Electric heating device and method for its production
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Solution Overview
Problem
Existing electric heating devices are heavy and non-compact due to aluminum die-casting manufacturing, and they face issues with fluid leakage and electrical safety due to loose connections and aging seals, particularly in vehicle applications.
Innovation Solution
The method involves using thin sheet metal components to create separate connection and heating chambers with inductive soldering for a secure, fluid-tight connection, allowing for a more compact design and reduced material mass, enabling a dense arrangement of heating elements without the need for extensive die-casting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum die-casting is used to manufacture the partition wall and heater housing as one piece, then structural strength and sealing are improved, but the device becomes heavy and non-compact
Solution Approach 1:
The partition wall and heater housing are manufactured as separate thin sheet metal components rather than a single die-cast piece. This segmentation allows each component to be optimized independently and assembled together, reducing overall material usage and weight while maintaining structural integrity through the joining process.
Solution Approach 2:
The invention uses composite construction by joining thin sheet metal parts through inductive soldering with filler material. This creates a hybrid structure that combines the advantages of thin materials (weight reduction) with the strength of joined connections, achieving both lightweight design and structural robustness.
2Strength
If aluminum die-casting is used to manufacture the partition wall and heater housing as one piece, then structural integrity is improved, but the device volume increases reducing compactness
Solution Approach 1:
By dividing the structure into separate thin sheet metal components that can be precisely fitted and joined, the overall device volume is reduced compared to a monolithic die-cast structure. The segmented approach allows for tighter tolerances and more efficient space utilization.
Solution Approach 2:
The use of thin sheet metal components (thin films) instead of thick die-cast parts significantly reduces the volume of each component. The thin-walled construction maintains sufficient structural integrity when properly joined, enabling a more compact overall device design.
3Ease of manufacture
If heater housings are spaced apart by a certain distance due to manufacturing reasons, then manufacturing feasibility is improved, but compactness and heating efficiency are reduced
Solution Approach 1:
The invention replaces traditional mechanical joining methods (which require spacing for tool access and tolerance compensation) with inductive soldering. This thermal joining process can effectively join thin sheet metal components with minimal spacing requirements, enabling tighter arrangement of heater housings and more compact device design.
4Reliability
If plastic seals are used at high temperatures, then sealing function is provided, but reliability deteriorates due to deterioration and leakage risk
Solution Approach 1:
The invention changes the material parameter of the seal from plastic to metal (copper-based filler material). This material substitution fundamentally alters the temperature resistance characteristics, allowing the seal to maintain its integrity and sealing function at high operating temperatures where plastic would deteriorate.
Solution Approach 2:
The use of copper-based filler material in the soldering process creates a metal-to-metal seal that is thermally stable. This composite joining method produces a seal that combines the sealing function with high-temperature resistance, eliminating the deterioration issues associated with plastic seals.
5Reliability
If fluid-tight sealing is implemented to prevent leakage, then safety is improved, but device complexity increases
Solution Approach 1:
The invention merges the sealing function with the structural joining process. The inductive soldering that joins the partition wall to the heater housing simultaneously creates the fluid-tight seal. This consolidation eliminates the need for separate sealing components and assembly steps, reducing device complexity while ensuring safety.
Solution Approach 2:
The copper-based filler material serves dual functions: it provides the structural joint between components and simultaneously creates the fluid-tight seal. This composite joining approach eliminates the need for additional sealing layers or gaskets, simplifying the overall sealing structure while maintaining safety.
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 results in a lighter, more compact, and safer electric heating device with improved thermal stability and fluid-tight connections, reducing the risk of leakage and ensuring operational safety, especially in vehicle environments.
Implementation Method 1
inductive soldering, wherein this housing wall can completely or partially surround the connection chamber and/or the heating chamber
Implementation Method 2
The solder flows into the gap and solidifies there
Data Source
Figure 1
Figure 2a~3
Figure 4~10
AI summary
The present invention relates to an electric heating device with a housing which has a partition separating a connection chamber from a heating chamber for heat emission, wherein a housing (2) with a partition (12) separating a connection chamber (8) from a heating chamber (10) for heat emission and from which at least one heating device housing (8) projects towards the heating chamber (10), in which at least one PTC element (20) and conductor tracks (22) electrically connected to the PTC element (20) with different polarity, which are electrically connected in the connection chamber (8), are insulated and supported.A compact electric heating device is created by connecting a housing wall (16) projecting from the partition (12) and defining the connection chamber (8) and/or the heating chamber (10) and the heating device housing (18) to the partition (12) in a materially bonded manner, in particular by inductive soldering.