Heating Cartridge Integrally Connected Terminal Lug
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Solution Overview
Problem
Existing cartridge heaters face challenges in reliably connecting their metal jacket tubes to conductors, particularly with metals that are difficult to weld or solder, such as titanium or aluminum, leading to error-prone electrical contacts.
Innovation Solution
Incorporating an integrally connected terminal lug on the metal jacket tube, which can protrude or be formed from the edge area, allowing for easier and more reliable connection via crimping, riveting, or screwing, and designed as a flat or circular connector for improved contact behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding or soldering is used to connect the protective conductor to the metal casing, then electrical connection is achieved, but the process becomes complex and unreliable for difficult-to-weld metals like titanium or aluminum
Solution Approach 1:
The connection system is divided into two parts: the metal casing and a separate connecting element (lug, clamp, or ring) that can be independently attached to the casing and then connected to the conductor. This segmentation allows the use of simple attachment methods (crimping, clamping, or mechanical fastening) instead of complex welding or soldering processes.
Solution Approach 2:
A connecting element serves as an intermediary between the metal casing and the conductor. This intermediary component facilitates the electrical connection without requiring direct welding or soldering between the casing and conductor, thereby simplifying the process and improving reliability for difficult-to-weld metals.
2Ease of manufacture
If clamping is used to connect the protective conductor to the metal casing, then the process is simpler, but the electrical connection becomes fault-prone and less reliable
Solution Approach 1:
The connecting element is pre-formed with specific geometries (such as flattened sections, ridges, or contact surfaces) that ensure proper electrical contact with the metal casing before the final assembly. This preliminary preparation of the connection interface guarantees reliable electrical contact while maintaining ease of installation.
Solution Approach 2:
The connecting element undergoes parameter changes during attachment, such as deformation (crimping), expansion (clamping), or positioning (mechanical fastening), to establish both mechanical and electrical contact. These controlled parameter changes ensure reliable electrical connection while keeping the process simple.
3Device complexity
If the metal casing is directly connected to conductors, then the structure remains simple, but the connection process becomes error-prone and difficult for difficult-to-weld metals
Solution Approach 1:
The connection system is divided into two parts: the metal casing and a separate connecting element (lug, clamp, or ring) that can be independently attached to the casing and then connected to the conductor. This segmentation allows the use of simple attachment methods (crimping, clamping, or mechanical fastening) instead of complex welding or soldering processes.
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 secure and error-free connection of the metal jacket tube to conductors, enhancing the reliability and ease of electrical contact, especially with metals that are hard to weld or solder.
Implementation Method 1
electric heating element, which can be, for example, a resistance wire wound on a carrier or a coiled resistance wire
Implementation Method 2
Heat transfer from the electric heating element to the metal sheath can be ensured, for example, by a highly thermally conductive, and, at least in the case of resistance wires, also electrically insulating, filler material
Data Source
Figure 1~3
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Figure 5
AI summary
The invention relates to a heating cartridge (10, 20, 30, 40) with a metal casing (11, 21, 31, 41) and an electric heating element (32) arranged inside the metal casing (11, 21, 31, 41), wherein at least one connecting tab (14, 24, 34, 44) is integrally connected to the metal casing (11, 21, 31, 41).