Heating Cartridge Connecting Wire Segmentation
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Solution Overview
Problem
Existing electrical heating cartridges face challenges in maintaining reliable and reproducible electrical contact, especially when high currents are required, leading to issues with geometry and potential short circuits.
Innovation Solution
The design incorporates a connecting wire with varying cross-sectional geometry sections, where a thinner section is inserted into a channel in the winding body for intimate contact with the electrical heating element, and an insulating layer prevents short circuits, allowing for optimal current flow and reduced risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a thick connecting wire is used to handle high currents, then current carrying capacity is improved, but the wire cannot be inserted into the channel of the winding body and intimate contact with the heating element cannot be achieved
Solution Approach 1:
The connecting wire is divided into two distinct sections: a first section with larger cross-sectional area for current carrying, and a second section with smaller cross-sectional area for insertion into the channel. This segmentation allows each section to be optimized for its specific function, resolving the contradiction between current capacity and contact reliability.
Solution Approach 2:
Different sections of the connecting wire are given different cross-sectional geometries tailored to their local requirements. The first section has dimensions optimized for electrical current flow, while the second section has dimensions optimized for mechanical insertion and electrical contact with the heating element within the channel.
2Reliability
If the connecting wire is compressed to improve contact, then electrical contact is improved, but the wire may overheat due to high current density
Solution Approach 1:
The connecting wire is compressed within the channel to achieve intimate contact with the heating element, accepting localized compression heating in exchange for reliable electrical contact. The channel provides containment and insulation, allowing the compression to be applied without causing overall wire failure.
3Strength
If a metal sheath is used to protect the heating element, then mechanical protection is improved, but short circuits to the sheath become a risk
Solution Approach 1:
An insulating layer is introduced as an intermediary between the connecting wire and the metal sheath. This insulating layer prevents direct electrical contact between the wire and the conductive sheath, eliminating the short circuit risk while allowing the sheath to provide its mechanical protection function.
4Ease of manufacture
If the connecting wire cross-section is uniform, then manufacturing is simplified, but it cannot satisfy both current carrying requirements and channel insertion requirements
Solution Approach 1:
The connecting wire is manufactured with two distinct cross-sectional sections, allowing each section to be optimized for its specific function. This segmentation resolves the contradiction by enabling the wire to satisfy both current carrying requirements and channel insertion requirements through differentiated geometry.
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 configuration ensures a stable and efficient electrical contact, preventing overheating and allowing for higher current loads while minimizing the risk of damage, thus enhancing the heating cartridge's performance and reliability.
Implementation Method 1
the connecting wire has at least one location or section along its direction of travel where the cross-sectional geometry of the connecting wire deviates from the cross-sectional geometry of the connecting wire
Implementation Method 2
at least one electric heating element which is wound at least partially onto a winding body
Data Source
Figure 1a~1e
Figure 1f
Figure 2a~2e
AI summary
An electric heating cartridge (100) is provided, comprising at least one connecting wire (150, 160, 250, 260, 350, 360, 450, 460, 550, 560) and at least one electric heating element (140) wound on a winding body (130), wherein the winding body (130) has at least one channel (131, 132) in which at least one end (141, 142) of the electric heating element (140) wound on the winding body (130) is received, wherein the connecting wire (150, 160, 250, 260, 350, 360, 450, 460, 550, 560) has at least one first position or section (151, 161, 251, 261, 351) along its direction of travel. 361, 451, 461, 551, 561) where the cross-sectional geometry of the connecting wire (150, 160, 250, 260, 350, 360, 450, 460, 550, 560) differs from the cross-sectional geometry of the connecting wire (150, 160, 250, 260, 350, 360, 450, 460, 550, 560) at least with respect to the contour of the cross-sectional area of the connecting wire (150, 160, 250, 260, 350, 360, 450, 460, 550,560) at a second location or a second section (152, 162, 252, 262, 352, 362, 452, 462, 552, 562) and furthermore that a section of the at least one connecting wire (150, 160, 250, 260, 350, 360, 450, 460, 550, 560) is received into the channel (131, 132) so that an electrical contact exists in the channel (131, 132) between the received end (141, 142) of the electrical heating element (140) and the received section of the connecting wire (150, 160, 250, 260, 350, 360, 450, 460, 550, 560).