PTC Heaters in Alternative Energy Vehicles

The market for electric vehicles in the U.S. is rising, with record sales reported in the second quarter of . This has resulted in a need for more efficient vehicle components, such as the ones used in modern heating and cooling systems. That is why KUS now offers components for energy-efficient vehicles, including our positive temperature coefficient (PTC) heating units. Here&#;s what you need to know about PTC heaters and their role in thermal management systems.

PAKE Product Page

What Is a PTC Heater?

PTC heaters operate on the principle that the electrical resistance of the heater increases as the heater&#;s temperature increases. The result is a self-regulating heating system. Unlike traditional heating elements that might require external thermostats or regulators, PTC heaters automatically adjust their heat output based on ambient temperature, this increases performance and reduces risks of potential thermal events.

One of the standout benefits of using PTC heaters over traditional heating elements is their efficiency. These systems can generate more heat while using less energy. By conserving energy, these heaters offer tangible benefits for electric vehicles, such as increased cruising ranges.

Comparing PTC Coolant Heaters and PTC Air Heaters

While PTC heaters have gained popularity in the automotive industry, it&#;s important to understand that different types are designed for specific applications. Two of the most commonly used types are PTC coolant heaters and PTC air heaters.

PTC Coolant Heaters

PTC Coolant Heaters

PTC coolant heaters are designed to heat a vehicle&#;s coolant. It primarily serves as a channel with a heating element to help maintain the vehicle&#;s battery at an optimal temperature. For this reason, they serve as an essential component for electric applications, especially during colder months. Maintaining the correct temperature for the battery ensures longevity and maximizes the vehicle&#;s performance.

PTC Air Heaters

PTC Air Heaters

As the name suggests, PTC air heaters focus on heating air directly. They are often used with a vehicle&#;s HVAC system to ensure the interior remains comfortable for passengers. In many modern vehicles, PTC air heaters have replaced the traditional heater core used in older models. PTC air heaters provide immediate warmth since they don&#;t rely on a secondary medium like coolant. This direct method can offer more rapid temperature changes in the cabin, enhancing passenger comfort, and help to decrease additional leak path potentials.

The Role of PTC Heaters in Alternative Energy Vehicles

KUS heaters feature impressive designs that help them serve in various applications. Our heaters stand out for several reasons, including:

• In-vehicle air conditioning. Air conditioning systems are necessary in modern vehicles, and PTC heaters ensure that the in-vehicle A/C systems are up to the mark.
• Battery thermal management. Batteries, especially those in electric vehicles, need to operate within a specific temperature range to ensure longevity and efficiency. PTC heaters help maintain this optimal temperature, especially during colder months.
• Hydrogen fuel cell cold starts. Starting a new energy vehicle in cold conditions can be challenging, especially if it&#;s a fuel-cell vehicle. PTC heaters assist in these cold starts, ensuring the vehicle operates smoothly regardless of the external temperature.

PTC Heater Benefits and FAQs

KUS PTC heaters offer several advantages over traditional heating elements. However, many are unfamiliar with these benefits. Here are some of the most common questions we receive about our PTC heater products.

What is the benefit of the PTC heating element?

The main benefits are energy efficiency, precise temperature control, and compact size. PTC heaters self-regulate their heat output based on conditions, maximizing efficiency.

How efficient is a PTC heater?

PTC heaters are very efficient. They generate more heat using less energy compared to traditional heating elements, thanks to their automated, self-regulating design.

What is the maximum temperature for a PTC heater?

PTC heaters can typically heat up to around 572°F (300°C) efficiently. The maximum temperature depends on the specific heater&#;s design and specifications.

Are PTC heaters cheaper to run?

Yes, PTC heaters are generally cheaper to operate. Their energy efficient design means they use less electricity to produce heat. This saves on energy costs compared to less efficient heating methods.

What size are KUS PTC heaters?

With the push toward more compact vehicles, every inch of space counts. KUS PTC heaters feature compact designs without compromising efficiency. At the same time, we offer multiple PTC heater products that meet the needs of a wide variety of applications.

PTC Heater Models and Specifications

From Electric Automotive vehicles to Material Handling and Industrial/Commercial platforms, KUS PTC heaters can be used in a wide range of applications. Review our popular PTC heater models in the chart below.

