Electric Heating Device Connection Circuit Board Adaptation
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Solution Overview
Problem
Existing electric heating devices for vehicles lack flexibility in adapting to individual customer specifications for connector design and arrangement, requiring changes to the control circuit board to meet specific power and control signal requirements.
Innovation Solution
A separate connection circuit board is introduced for electrical connection to power and control signals, allowing the control circuit board to remain unchanged, with the connection circuit board being adapted to meet specific customer specifications by using connector mating elements and board-to-board connectors for secure and safe electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the control circuit board is directly connected to plugging elements for power and control signals, then electrical connection is simplified, but adaptability to customer-specific connector designs is reduced
Solution Approach 1:
The electrical connection system is segmented into two independent parts: a control circuit board for control functions and a separate connection circuit board for power and signal connections. This segmentation allows the connection circuit board to be adapted to different customer-specific connector designs without modifying the control circuit board, thereby improving adaptability while maintaining clear functional separation.
Solution Approach 2:
A connection circuit board is introduced as an intermediary component between the plugging elements and the control circuit board. This intermediary handles all electrical connections for power and control signals, allowing the control circuit board to remain unchanged while the connection circuit board adapts to different connector designs, thus resolving the contradiction between adaptability and complexity.
2Adaptability or versatility
If connector design and arrangement are adapted to customer specifications, then adaptability is improved, but modification requirements increase
Solution Approach 1:
By segmenting the electrical connection system into control and connection functions handled by separate boards, modifications for customer specifications are confined to the connection circuit board only. The control circuit board remains standardized and unchanged, simplifying the manufacturing process while maintaining adaptability to customer needs.
Solution Approach 2:
The connection functionality is extracted from the control circuit board and placed on a separate connection circuit board. This extraction allows customer-specific adaptations to be implemented solely on the connection board, leaving the control board manufacturing unchanged and thus improving ease of manufacture while maintaining adaptability.
3Reliability
If insulating webs and U-shaped busbars are used for electrical safety at high voltages, then reliability is improved, but device complexity increases
Solution Approach 1:
The connection circuit board serves as an intermediary that incorporates insulating webs and U-shaped busbars to ensure electrical safety at high voltages. These safety features are integrated into the connection board rather than the control board, concentrating the complexity in one component while maintaining overall system reliability.
Solution Approach 2:
Insulating webs are placed locally at critical high-voltage connection points, and U-shaped busbars are used specifically for power transmission. This localized application of safety features provides necessary electrical protection without adding complexity to the entire device, maintaining reliability while minimizing overall complexity.
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
Enables easy adaptation to customer-specific connector designs without modifying the control circuit board, ensuring electrical safety and reliability, especially at high voltages like 48 volts, by using insulating webs and U-shaped busbars for increased clearance and creepage distance.
Implementation Method 1
The heating rib supports at least one PTC element and conductor tracks electrically connected in the connection chamber for energizing the PTC element
Implementation Method 2
This is typically done by passing the heated liquid medium over a heat exchanger through which air to be heated flows
Data Source
AI summary
An electric heating device includes a casing with a partition wall which separates a connection chamber from a heating chamber for dissipating heat to a medium to be heated. At least one heating rib projects from the partition wall in the direction toward the heating chamber and supports, in an insulated manner, at least one PTC element and conductor tracks for energizing the PTC element with different polarities. A control device with a populated control circuit board is provided in the casing. At least one connector casing is provided in the casing and has electrically conductive plugging elements that are electrically connected to the control circuit board. An electric heating device, which is used exclusively for the electrical connection of the plugging elements, is electrically connected to the control circuit board by way of at least one electrical connector.