Electric Heater Connection Interface for Terminal Shear Resistance
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Solution Overview
Problem
Existing electric heating devices in vehicles face issues with rapid and efficient heating of the passenger compartment, particularly in cold weather, due to insufficient heat from the engine coolant, and risk of connection terminal shearing under vibrations.
Innovation Solution
An additional electric heating device with a connection interface featuring a shear limiting device, comprising ribs and notches, and a displacement limiting device using plastically deformable pins to secure heating elements, ensuring reliable electrical connection and reduced risk of shearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the thickness of the electrodes is reduced for miniaturization and cost reduction, then the device size and cost are reduced, but the risk of shearing of the connection terminal increases under vibrations
Solution Approach 1:
The patent introduces a shear limiting device as an intermediary component between the connection terminal and the housing walls. This device includes a first element with a first face having a first area and a second element with a second face having a second area, where the first area is greater than the second area. The shear limiting device distributes the mechanical stresses and vibrations away from the thin connection terminal, preventing shearing while allowing the terminal thickness to be reduced for miniaturization and cost reduction.
2Strength
If the contact area between the connection terminal and housing walls is increased for better holding, then the holding strength is improved, but the complexity of the connection interface increases
Solution Approach 1:
The patent segments the contact area into two distinct elements: a first element with a first face having a first area, and a second element with a second face having a second area. The first area is greater than the second area, creating a stepped or tiered contact structure. This segmentation allows the total contact area to be increased for better holding strength while maintaining a relatively simple connection interface design through the modular arrangement of the two elements.
3Reliability
If additional structural elements are added to prevent shearing, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the shear limiting function with the electrical connection function by integrating the first element and second element directly into the connection interface structure. The shear limiting device is formed as part of the connection interface itself, combining multiple functions (electrical connection, mechanical holding, and shear protection) into a single integrated component rather than adding separate structural elements, thereby improving reliability without significantly increasing device complexity.
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 provides a secure and reliable electrical connection, reducing the risk of shearing and ensuring efficient heating performance by enhancing the contact area between the connection interface and terminals, while maintaining the heating elements in place.
Implementation Method 1
a heating body comprising a plurality of parallel conductive plates between which are mounted resistive heating elements
Implementation Method 2
radiant elements increasing the heat exchange surface with the air flow passing through the electric heating device
Data Source
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AI summary
An electrical connection interface (100) of a device for electrically heating a flow of air flowing within a ventilation, heating and/or air conditioning system of a motor vehicle comprises, in a panel (102), at least one notch that is dimensioned for receiving a connection terminal (126) mounted at the end of an electrode of a heating element of the electric heating device. The electrical connection interface comprises at least one device for limiting the shear (101) of the connection terminal which extends proud from the panel (102) adjacent to the notch.