PTC thermistor module for a temperature control device
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
PTC thermistor modules experience reduced efficiency and potential damage due to localized 'hot spots' caused by diagonal current flow, which increases with higher operating voltages, leading to inefficient temperature control and potential damage to adjacent components.
Innovation Solution
The PTC thermistor module design features a zigzag current path between large outer surfaces, creating multiple hot spots with reduced temperature, resulting in a more homogeneous temperature distribution and increased efficiency, and includes multiple conductor coatings on insulator plates to lengthen the current path and enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If diagonal current flow is used through the PTC thermistor element, then the structure is simple, but hot spots are generated causing reduced efficiency and potential damage
Solution Approach 1:
The current path is segmented into multiple sections by introducing intermediate conductor coatings on the insulator plates. Instead of a single diagonal current path, the current flows through multiple segmented paths between the large outer surfaces, creating multiple hot spots that distribute the heat more evenly and prevent localized overheating.
Solution Approach 2:
Intermediate conductor coatings are introduced as mediator elements on the insulator plates. These conductor coatings serve as intermediary contact points that redirect the current flow from a direct diagonal path to a zigzag path, enabling better heat distribution while maintaining structural simplicity.
2Power
If higher operating voltages are applied to increase heating efficiency, then more heat is generated, but hot spots become more severe causing damage to adjacent parts
Solution Approach 1:
The heating function is segmented across multiple current path sections. By creating multiple hot spots through segmented current paths, the total heating power is distributed across several locations rather than concentrated in one area, allowing higher overall power while preventing excessive localized temperatures that would damage adjacent components.
3Productivity
If a single hot spot is created in the PTC thermistor element, then the current path is short and efficient, but the temperature distribution becomes non-uniform reducing overall efficiency
Solution Approach 1:
The single hot spot is segmented into multiple hot spots by introducing intermediate conductor coatings. This segmentation creates multiple heating zones along the current path, improving temperature distribution uniformity across the PTC thermistor element while maintaining efficient heating through the extended current path length.
Solution Approach 2:
The current path transitions from a simple diagonal line to a zigzag pattern that utilizes the third dimension (depth) by incorporating conductor coatings on insulator plates positioned between the large outer surfaces. This dimensional change allows the current to traverse a longer path through multiple sections, creating multiple hot spots that improve temperature uniformity.
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 enhances the efficiency and operational reliability of the PTC thermistor module by distributing heat more evenly, preventing damage from hot spots and allowing for efficient operation at higher voltages.
Implementation Method 1
PTC thermistor elements through which a current flows during operation as a result of an electrical voltage being applied and which generate heat in the process
Implementation Method 2
PTC thermistor elements, also called PTC element, where PTC stands for 'Positive Temperature Coefficient'
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a PTC thermistor module (2) for a temperature control device (1), comprising at least one PTC thermistor element (9) having two large outer surfaces (12, 13), facing away from one another, and two small outer surfaces (14, 15), facing away from one another. The PTC thermistor module (2) furthermore comprises conductors (22, 23) for the electrical supply of the respective PTC thermistor element (9), said conductors being formed in each case as a conductor coating (27, 28). An improved efficiency of the PTC thermistor module (2) and an increased operational reliability are achieved by virtue of the fact that one of the large outer surfaces (12, 13) is electrically connected to at least one conductor coating (27, 28) and the other large outer surface (12, 13) is electrically connected to at least two conductor coatings (27, 28), wherein the conductor coatings (27, 28) are in each case spaced apart from one another. The invention furthermore relates to a temperature control device (1) comprising at least one such PTC thermistor module (2).