Snap-In Heater Plug Assembly for Easier Cable Connection
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Solution Overview
Problem
The existing methods for connecting electrical cables to wall-mounted heaters are time-consuming and difficult due to the need to access and manipulate cables in hard-to-reach locations, especially when connecting mains and controller lines.
Innovation Solution
A heater design featuring a slot on its underside with a snap-in connector system that allows cables to be easily connected to luster terminals, forming a unit with the plug, which can be inserted into the slot for secure and accessible assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cover is opened and luster terminals are used to connect cables, then reliable electrical connection is achieved, but the installation process becomes time-consuming and difficult in hard-to-reach locations
Solution Approach 1:
The connection system is divided into separate components: a connection unit with socket that remains in the heater, and a plug element that attaches to the boiler. This segmentation allows the plug to be connected from the accessible front side while the socket stays protected inside, eliminating the need to open the cover for cable connections.
Solution Approach 2:
The plug element acts as an intermediary component that bridges the external power supply/cable connections and the internal heater components. By connecting cables to the plug from the front and then inserting the plug into the connection unit, the system provides reliable electrical connection without requiring access to the internal recess.
2Ease of operation
If the cover is opened to access the recess for cable connection, then cable connection is possible, but the housing protection is compromised and reassembly is required
Solution Approach 1:
The connection unit is pre-assembled with the socket integrated into the housing structure before final installation. The plug element is designed with pre-attached cable connection points, allowing cables to be connected to the plug from the front without needing to access the internal recess or open the cover.
Solution Approach 2:
Instead of bringing cable connections from the inside out (requiring cover removal), the system inverts the approach by bringing the plug element from the outside in. Cables are connected to the plug from the accessible front side, and the plug is then inserted into the connection unit, eliminating the need to open the cover.
3Ease of operation
If a snap-in connector system is used, then assembly is simplified and accessibility is improved, but the connection structure becomes more complex
Solution Approach 1:
The plug element is designed to nest into the connection unit through a slot opening. The plug contains the cable connection points (luster terminals), and when inserted, it becomes nested within the connection unit structure, providing a compact integrated assembly that simplifies the overall connection process despite the added connector components.
Data Source
Figure 1~3
Figure 4~5
AI summary
A heater (1) has a slot (2) on its underside, which is used to hold a plug (3) with connecting cables for the mains connection and controller.