A high-voltage positive temperature coefficient (PTC) heater has a simple structure and a\nswift response. Therefore, for cabin heating in electric vehicles (EVs), such heaters are used either on\ntheir own or with a heat pump system. In this study, the sintering process in the manufacturing of\nPTC elements for an EV heating system was improved to enhance surface uniformity. The electrode\nproduction process entailing thin-film sputtering deposition was applied to ensure the high heating\nperformance of PTC elements and reduce the electrode thickness. The allowable voltage and\nsurface heat temperature of the high-voltage PTC elements with thin-film electrodes were 800 V\nand 172 ââ??¦C, respectively. The electrode layer thickness was uniform at approximately 3.8 Ã?¼m or\nless, approximately 69% less electrode materials were required compared to that before process\nimprovement. Furthermore, a heater for the EV heating system was manufactured using the\ndeveloped high-voltage PTC elements to verify performance and reliability.
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