Electric Heating Module Frame with Integrated Heat Sink Positioning
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Solution Overview
Problem
The existing electric heating modules for motor vehicles face challenges in the complex and costly manufacturing process due to the difficulty of accurately positioning and aligning heat sinks with the frame, requiring manual or robotic adjustments to ensure proper alignment during assembly.
Innovation Solution
An armature with integrated positioning means, including main and secondary walls, ribs, enclosures, and keying features, is used to securely hold and align heat sinks on the frame, allowing for precise placement and retention without the need for additional tools, forming a unitary piece made of flexible plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the frame structure is simplified to reduce manufacturing complexity, then the manufacturing process becomes easier and less costly, but the positioning precision of heat sinks deteriorates
Solution Approach 1:
The frame is segmented into functional zones: positioning means with walls and ribs for precise heat sink alignment, resistive element holding structures, and heat sink support areas. This segmentation allows each zone to be optimized independently - the positioning means provides precision while the overall frame structure remains simple and cost-effective to manufacture.
2Manufacturing precision
If multiple positioning means are integrated into the frame, then the heat sink alignment precision is improved, but the device complexity increases
Solution Approach 1:
Multiple positioning functions are merged into a single integrated frame structure. The positioning means including walls, ribs, and support features are all combined in one piece that also holds the resistive elements and supports the heat sinks. This merging reduces the number of separate components and assembly steps while maintaining high positioning precision through the integrated design.
Solution Approach 2:
The frame serves multiple functions simultaneously: it positions the heat sinks with precision walls and ribs, holds the resistive heating elements, provides structural support, and facilitates assembly. This multi-functionality reduces the need for separate positioning devices, brackets, or alignment tools, thereby reducing overall device complexity while maintaining positioning accuracy.
3Manufacturing precision
If manual tools are used to maintain heat sink position during assembly, then the positioning accuracy is improved, but the manufacturing time and cost increase
Solution Approach 1:
The frame's positioning means is designed to self-position the heat sinks during assembly. The walls, ribs, and support structures automatically guide and hold the heat sinks in the correct positions without requiring external manual tools or complex alignment procedures. This self-positioning capability maintains high positioning accuracy while significantly improving manufacturing efficiency by eliminating time-consuming manual adjustment steps.
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 solution simplifies and reduces the manufacturing cost by ensuring precise alignment and retention of heat sinks, eliminating the need for manual adjustments and reducing the number of manufacturing steps, resulting in a more efficient and cost-effective assembly process.
Implementation Method 1
heating modules comprising resistive heating elements
Implementation Method 2
heat sinks allowing the exchange of heat between the calories produced by the resistive heating elements and an air flow passing through the heating module
Implementation Method 3
heat sinks allowing the exchange of heat between the calories produced by the resistive heating elements and an air flow passing through the heating module
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Frame (2) for an electric heating module (M) capable of cooperating with at least one heat sink (4) and at least one resistive element (20) of the electric heating module (M), said frame (2) comprising a frame (14) delimited by two longitudinal edges (16) and two lateral edges (18), the frame (14) being provided with at least one recess (19) for housing the resistive element (20), characterized in that that the armature (2) comprises at least one means (12) for positioning the heat sink (4) on the armature (2) so as to prohibit both a longitudinal movement of the heat sink (4) and a lateral movement of the heat sink (4) relative to the frame (2).