Heat Generating Element Slide Plate Assembly Alignment
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Solution Overview
Problem
Existing heat generating elements face issues such as layer misalignment during assembly, inadequate insulation, and defects due to the injection molding process, leading to unreliable electric insulation and potential overheating of FTC elements.
Innovation Solution
A heat generating element design that incorporates a slide plate connected to the housing via a form-fit or frictional connection to prevent layer misalignment, with retaining arms to secure the wedge element and a bent-over tongue for secure contact sheet attachment, ensuring proper assembly and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the wedge element is shifted during assembly, then the heat generating element can be assembled into the pocket, but the layers (contact sheets, insulation layers, PTC element) may shift relative to each other causing misalignment
Solution Approach 1:
The contact sheets are pre-attached to the housing before the wedge element is inserted. This preliminary action ensures that the layers are already in their correct positions before assembly begins, preventing misalignment during the subsequent insertion of the wedge element and heating elements.
Solution Approach 2:
The contact sheets act as an intermediary component that is first fixed to the housing, providing a stable base layer. This intermediary step ensures proper positioning of subsequent components (insulation layers, PTC elements, wedge element) and prevents direct contact between the wedge element and the heating elements that could cause misalignment.
2Reliability
If the contact sheet is surrounded by insulation layer covering edge regions, then electric insulation is improved, but defects occur during injection molding due to heat introduction and injection pressures
Solution Approach 1:
The insulation structure is segmented into multiple parts: a first insulation layer attached to the contact sheet, and a second insulation layer attached to the housing. This segmentation allows each layer to be optimized independently - the first layer provides necessary insulation coverage while the second layer protects against molding defects, thereby maintaining both electrical insulation reliability and manufacturing quality.
Solution Approach 2:
Different insulation layers are applied at different locations with different properties. The first insulation layer covers the contact sheet edges where electrical insulation is most critical, while the second insulation layer is positioned to protect against the specific stresses of the injection molding process. This local differentiation optimizes both insulation performance and manufacturing reliability.
3Strength
If the wedge element is inserted to wedge up the heat generating element, then secure mounting is achieved, but flat contact between the heat generating element and pocket is compromised
Solution Approach 1:
The contact sheets are pre-attached to the housing in a flat configuration before the wedge element is inserted. This preliminary action establishes the correct flat contact geometry. The wedge element is then inserted to provide securing force without disrupting the pre-established flat contact between the heating elements and the pocket, as the contact sheets act as a protective intermediary layer.
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 enhances assembly efficiency, reduces the risk of layer misalignment, and improves insulation reliability, preventing overheating and increasing the operational reliability of the heat generating element.
Implementation Method 1
a first heating element which comprises a PTC element
Implementation Method 2
a second heating element which comprises an FTC element
Data Source
AI summary
A heat generating element includes at least one PTC element, contact sheets flatly lying against the PTC element on either side, a housing which forms at least one opening for receiving the at least one PTC element and which has a terminal side at which contact tongues allocated to the contact sheets are exposed. The device also has a wedge element with a broader and a narrower end face which are connected to each other via first and second wedge surfaces, the first wedge surface extending in parallel to one of the contact sheets and lying against it with a slide plate being inserted, and the second wedge surface being exposed at the outer side of the housing. A heat generating element less susceptible to damages during assembly has a slide plate connected to the housing.