Customized PTC Product Solution for Automotive and New Energy Industry
Customized PTC Product Solutions for Automotive and New Energy Industry
In the rapidly developing automotive and new energy industries, the demand for reliable, durable and high-performance materials is critical. Customized PTC product solutions have become an integral part of modern automotive design, and their many advantages can meet the stringent requirements of automotive applications.
Safe and reliable, self-controlling temperature characteristics
PTC heating elements have positive temperature coefficient characteristics. When the temperature rises, the resistance increases, and the power output is automatically limited to avoid overheating risks. This self-limiting temperature characteristic makes it particularly safe in scenarios such as electric vehicle high-voltage systems and battery heating. No additional protection circuit is required, and it complies with the ISO 26262
High efficiency and energy saving, fast response
Compared with traditional resistance wire, PTC heater starts quickly (10-15 seconds to reach the working temperature), and can automatically adjust the power according to the ambient temperature to reduce energy waste. In applications such as electric vehicle air conditioning and seat heating, it can reduce energy consumption by 20%-30%, effectively improving the driving range.
Strong environmental adaptability
PTC components can work stably in extreme environments of -40℃~125℃, are vibration-resistant, moisture-proof and dust-proof (IP67 grade), and are suitable for complex automotive working conditions. For example, in scenarios such as rearview mirror defrosting and fuel line heating, they can respond quickly even in severe cold.
Lightweight and integrated design
The modular PTC heating component is small in size and light in weight (40% lighter than traditional solutions), and can be flexibly integrated into small spaces such as seats, steering wheels, and battery packs. It supports independent temperature control in multiple zones (such as zoned seat heating) to improve comfort.
Customized PTC Product Solutions for Automotive and New Energy Industry
Tianrui understands that reliability and performance are critical in the rapidly evolving automotive and new energy industries. That’s why we offer tailor-made PTC product solutions specifically designed to address the industry’s unique challenges.
Why book with us?
Our expertise lies in creating high-quality PTC product components that enhance the durability, safety, and efficiency of automotive systems. Whether you need to deal with extreme temperatures, high-intensity vibrations, or require precise sealing, our PTC products deliver superior performance under the most demanding conditions.
Customized to your needs
We work closely with you to develop PTC heating components that meet your specific requirements, ensuring your vehicle is equipped with the best materials for optimal functionality.
Enhanced durability
Known for their outstanding stability, our PTC product solutions deliver long-lasting performance, reducing maintenance costs and downtime.
Innovation driven
We stay at the forefront of industry trends and technological advances, ensuring our PTC products are at the forefront of innovation, giving you a competitive advantage in the market.
What Are the Pain Points of Customizing PTC Products for Automotive and New Energy Industry?
In the automotive and new energy industries, the demand for customization of PTC (positive temperature coefficient) heating sheets, heaters and components is growing, but there are many pain points in their development and implementation, involving technology, supply chain, cost, industry standards and other aspects.
1. Pain points at the technical level
PTC materials need to ensure temperature uniformity while heating rapidly, but under complex working conditions (such as heating of new energy vehicle batteries), uneven heat distribution may lead to local overheating or inefficiency, which needs to be solved through material formulation and structural design optimization.
2. Pain points of materials and supply chain
High-performance PTC ceramics (such as doped BaTiO₃) or electrode materials (silver paste) may rely on foreign suppliers, resulting in high costs and long delivery times. Domestic alternative materials need to verify reliability.
3. Difficulties in cost control
Precious metal electrodes (such as silver) or special polymer materials push up costs, and costs need to be reduced through material modification (such as carbon-based fillers) or process optimization (such as thick film printing).
4. Special challenges for industry applications
The 800V high-voltage system has higher requirements for PTC's insulation withstand voltage and arc resistance, and the electrical safety structure needs to be redesigned.
5. Customized service support
Different car companies have different requirements for the size, interface, and communication protocol (such as CAN bus temperature control) of PTC components, which increases the complexity of customization.
Typical Applications of PTC Products for Automotive and New Energy Industry
Comparison of typical application scenarios
| Application Areas | Pain Points of Traditional Solutions | Advantages of PTC solutions |
|---|---|---|
| Electric vehicle air conditioner | Impact on driving range | Power consumption is reduced by 30%, and battery preheating is supported |
| Heated seats | Risk of local overheating | Zoned temperature control, uniform surface temperature |
| Battery Thermal Management | Uneven heating | Precise temperature control ±0.5°C, extending battery life |
| Rearview mirror defrosting | Slow response time | 10-second fast defrosting, automatic power adjustment |
| Fuel line heating | Big safety hazard | Explosion-proof design, self-limiting temperature protection |
PTC Heating Component Production Process for Automotive and New Energy Industry
The application of PTC (positive temperature coefficient) heating components in the automotive and new energy industries (such as electric vehicle battery heating, thermal management systems, charging pile antifreeze, etc.) requires high reliability, long life and adaptability to harsh environments. Its production process mainly includes the following key links:
1. Raw material preparation
(1) PTC ceramic chip manufacturing Formula mixing: Barium titanate (BaTiO₃)-based materials are doped with rare earth elements (such as Y, Nb) to adjust the Curie temperature (such as 80℃~250℃). Cast molding: Thin sheets (0.2~1.0mm) are made using the cast molding process, which is suitable for different power requirements. Sintering: High-temperature sintering (1200℃~1400℃) forms a dense ceramic structure to ensure a stable PTC effect. (2) Electrode preparation Screen printing: Silver paste or nickel electrodes are printed on both sides of the ceramic sheet to ensure low contact resistance. Co-firing process: The electrode is co-fired with the ceramic sheet to improve the bonding strength and conductivity.
2. PTC heating element assembly
(1) Monomer preparation Cutting and slicing: Laser/diamond cutting into required size (e.g. 10×10mm to 50×100mm). Electrode welding: Ultrasonic welding or conductive adhesive bonding of copper/aluminum electrodes to reduce contact resistance. (2) Modular packaging Insulation layer coating: High temperature resistant polyimide (PI) film or ceramic coating is used to improve insulation (withstand voltage > 3000V). Heat dissipation structure design: Aluminum substrate: High thermal conductivity aluminum plate (e.g. 5052 aluminum alloy) improves heat dissipation efficiency. Fins/heat pipes: Enhance convection heat dissipation, suitable for high-power heaters (e.g. battery pack heating).
3. Automated assembly and testing
(1) Automated production line SMT patch process: suitable for small PTC heaters (such as seat heaters). Laser welding: ensure that the electrode connection is firm and avoid cold solder joints. Potting process: use silicone/epoxy resin encapsulation to improve waterproof and shockproof performance (IP67).
Key testing items:
| Test items | Test Standards | Qualified Standard |
|---|---|---|
| Resistance-Temperature Characteristics | IEC 60738 | Curie temperature tolerance ±5°C |
| Insulation withstand voltage | ISO 6469-3 | 1500V AC/1min No breakdown |
| Vibration Testing | GB/T 28046.3 | 20G acceleration/200 hours without damage |
| Salt spray test | ASTM B117 | 1000 hours of no corrosion |
| Life test | High temperature and high humidity cycle (85°C/85%RH) | 5000 hours power attenuation <10% |