Electric Heat Exchanger Adaptor with Standardized Bus Bar Interfaces
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Solution Overview
Problem
The manufacturing of electric heat exchangers for motor vehicles is hindered by the need for custom-designed electric connectors for each application, leading to increased design work, tooling costs, and overall higher costs.
Innovation Solution
An electrical adaptor with a base body featuring first and second electric interfaces, and at least two bus bars intersecting the base body to create electric connectors on both sides, allowing for mechanical and electrical connection to a control unit and a power supply connector respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom-designed electric connectors are used for each application, then the electrical connection is optimized for specific applications, but the design work, tooling costs, and manufacturing costs increase
Solution Approach 1:
The patent applies universality by designing a standardized electric connector that can be used across multiple applications and vehicle types. The connector features a uniform contact arrangement and housing design that allows it to interface with different heat exchanger models and power supply systems, eliminating the need for custom-designed connectors for each application while maintaining reliable electrical connection
Solution Approach 2:
The patent applies segmentation by separating the connector into modular components including a housing, contact elements, and interface sections. This modular design allows the same basic connector structure to be adapted to different applications through configuration changes rather than complete redesign, reducing tooling costs while maintaining application-specific optimization
2Reliability
If custom-designed electric connectors are used for each application, then the electrical connection is optimized for specific applications, but the design work and development time increase
Solution Approach 1:
The standardized connector design serves multiple applications across different heat exchanger models and vehicle platforms, eliminating the need for repeated custom design work. The universal interface allows the same connector to be used in various configurations, significantly reducing development time and design resources required
3Ease of manufacture
If standardized electric connectors are used across applications, then the manufacturing cost is reduced, but the electrical connection may not be optimized for specific applications
Solution Approach 1:
The patent applies local quality by maintaining a standardized overall connector design for cost efficiency while allowing specific contact arrangements, pin configurations, and interface features to be optimized for local application requirements. This enables the same basic connector structure to provide application-specific electrical connection optimization through localized design variations
Data Source
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AI summary
The invention relates to an electrical adaptor (3), especially for an electric heat exchanger (2), having a base body (6) having a first side (7) and having a second side (8), the first side (7) of the base body (6) and the second side (8) of the base body (6) are located at the opposite sides of the base body (6), the base body (6) is provided with a first electric interface (9) on the first side (7) and the base body (6) is provided with a second electric interface (10) on the second side (8), the first electric interface (9) is designed to be mechanically and electrically connected with a control unit (1) whereas the second electric interface (10) is designed to be mechanically and electrically connected to a connector (4) of a power supply, whereas the base body (6) comprises at least two bus bars (12) which intersect the base body (6) from the first side (7) to the second side (8) creating each electric connectors (13, 14) on the first side (7) and on the second side (8). The invention further relates to an electric heat exchanger (2) having an electric adaptor.