Elastic Connector Design for Vibration-Resistant PCB Heating Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical heating devices in motor vehicles face significant thermal stresses and vibration loads, leading to unreliable electrical connections and potential disconnection under varying temperature and vibration conditions.
Innovation Solution
The connecting piece is designed with at least two fastening sections elastically connected via a connecting section, generating prestressing forces that enhance the holding force on the circuit board, and can be further secured through soldering and spring tongues for improved electrical and mechanical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connector with rigid fastening sections is used, then the electrical connection is simple to manufacture, but the connection reliability deteriorates under thermal stresses and vibration loads
Solution Approach 1:
The connector employs dynamic fastening sections that can elastically deform and adapt to thermal expansion and vibration loads, transforming the rigid structure into a flexible one that maintains reliable electrical connection under varying conditions
Solution Approach 2:
The fastening sections are designed with elastic properties that allow them to change their mechanical parameters (force, position) in response to thermal stresses and vibrations, maintaining optimal contact pressure and connection reliability across different operating conditions
2Reliability
If the connector is rigidly fixed to the circuit board, then the manufacturing process is simple, but the electrical connection deteriorates under vibration loads
Solution Approach 1:
The fastening sections are designed to be elastically deformable rather than rigid, allowing them to dynamically absorb vibration loads while maintaining reliable electrical connection, at the cost of increased assembly complexity
Solution Approach 2:
The connector is pre-assembled with the elastic fastening sections attached to the circuit board before final installation, allowing the elastic elements to be pre-positioned and pre-stressed to ensure reliable connection from the outset
3Force
If elastic prestress is applied to the fastening sections, then the holding force increases, but the device complexity increases due to additional elastic components
Solution Approach 1:
The fastening sections are designed with inherent elastic properties that generate prestress forces, changing the mechanical parameters of the connector to achieve higher holding forces without requiring separate spring or elastic components
Solution Approach 2:
The elastic fastening sections combine multiple functions (mechanical fastening, electrical connection, vibration absorption, and force application) into a single integrated component, increasing holding force while minimizing additional complexity
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 design significantly increases the holding force and reliability of the electrical connection, ensuring secure attachment and operational safety even under thermal and vibrational stresses, enhancing the overall performance of the electrical heating device.
Implementation Method 1
The connecting piece with the two fastening sections is formed in one piece and the two fastening sections are elastically connected to one another via the connecting section
Implementation Method 2
the connector can be soldered to the circuit board in an electrically conductive manner
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
To specify an electric heating device that allows an improved electrical connection of the electric heating element (23), the electric heating device, which has at least one electric heating element (23) and a circuit board (40) which is electrically connected to at least one connector (62) for the electrical connection of the electric heating element (23), which forms at least one mounting section (72) resting on the circuit board (40) and from which at least two retaining webs (74) project, each engaging in a mounting hole (70) recessed in the circuit board (40), can be characterized in that the connector (62) forms at least two mounting sections (72) elastically connected to each other via a connecting section (80), each having one of the retaining webs (74), and is pre-tensioned in such a way thatthat the retaining webs (74) of the fastening sections (72) act with opposing holding forces (86) against an inner wall (84) of the fastening hole (70) associated with them.