Heat Exchanger Heater Assembly With Integrated Clamp Fixing
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Solution Overview
Problem
Existing heaters for maintaining electronic equipment temperatures at low outside temperatures are costly to manufacture and assemble due to complex assembly requirements and additional processing steps for holding devices.
Innovation Solution
A heater design featuring a heat exchanger with extruded profiles and plastic molded parts with bendable extensions for easy assembly, along with tongue and groove devices and a U-shaped base for quick installation, eliminating the need for additional processing steps and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional assembly methods are used for heaters, then reliable fixation of components is achieved, but manufacturing and assembly costs increase due to complex processing steps
Solution Approach 1:
The patent combines the fixation function and the structural support function into a single integrated housing component. The housing includes integrated fixation elements that directly secure the heating element and heat exchanger without requiring separate fixation devices, thereby reducing manufacturing complexity and cost while maintaining reliable fixation.
Solution Approach 2:
The housing is designed with self-fixating features where the housing structure itself provides the fixation mechanism through integrated elements such as recesses, protrusions, or deformation zones that automatically secure components during assembly without requiring additional fixation operations or devices.
2Stability of the object's composition
If additional holding devices are added to the heat exchanger, then component stability is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The housing integrates multiple functions including structural support, component positioning, and fixation into a single component. The housing contains integrated fixation elements that directly secure the heating element and heat exchanger, eliminating the need for separate holding devices and reducing overall device complexity.
Solution Approach 2:
The housing is designed as a multi-functional component that simultaneously provides structural support, thermal management, component positioning, and fixation. This universal design consolidates multiple functions into one element, reducing the total number of parts and simplifying the assembly process while ensuring component stability.
3Manufacturing precision
If precise positioning features are added to ensure proper assembly, then assembly precision is improved, but manufacturing cost and production time increase
Solution Approach 1:
The housing is pre-designed with integrated positioning features and fixation elements during the housing manufacturing process. These features are built into the housing structure beforehand, allowing for quick and precise assembly of the heating element and heat exchanger without requiring additional positioning operations or adjustments during assembly, thereby maintaining high precision while improving production efficiency.
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
The solution enables a cost-effective and efficient assembly process with reduced manufacturing steps, facilitating the production of heaters with minimal additional effort, ensuring effective heat transfer and efficient heat dissipation with minimal losses.
Implementation Method 1
a heating unit (300), which is arranged in a receiving cavity (206) of the heat exchanger (200)
Implementation Method 2
a heat exchanger (200)... through which air can flow through the grille walls
Implementation Method 3
the heat exchanger (200) with inserted heating unit (300), wherein surfaces of the receiving cavity (206) are pressed against surfaces of the heating unit (300) in order to obtain good heat transfer
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A heater has a heat exchanger (200), and a heating unit (300) is arranged in the receiving cavity (206) of the heat exchanger. The plastic shaped part (100) has fixing units for clamp fixing at front side of the heat exchanger. The plastic shaped part has guide units (109) which engages form fit with counter guide units (404, 405) at the housing (600).