Split heater apparatus and method of manufacturing the same
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Solution Overview
Problem
Existing electric vehicle heating systems, particularly PTC heaters, face challenges in individually heating vehicle interior zones due to the need for multiple components and assembly processes, and they often produce unpleasant silicone fumes from insulation, making it difficult to maintain optimal battery performance and vehicle warmth.
Innovation Solution
A split heater apparatus with a heat radiating unit featuring a frame and heat radiating plates that accommodate heat generating elements, allowing for individual zone heating by separating electrode plates and reducing the number of components and assembly processes, and eliminating the need for silicone injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PTC elements and heat radiating fins are alternately assembled, then heating function is achieved, but the number of components and assembly processes increases
Solution Approach 1:
The patent combines the heat radiating fin and the frame into a single integrated frame structure. The frame serves dual functions: providing structural support and acting as the heat radiating surface. This eliminates the need for separate heat radiating fins, reducing component count and simplifying assembly while maintaining the heating function.
2Reliability
If integrated silicone injection molding is applied to insulate high-voltage terminal, then insulation is achieved, but silicone rubber smell is produced at high temperature
Solution Approach 1:
The patent removes the silicone rubber insulation material entirely from the design. Instead of using silicone injection molding, the patent employs an insulating board made of non-silicone materials to insulate the high-voltage terminal, eliminating the source of harmful silicone fumes while maintaining insulation functionality.
3Reliability
If PTC heater is configured to be heated as a whole, then heating is provided, but individual zone heating is difficult
Solution Approach 1:
The patent divides the heating system into multiple independent heating zones, each with its own PTC element and control circuitry. This segmentation allows different regions (such as front and rear seats) to be heated independently according to different temperature requirements, providing zone-specific heating control while maintaining system reliability.
4Adaptability or versatility
If multiple components are used for zone heating, then individual zone heating is achieved, but assembly complexity increases
Solution Approach 1:
The patent integrates multiple functions into unified components: the frame serves as both structural support and heat radiating surface, and the insulating board provides both insulation and structural function. This merging reduces the total number of components needed for zone heating while simplifying assembly processes.
5Reliability
If silicone injection molding is used for insulation, then insulation is provided, but harmful fumes are generated during operation
Solution Approach 1:
The patent extracts and removes the silicone-based insulation material from the system. It replaces silicone injection molding with insulating boards made from non-silicone materials that do not generate harmful fumes when exposed to high temperatures, thereby eliminating the harmful effect while preserving the insulation function.
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 split heater apparatus efficiently heats individual zones while reducing component count and assembly complexity, preventing silicone fume issues and enhancing temperature control for electric vehicle interiors.
Implementation Method 1
heat generating elements, and electrode plates respectively joined to two opposite surfaces of the frame and configured to apply power to allow the heat generating element to generate the heat
Implementation Method 2
heat radiating plate configured to radiate the heat generated by the heat generating elements
Data Source
AI summary
The present disclosure provides a split heater apparatus and a method of manufacturing the same, the split heater apparatus being capable of dividing a heating region into zones, heating the zones individually, and having components capable of being simply assembled, such that the number of components and the number of assembly processes are reduced.