PTC Module Conductor Coating Design for Compact Heat Transfer
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Solution Overview
Problem
Existing PTC module designs face challenges in achieving a compact and economical manufacturing process while maintaining efficient heat transfer and thermoelectric conversion, as traditional electrical contacting methods either impair heat transfer or increase manufacturing costs.
Innovation Solution
The use of electrically conducting coatings on insulator plates, positioned near the edge regions of large outer surfaces, allows for efficient electric current flow diagonally through the PTC element, enhancing thermoelectric conversion efficiency and maintaining a compact design with reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrical conductors are connected to the two large outer surfaces of the PTC element, then electrical contacting is simplified, but heat transfer is impaired and module thickness increases
Solution Approach 1:
The patent transitions from connecting conductors to the large outer surfaces (thickness direction) to connecting them to the small outer surfaces (width direction), changing the dimensional orientation of electrical contact. This allows current to flow through the width of the element rather than the thickness, extending the electrical pathway while maintaining good thermal contact through the large surfaces.
2Volume of moving object
If electrical conductors are connected to the two small outer surfaces of the PTC element, then module thickness is reduced and thermoelectric conversion efficiency is improved, but manufacturing expense increases
Solution Approach 1:
The patent embeds the electrical conductors within recesses or cavities in the support structure, nesting them into the existing module architecture. This integration simplifies the overall manufacturing process by combining multiple functions (structural support and electrical contact) into a single component, reducing assembly steps and manufacturing complexity.
3Power
If the electrical pathway through the PTC element is extended, then thermoelectric conversion efficiency is improved, but the positioning complexity of electrical conductors increases
Solution Approach 1:
The patent employs asymmetric support structure design where the support body includes recesses specifically shaped to receive and position the electrical conductors at optimal locations. This asymmetric geometry naturally guides conductor placement and extends the electrical pathway through the PTC element without requiring complex positioning mechanisms or multiple adjustment steps.
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 a compact and efficient PTC module with improved heat transfer and thermoelectric conversion efficiency, combining economical manufacturing with high performance by extending the electrical pathway within the PTC element.
Implementation Method 1
PTC elements, which have an increasing electrical resistance with rising temperature. Such PTC elements are also known as cold conductor elements, and PTC stands for Positive Temperature Coefficient. During operation, an electrical voltage is applied to the PTC element in order to generate heat inside the respective PTC element.
Implementation Method 2
PTC elements, which have an increasing electrical resistance with rising temperature. Such PTC elements are also known as cold conductor elements, and PTC stands for Positive Temperature Coefficient. The self-regulating property of PTC elements allows them to automatically control their resistance based on temperature changes.
Implementation Method 3
first and second electrically isolating insulator plates, which extend in the module longitudinal direction. The insulator plates serve both electrical isolation and thermal management functions, conducting heat away from the PTC element while preventing electrical short circuits.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present invention relates to a PTC module (2) for a temperature control device (1), especially for a motor vehicle, with at least one PTC element (9), having a flat element cross section (11) and two large outer surfaces (12, 13) as well as having two small outer surfaces (14, 15), with an envelope body (16), which encloses the respective PTC element (9) at least in the circumferential direction (17), with two electrical conductors (22, 23), which are spaced apart from each other in the element cross section (11) and electrically conductively connected to the respective PTC element (9), and with two electrically isolating insulator plates (19, 20), each of which is connected in heat transfer manner to one of the large outer surfaces (12, 13) of the respective PTC element (9). A compact design is achieved when the respective electrical conductor (22, 23) is formed each time by an electrically conducting conductor coating (26, 27), formed each time on one of the insulator plates (19, 20), wherein the one or first conductor coating (26) is arranged on the one or first insulator plate (19) only in a first edge region (28), which borders on the one or first small outer surface (14), while the other or second conductor coating (27) is arranged on the other or second insulator plate (20) only in a second edge region (29), which borders on the other or second small outer surface (15).