PTC Rod Assembly with Open-Side Cover for Heat Transfer
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Solution Overview
Problem
Conventional PTC rod assemblies have complex structures with many parts, leading to increased thickness, difficulty in assembly, reduced heat transfer efficiency due to insulating effects, and air leakage, which results in noise and performance issues during initial operation.
Innovation Solution
A PTC rod assembly with a channel-shaped rod cover having an open side and flanges, where PTC elements are in direct contact with the inner bottom and an electrode terminal is caught by the flanges, with an insulator attached to the outer surface of the terminal, allowing direct heat transfer to heat-radiating fins, minimizing internal space and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional PTC rod assembly structure is used with separate insulators and closed rod covers, then electrical insulation is provided, but the structure becomes complex, thickness increases, and heat transfer efficiency is reduced due to insulating effects and air gaps
Solution Approach 1:
The patent merges the insulator and rod cover into an integrated structure where the rod cover itself provides both mechanical containment and electrical insulation functions. The insulator is positioned within the rod cover to provide electrical insulation for the electrode terminal while the open side configuration allows direct heat transfer paths, eliminating the need for separate insulating components and reducing overall structural complexity.
Solution Approach 2:
The rod cover is segmented with an open side configuration rather than being fully enclosed, creating distinct functional zones: one side remains open to allow direct heat transfer from PTC elements to heat-radiating fins, while the opposite side provides structural containment and electrical insulation. This segmentation optimizes both thermal performance and electrical safety.
2Strength
If conventional closed rod covers are used, then structural containment is provided, but empty spaces increase and heat transfer efficiency decreases
Solution Approach 1:
The rod cover is divided into a closed portion providing structural containment and an open side portion that eliminates barriers between heat-generating components and heat-radiating fins. This segmentation allows the structure to simultaneously maintain mechanical integrity while maximizing thermal contact and minimizing energy loss through improved heat transfer pathways.
Solution Approach 2:
The open side configuration introduces a dimensional change from a fully enclosed three-dimensional structure to a partially open structure, creating direct thermal pathways that reduce thermal resistance. This dimensional modification allows heat to transfer more efficiently from the PTC elements through the electrode terminal to the heat-radiating fins without being blocked by closed cover structures.
3Reliability
If multiple separate parts are assembled, then electrical insulation is achieved, but manufacturing complexity increases and assembly becomes difficult
Solution Approach 1:
The patent combines multiple functions into fewer components: the rod cover provides both structural containment and serves as a mounting structure for the insulator, while the insulator simultaneously provides electrical insulation and thermal conduction pathways. This merging reduces the total number of parts that need to be manufactured and assembled, simplifying both manufacturing processes and assembly procedures while maintaining electrical insulation reliability.
4Length of moving object
If air gaps are present in the structure, then component clearance is provided, but noise is generated and performance deteriorates during initial operation
Solution Approach 1:
The rod cover is segmented with an open side that strategically positions components to minimize air gap formation between heat-generating PTC elements and heat-radiating fins. The open configuration allows components to be positioned in direct thermal contact while maintaining necessary electrical clearances, thereby eliminating the harmful effects of air gaps such as noise and performance deterioration during initial operation.
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 transfer efficiency, reduces manufacturing complexity, and improves overall energy efficiency and performance by minimizing empty spaces and simplifying the assembly process.
Implementation Method 1
PTC elements having lower surfaces in contact with an inner bottom of the rod cover and upper surfaces in contact with an electrode terminal
Implementation Method 2
a heat-radiating fin being in direct contact with one surface of the rod cover so as to conduct heat, and another heat-radiating fin being in direct contact with one surface of the insulator attached to an outer surface of the electrode terminal so as to conduct heat
Data Source
AI summary
A positive temperature coefficient (PTC) rod assembly is provided for a PTC heater. PTC elements and an electrode terminal to which an insulator is attached may be retained in a channel-shaped rod cover having an open side so as to be exposed to the outside, and a heat-radiating fin is in direct contact with one surface of the rod cover so as to conduct heat, and another heat-radiating fin may be in direct contact with one surface of the insulator attached to an outer surface of the electrode terminal so as to conduct heat, so that the PTC rod assembly minimizes empty space in an inner space of the rod cover, increases heat transfer efficiency, and is easily manufactured due to a simple structure and reduction in the number of parts.