Vehicle Heater PCB Plug-In Assembly Without Soldering
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Solution Overview
Problem
The existing electrical heating devices for motor vehicles, particularly in the context of electromobility, face challenges in manufacturing efficiency and cost-effectiveness, with complex assembly processes and the need for soldered connections complicating the production of compact and efficient heating solutions.
Innovation Solution
The electrical heating device features a connecting circuit board that protrudes beyond the housing, allowing for direct plug-in connections with the control circuit board without soldering, utilizing a plastic plate and stamped metal plate with plug-in elements for easy assembly and reduced scrap rates, and includes a method where the electrical heating elements are inserted into U-shaped recesses with the circuit boards connected in a way that simplifies the electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connecting circuit board is extended laterally beyond the housing with direct plug-in connections, then the ease of manufacture and assembly is improved, but the device complexity increases due to extended board layout
Solution Approach 1:
The device is divided into two separate functional units: a power unit containing the heating elements and a control unit containing the control circuit board. The connecting circuit board acts as an interface between these segments, allowing independent manufacturing and assembly of each unit while maintaining electrical connectivity through the extended board design.
2Productivity
If soldered connections are eliminated in favor of direct plug-in connections, then the productivity and manufacturing speed are improved, but the reliability of electrical connections may worsen
Solution Approach 1:
The connecting circuit board is pre-assembled with the power unit, including the extension beyond the housing and the connection elements. This preliminary assembly ensures proper alignment and positioning before the final connection to the control unit, maintaining connection reliability while enabling faster assembly through plug-in rather than soldering.
3Ease of operation
If the connecting circuit board protrudes beyond the housing, then the ease of operation for connection is improved, but the volume of the device increases
Solution Approach 1:
The connecting circuit board extends in the lateral direction (one dimension) beyond the housing rather than increasing the overall device volume in three dimensions. This dimensional approach allows the connection interface to be accessible while maintaining a compact overall device footprint.
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 simplifies the assembly process, reduces production costs, and enhances the compactness and efficiency of the heating device by eliminating the need for soldering, allowing for easier exchange and testing of components while maintaining effective heat transfer and minimal heat loss.
Implementation Method 1
an electrical heating device for heating a liquid temperature control medium... an electric heating device, in particular for heating liquid tempering media in a motor vehicle
Implementation Method 2
the housing cover generally having a peripheral edge which surrounds the connection chamber... good heat transfer to the medium to be heated
Data Source
AI summary
The present invention relates to an electric heating device, in particular for a motor vehicle, with a housing (2) which encloses a circulation chamber (14) through which a medium flows, into which at least one heating fin (22) projects, which opens to a connection chamber (30) in which electrical connection elements (28.1) of at least one electrical heating element (28) of the heating fin (22) project, wherein the connection elements (28.1) are electrically connected via a connection circuit board (40).To simplify the manufacture of this previously known electric heating device, the present invention proposes extending the connecting circuit board (40) laterally beyond the housing (2) and passing it through a connecting circuit board connection opening (118) of a control housing (60), wherein conductor tracks formed on the connecting circuit board (40) are directly contacted with conductor tracks of a control circuit board (64) which is received in the control housing. Furthermore, the present invention proposes a method for manufacturing such an electric heating device in which the electric heating element (28) is first arranged in the heating fin (22) and then the connecting circuit board (40) is slid onto the connection elements (28.1) to connect conductor tracks of the connecting circuit board (40) with the connection elements (28.1).1) to contact, a control housing (60) is pushed onto the terminal circuit board (40) in a direction lying substantially in the plane of the terminal circuit board (40) and electrical connection elements (38;114) of the terminal circuit board (40) are connected to conductor tracks of a control circuit board (64) provided in the control housing (60) by plugging them in.