KUS PTC Water (Coolant) Heater Models

NPH10A

80V

3kW

Flow rate: 10L/min

Coolant temp: 32°F/0&#;

182*136*112

10kPa

NPL20

350V

5kW

Flow rate: 10L/min

Coolant temp: 140°F/60&#;

182*136*110

5.5kPA

NPH30A

600V

7kW

Flow rate: 10L/min

Coolant temp: 32°F/0&#;

221*136*110

20kPa

NPH30C

600V

7kW

Flow rate: 25L/min

Coolant temp: 32°F/0&#;

321*170*128

14.7kPa

NPH40

600V

10kW

Flow rate: 10L/min

Coolant temp: 32°F/0&#;

255*299*104

3kPa

NPH50

600V

15kW

Flow rate: 25L/min

Coolant temp: 32°F/0&#;

255*229*104

8.6kPa

NPK40

The company is the world’s best Polymer Ptc Heating Elements supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

800V

10kW

Flow rate: 12L/min

Coolant temp: 140°F/60&#;

255*247*104

3kPA

NWL40

350V

4kW

Flow rate: 12L/min

Coolant temp: 68°F/20&#;

153*191*88

3kPa

NWH80

800V

8kW

Flow rate: 12L/min

Coolant temp: 68°F/20&#;

200*237*88

5kPa

KUS PTC Air Heater Models

Air Heater (Integrated Type)

800V

10kW

Inlet air temp: 77°F/25&#;

Air speed: 7m/s

370*260*108

6.5kg

Air Heater (Split Type)

600V

5kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

250*280*32

3.0kg

Air Heater (Integrated Type)

600V

5kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

317*180*108

3.7kg

Air Heater (Split Type)

350V

5kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

250*280*32

2.8kg

Air Heater (Integrated Type)

48V

4kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

227*167*98

3.1kg

Air Heater (Integrated Type)

350V

3kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

305*180*108

3.1kg

Heat Pump Air Conditioning Auxiliary Heater

12V

1kW

Inlet air temp: 77°F/25&#;

Air speed: 4.5m/s

27*93*30

0.7kg

For more information, visit our PTC heaters product page.

Explore More New Energy Products From KUS

PTC heaters will play an increasingly important role in vehicles moving forward. With their efficiency, safety features, and adaptability, they are set to redefine vehicle heating systems.

At KUS, we&#;re ready to meet the changing demands of the automotive industry. With our range of PTC heaters and other new energy products built and tested in-house, we&#;re your trusted partner for a large selection of marine, vehicle, and industrial applications. Contact us today to speak with an expert on our team to learn more about how our products can meet your project needs.

I figure I'd throw my hat in here as well...

I remember the heater system. Hilariously complex, but efficient.

It consists of a completely separate coolant loop, but the "coolant" is rather used as "heatant" instead here. I think they just jimmied a standard Nissan HVAC system in there, one typically used for ICE engine cars.

In that coolant loop, there's:
- its own reservoir
- a heating element
- its own pump
- a heater core (goes to the vents) - and pretty much is immune to failure (it's just a dumb copper block!)
- a valve to regulate flow through the heater core
- a few sensors

Right now, the diagnosis is focused on the heating element (I assume - though the title says "heater core", "PTC" and the part number refers to the element). That may or may not be the right one to look at.

To know for sure, you should probably check that the coolant is actually flowing (pump; valve). It flows at all times the car is running, in my experience. So, you should be able to pop the cap off of either reservoir, and see coolant flowing in both. Don't worry, it's a closed system - popping the cap while the car is running won't leak anything out at you, and you should be able to observe turbulence in the liquid inside. No flow? Check your pump.

Next, check if either reservoir gets warm when you've got the heater running - kind of unlikely at this point. Turn car on, set to 90, foot, no A/C, fan on 2. It ought to get warm within 30 seconds to 1 minute.

Next, check the "energy monitor" screen and see if you have any AC/Heating power consumption on the screen. Yes? Then something is heating up (and the heating element is OK) - as that screen monitors actual load. But through those other tests, that ought to have been eliminated...

Then, you can take the diagnosis to eBay, pick up the right part, and quite possibly fix it yourself if you know how to Google the service manual for the Leaf. :mrgreen:

If you are looking for more details, kindly visit Prc Heater.