Electric Heater Module Assembly with Terminal Stress Positioning
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Solution Overview
Problem
During the assembly of electric heating devices for vehicles, the electrical terminals connected to the power supply circuit can be overstressed, causing mechanical stress to the circuit board, which needs to be avoided.
Innovation Solution
Incorporating positioning means within the control box to limit the assembly movement of the heating modules, ensuring they are correctly positioned and securely connected, thereby preventing terminal stress and mechanical strain on the circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the heating modules are assembled without positioning means, then the assembly process is simpler, but the electrical terminals can be overstressed causing mechanical stress to the circuit board
Solution Approach 1:
The positioning means (positioning protrusions and positioning grooves) are pre-formed on the heating module and control box respectively, before the assembly operation. This preliminary structuring ensures that when assembly occurs, the components automatically align in the correct position, preventing terminal stress while maintaining assembly simplicity
Solution Approach 2:
The positioning means act as an intermediary mechanism between the heating module and control box. The positioning protrusions engage with positioning grooves to mediate the connection, ensuring proper alignment is achieved before electrical terminals make contact, thus preventing direct stress transmission to the circuit board
2Reliability
If positioning means are added to the control box, then the electrical terminals are protected from stress, but the device complexity increases
Solution Approach 1:
The positioning function is segmented from the main structural components and implemented as separate positioning protrusions and positioning grooves. This segmentation allows the positioning means to be added as discrete features rather than requiring a complete redesign of the control box structure, thus limiting the increase in device complexity
Solution Approach 2:
The positioning means are implemented as localized features (specific protrusions and grooves at specific locations) rather than requiring changes to the entire control box structure. This local implementation minimizes the increase in overall device complexity while providing the necessary protection for electrical terminals
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 positioning means facilitate precise and stress-free assembly of the heating device, ensuring the electrical terminals are correctly aligned and connected, thus preventing damage to the circuit board and ensuring reliable operation.
Implementation Method 1
electric heating modules intended to be crossed by the flow of air to be heated
Data Source
AI summary
The invention relates to an electric heating device for reheating an air stream flowing through same, said heating device comprising: a pre-determined number of electric heating modules (23) through which the air stream to be reheated flows and which have first electric terminals (45) to be electrically powered, and a control box (47) for controlling said heating modules (23) comprising second electric terminals (51) connected to the first terminals (45) and designed in such a way as to be connected to a power supply source for electrically powering said first terminals (45). According to the invention, the control box (47) also comprises means (53) for positioning said heating modules (23) in relation to said box (47) in order to define a suitable operating position before connecting said first (45) and second (51) terminals during the assembly of said heating device. The invention also relates to a method for assembling such a device.