PTC Heating Rib Frame Windows for Better Heat Dissipation
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Solution Overview
Problem
Electric heating devices for automotive vehicles face a contradiction between the need for electrical insulation to prevent heat loss and the requirement to allow free heat dissipation from PTC elements, which affects the performance of the heating elements.
Innovation Solution
The introduction of a heating rib frame with windows exposing the insulation layer to facilitate heat dissipation, combined with a thermally conductive material and a sealing adhesive to ensure insulation and efficient heat transfer, while preventing electrical flashover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the PTC element is completely enclosed in the heating rib to ensure electrical insulation, then electrical safety is improved, but heat dissipation performance deteriorates due to longer heat conduction paths
Solution Approach 1:
The patent extracts the electrical insulation function from the entire heating rib structure and concentrates it specifically on the insulation layer positioned at the window opening. This allows the PTC element to remain enclosed for safety while minimizing the insulation barrier to only where absolutely necessary, thus resolving the contradiction between electrical safety and heat dissipation efficiency.
Solution Approach 2:
The patent applies electrical insulation locally rather than uniformly throughout the heating rib. The insulation layer is strategically placed only at the window opening where electrical exposure occurs, while the rest of the heating rib structure remains thermally conductive to optimize heat dissipation. This local quality approach resolves the contradiction by providing insulation only where needed for safety.
2Reliability
If the insulation layer is completely covered to maintain electrical insulation, then electrical safety is improved, but heat conduction path length increases reducing PTC element performance
Solution Approach 1:
The patent extracts the insulation layer from complete coverage and positions it only at the window opening where electrical insulation is critical. This extraction allows the heating rib frame to maintain full thermal conductivity across the majority of its structure, maximizing heat dissipation and PTC element performance while providing necessary insulation only at the electrical exposure point.
Solution Approach 2:
The patent implements local quality by concentrating the insulation layer specifically at the window opening rather than covering the entire PTC element. This localized insulation approach maintains electrical safety at the critical exposure point while allowing optimal heat conduction through the rest of the heating structure, thereby resolving the contradiction between electrical safety and heating performance.
3Loss of energy
If the heating rib frame is made from highly thermally conductive material, then heat dissipation is improved, but electrical insulation capability deteriorates
Solution Approach 1:
The patent segments the heating rib structure into two functional parts: the heating rib frame made of thermally conductive material for optimal heat dissipation, and the separate insulation layer providing electrical insulation at the window opening. This segmentation allows each component to be optimized for its specific function without compromise, resolving the contradiction between heat dissipation efficiency and electrical insulation capability.
Solution Approach 2:
The patent employs a composite structure combining thermally conductive material (heating rib frame) with electrically insulating material (insulation layer). This composite approach allows the system to simultaneously achieve excellent thermal conductivity for heat dissipation and adequate electrical insulation for safety, resolving the contradiction between these two opposing 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 configuration enhances heat dissipation, maintains electrical insulation, and ensures efficient performance of the PTC heating element by shortening heat conduction paths and sealing the device effectively.
Implementation Method 1
heat generated by the PTC element
Implementation Method 2
heat conduction paths are shortened
Implementation Method 3
heat can be dissipated by way of convection on the surface of the electrical insulation layer
Data Source
AI summary
An electric heating device including a heater housing in which a partition separates a circulation chamber, through which a medium to be heated can flow, from a connection chamber in which electrical connections of a PTC heating element introduced into a recess of a heating rib projecting from the partition into the circulation chamber are exposed. The PTC heating element has at least one PTC element and strip conductors lying against it at both sides, of which at least one strip conductor is covered by an electrical insulation layer. To create an electric heating device which permits a delivery of heat of the PTC heating element to the environment in an improved way, the heating rib is formed by a heating rib frame which comprises at least one window in which the insulation layer is exposed.