Segmented PTC Heater Contact Plates for Zoned Output Control
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Solution Overview
Problem
Existing PTC heating devices for motor vehicle air-conditioning systems are sensitive due to their thin design, making them difficult to handle and maintain, and lack the ability to adjust heating output in different zones, requiring a compromise in heating output across all zones.
Innovation Solution
A PTC heating device with a contact plate featuring a narrow, angled cross-sectional profile, allowing for stronger and less sensitive contact plates, enabling individual control of heating element groups and a more compact design, along with insulation for positioning and preventing short-circuits, facilitating easier assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the contact plate is designed thin to achieve a compact design, then the device size is reduced, but the contact plate becomes highly sensitive and difficult to handle
Solution Approach 1:
The contact plate is segmented into a first contact plate and a second contact plate that are spatially separated and independently controllable. This segmentation allows each contact plate to be optimized independently - they can be made thinner for compactness while the overall structure maintains robustness through the distributed configuration of multiple contact plates rather than relying on a single thick plate.
2Volume of moving object
If the contact plate is designed thin to achieve a compact design, then the device size is reduced, but the structural strength is reduced
Solution Approach 1:
The contact plate is divided into a first contact plate and a second contact plate positioned at different locations. This segmentation distributes the mechanical and electrical load across multiple contact points rather than concentrating it in a single thick plate, allowing for a compact overall design while maintaining adequate structural strength through the distributed contact configuration.
Solution Approach 2:
An insulating element is introduced as an intermediary component between the first and second contact plates. This insulator provides mechanical support and spacing, enabling the contact plates to be positioned optimally for both compactness and strength without direct contact, thus mediating between the conflicting requirements of thin design and structural integrity.
3Device complexity
If all PTC heating elements are controlled simultaneously, then the control system is simple, but the ability to adjust heating output in different zones is lost
Solution Approach 1:
The heating elements are segmented into a first group and a second group, each controlled by its own contact plate (first contact plate and second contact plate respectively). This spatial and functional segmentation of the heating system enables independent control of different heating zones, providing adaptability and versatility in heating output adjustment while keeping each control subsystem relatively simple.
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
The solution results in a stronger, more durable PTC heating device with improved handling and the ability to adjust heating output in different zones, enhancing the efficiency and reliability of the air-conditioning system.
Implementation Method 1
PTC heating devices, that is heating devices having PTC heating elements, are employed in air-conditioning systems of motor vehicles in order to heat air prior to being introduced into the vehicle interior
Data Source
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Figure 5~6
AI summary
The invention relates to a PTC heating device (1), - having a number of PTC heating elements (4), - having a first contact plate (7), a second contact plate (8) and at least one further contact plate (9), - wherein the first contact plate (7) contacts only a first part (10) of the number of the PTC heating elements (4) and the further contact plate (9) only a second part (11) of the number of the PTC heating elements (4), while the second contact plate (8) contacts all PTC heating elements (4), - wherein the further contact plate (9) has a first portion (12) and a second portion (13), - wherein the PTC heating elements (4) are arranged linearly to one another. It is substantial for the invention - that the first portion (12) of the further contact plate (9) runs along a narrow side (14) of the first part (10) of the number of the PTC heating elements (4) and spaced apart from the narrow side (14), - that the first portion (12) of the further contact plate (9) has an angled cross-sectional profile (23).