Vehicle Electric Heater Layout for Higher PTC Heating Capacity

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Solution Overview

Problem

Conventional electric heaters for vehicles face limitations in maximum heating temperature due to the thermal melting point of the air-conditioner case, restricting the power output and making it difficult to achieve additional heating during the initial driving stage after engine ignition.

Innovation Solution

The electric heater incorporates a combination of first and second PTC elements with different heating powers and resistance values, arranged in various configurations within a housing and heat dissipation fin, allowing for increased heating temperature and reduced production costs by minimizing the number of standard PTC elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a standard PTC element is used in the electric heater, then the heating function is provided, but the maximum heating temperature is restricted due to the thermal melting point of the air-conditioner case

Engineering Contradiction:

Improveheating temperatureVSAvoidthermal melting point restriction

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The heating system is divided into multiple independent heating zones with different PTC elements (first PTC element and second PTC element) that can operate at different temperature levels. This segmentation allows the system to provide both low-temperature and high-temperature heating without requiring the entire air-conditioner case to withstand high temperatures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the heating system are assigned different thermal characteristics. The first PTC element operates at a lower temperature suitable for the air-conditioner case environment, while the second PTC element operates at a higher temperature in a protected region, providing localized high-temperature heating capability without compromising the overall system's thermal safety.

Inventive Principle:

Principle #3Local quality

2Power

If the heating region of the electric heater is restricted, then the air-conditioner case structure is maintained, but the power output and heating capacity are limited

Engineering Contradiction:

Improvepower outputVSAvoidheating region

Core Design Contradiction:

PowerVSArea of stationary object

Solution Approach 1:

The patent utilizes the spatial dimension within the air-conditioner case to accommodate multiple heating elements. By arranging the first and second PTC elements in different spatial positions and configurations, the system maximizes the use of available three-dimensional space to achieve higher total power output without expanding the external footprint of the heating region.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The second PTC element is positioned within or alongside the first PTC element's housing structure, creating a nested arrangement. This allows the high-temperature heating component to be integrated into the existing low-temperature heating structure, effectively doubling the power output within the same external boundaries.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Power

If multiple standard PTC elements are used to increase heating capacity, then the heating temperature can be increased, but the production cost increases

Engineering Contradiction:

Improveheating capacityVSAvoidproduction cost

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

Instead of using multiple identical standard PTC elements, the patent employs PTC elements with different resistance values and power ratings (first PTC element with lower power, second PTC element with higher power). This parameter differentiation allows the system to achieve the required total heating capacity while optimizing the number of elements needed and reducing overall production costs compared to using only high-power elements.

Inventive Principle:

Principle #35Parameter changes

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 the heating capacity within the restricted heating region, overcoming power limitations and reducing production costs while maintaining efficient heating performance.

Implementation Method 1

at least one ceramic element configured to emit heat by receiving a power-supply voltage. The at least one ceramic element includes a first positive temperature coefficient (PTC) element, and a second PTC element having a higher amount of heating power than a heating power of the first PTC element

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a heat dissipation fin configured to exchange heat with air

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 3

a heat dissipation fin configured to exchange heat with air

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11400793B2Electric heater for use in vehicle and vehicle including the same

Publication Date: 2022.08.02 HYUNDAI MOTOR CO LTD

AI summary

An electric heater for a vehicle includes a heat dissipation fin for heat-exchange with air, a ceramic element to emit heat by receiving a power-supply voltage, and a housing to support the heat dissipation fin and the ceramic element. The ceramic element includes a first positive temperature coefficient (PTC) element, and a second PTC element having a heating power greater than a heating power of the first PTC element.