available space more efficiently.
3Reliability
If insulating boards are placed against main surfaces, then electrical insulation is achieved, but heat transfer efficiency may be reduced
Solution Approach 1:
The patent applies different properties to different regions of the insulating board. The areas contacting the main surfaces of PTC elements are designed for electrical insulation, while the contacting track regions are made electroconductive to enable electrical connection. This local differentiation allows the board to simultaneously provide both insulation and conduction functions in appropriate locations.
Solution Approach 2:
The insulating board is designed as a composite structure with regions of different electrical properties. The board combines insulating material for electrical isolation with electroconductive contacting tracks for electrical connection, creating a multi-functional component that addresses both electrical insulation and heat transfer requirements.
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 approach reduces production effort and costs by simplifying the contacting process and ensuring reliable electrical and heat transfer connections, even with limited installation space, while maintaining mechanical stability and efficient heat exchange.
Implementation Method 1
PTC elements which are produced from a PTC thermistor material with a temperature-dependent OHMIC resistance. When a voltage is applied, the resistance of the PTC element increases and the PTC element is heated.
Implementation Method 2
an insulating plate each lies against the main surfaces of the PTC thermistor element in a heat-transferring manner, which electrically insulates the at least one PTC thermistor element from the housing and connects the same to the housing in a heat-transferring manner
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a PTC heating module (1) for heating a fluid. The PTC heating module (1) comprises at least one cuboid PTC thermistor element (2) with two main surfaces (3a, 3b) which are located opposite one another, which are connected to one another via two lateral surfaces (4a, 4b) arranged located opposite one another. Here, the PTC thermistor element (2) is electrically contactable to the outside in each case via a contact element (7a, 7b) lying against the respective lateral surface (4a, 4b). Furthermore, the PTC heating module (1) comprises a housing (6), in which the at least one PTC thermistor element (2) and the respective contact elements (7a, 7b) are arranged. An insulating board (5a, 5b) each lies against the main surfaces (3a, 3b) of the at least one PTC thermistor element (2) in a heat-transferring manner. According to the invention, the respective contact element (7a, 7b) is electroconductively fixed on the one side on the respective lateral surface (4a, 4b) of he at least one PTC thermistor element (2) and on the other side on a contacting track (8a, 8b). The contacting track (8a, 8b) in this case is arranged on one of the insulating boards (5a, 5b). The invention also relates to a method for producing the PTC heating module (1).