Cast Housing Plastic Deformation for Thermal Coupling
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Solution Overview
Problem
Existing heating devices face challenges in cost-effectively achieving good thermal coupling between ceramic heating elements and metal housings, particularly when exposed to chemically aggressive fluids, as traditional methods like pressing after insertion or using plastic-coated metal housings are inefficient.
Innovation Solution
A cast housing with a wedge-shaped interior is plastically deformed to accommodate the heating element, allowing for easier insertion and demolding, and is then pressed to achieve parallel sides, with a mounting frame and plastic assembly enhancing heat transfer and handling, using an aluminum-silicon alloy for high thermal conductivity and mechanical strength, and optionally coated with a plastic jacket for added protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cast housing with wedge-shaped interior is used before pressing, then heating element insertion and demolding are easier, but the housing requires plastic deformation to achieve parallel sides for proper assembly
Solution Approach 1:
The housing is cast with a preliminary wedge-shaped interior that facilitates easy insertion of the heating element and simplifies demolding. This preliminary shape is intentionally designed to be deformed later into the final parallel-sided configuration, allowing manufacturing steps to be performed in an optimized sequence
2Reliability
If the housing is pressed to achieve parallel sides, then thermal coupling of the heating element is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The housing undergoes plastic deformation through pressing that changes its geometric parameters from a wedge-shaped interior to parallel sides. This parameter change is essential for achieving the proper thermal coupling between the heating element and housing, as the parallel configuration ensures uniform contact and heat transfer
3Reliability
If aluminum-silicon alloy is used for the housing, then thermal conductivity and mechanical strength are improved, but the material selection and casting process become more specific
Solution Approach 1:
An aluminum-silicon alloy is used for the housing, combining the high thermal conductivity of aluminum with the strength and castability provided by silicon. This composite material approach optimizes both thermal performance and mechanical properties while maintaining good casting characteristics for producing the complex wedge-shaped preliminary housing
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 approach facilitates efficient heat transfer from the ceramic heating element to the metal housing, reduces the need for aggressive deformation, and allows for easier assembly and disassembly, while maintaining effective thermal conductivity and mechanical integrity over time.
Implementation Method 1
aluminum-silicon alloys combine good thermal conductivity with advantageous mechanical properties
Implementation Method 2
two opposite side walls are plastically deformed by pressing the cast housing
Data Source
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AI summary
The invention relates to a heating device with at least one heating element (2) having two opposing contact surfaces where it is electrically contacted, a contact plate (4) bearing against one of the two contact surfaces of the heating element (2), a cast metal housing (1) enclosing an interior space in which the heating element (2) is arranged, the interior space being bounded by an upper wall (1a) and a lower wall (1b), and the upper wall (1a) and the lower wall (1b) being connected to each other via two opposing side walls (1c), the heating element (2) having one of its two contact surfaces facing the upper wall (1a) and the other contact surface facing the lower wall (1b), and the side walls (1c) being plastically deformed by pressing the housing (1). According to the invention, the plastic deformation of the two opposing side walls (1c) increases in the longitudinal direction of the side walls (1c).