Flow Heater Clamped Electrical Connector to Eliminate Soldered Joints
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Solution Overview
Problem
Existing flow heaters require soldered joints between the heating plate and circuit board, which complicates production and can be prone to failure over time.
Innovation Solution
Establishing an electrical contact by clamping the heating plate between a clamping part of the electrical connector and a conductor projecting from the plastic body, eliminating the need for soldered joints and allowing for better tolerance compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered joints are used to connect the heating plate to the circuit board, then electrical contact is established, but production becomes complicated and reliability decreases over time
Solution Approach 1:
The patent replaces the soldered joint (chemical/thermal bonding) with a mechanical clamping connection. The heating plate is clamped between the clamping part of the electrical connector and the circuit board, establishing electrical contact through direct mechanical pressure rather than soldering. This substitution eliminates the need for soldering processes while providing a more reliable electrical connection that can be easily assembled and disassembled.
2Manufacturing precision
If soldered joints are used to connect the heating plate to the circuit board, then electrical contact is established, but production tolerances cannot be easily compensated
Solution Approach 1:
The clamping connection allows for dynamic adjustment to accommodate manufacturing tolerances. The clamping force can be adjusted during assembly to ensure proper electrical contact even when there are variations in the dimensions of the heating plate or circuit board. This dynamic adjustment capability is not available with rigid soldered joints, which require precise pre-alignment during the soldering process.
3Duration of action of stationary object
If soldered joints are used to connect the heating plate to the circuit board, then electrical contact is established, but service life is reduced due to connection weakness
Solution Approach 1:
The electrical connector is divided into distinct functional parts: a clamping part for mechanical securing, a conductor for electrical conduction, and a plastic body for insulation and structural support. This segmentation allows each part to be optimized for its specific function, with the clamping part providing strong mechanical retention and the conductor ensuring reliable electrical contact, thereby extending the overall service life of the heating device.
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
Simplifies production, enhances reliability, and extends the service life of the flow heater by providing a stronger and more reliable electrical connection.
Implementation Method 1
an electrical contact with the heating plate is established by clamping the heating plate between a clamping part of the electrical connector and an end section of a conductor projecting from the plastic body of the electrical connector
Data Source
AI summary
A flow heater has a heating plate that has a metal plate, a heating conductor track, and an insulating layer between the heating conductor track and the metal plate. The heating plate is arranged in a housing and the housing encloses a flow channel for fluid to be heated, which leads from an inlet port of the housing to an outlet port of the housing. A circuit board with control electronics is provided. An electrical connector connects the heating conductor track of the heating plate electrically to the control electronics, and the electrical connector has a plastic body from which a conductor projects and extends into a hole of the circuit board. The heating plate is clamped between a clamping part of the electrical connector and an end section of the conductor projecting from the plastic body. A heating plate for such a flow heater is also described.