Water Heater Heating Pad Lead Wire Clamp Structure
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Solution Overview
Problem
Existing electric heating pads for water tanks face issues with the leading wire becoming detached from the heating layer due to undue force, leading to malfunction and ice formation in water tanks during cold weather.
Innovation Solution
An electric heating pad design featuring a substrate with a fastener system that securely fixes the leading wire to the heating layer using a clamp mechanism, reinforcing material, and adhesive layers to enhance strength and prevent disconnection, along with a through pipe to distribute the force and prevent substrate damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the leading wire is directly soldered and fixed on the heating layer, then the structure is simple and easy to manufacture, but the leading wire is easily separated from the heating layer when undue force acts on it
Solution Approach 1:
The patent divides the fixing system into multiple components: a fastener with clamp parts, a reinforcing material layer, and adhesive layers. This segmentation allows each component to perform a specific function - the clamp provides mechanical retention, the reinforcing layer distributes stress, and the adhesive ensures bonding - thereby improving reliability while maintaining manufacturing feasibility through modular assembly
Solution Approach 2:
The patent applies preliminary action by pre-installing the reinforcing material layer on the substrate and pre-positioning the fastener components before final assembly. The adhesive layer is applied in advance to ensure proper bonding when components are assembled. This preliminary preparation ensures that when the leading wire is installed, the entire fixing system is already in place to provide immediate protection against separation
2Strength
If a fastener system with clamp parts is used to fix the leading wire, then the connection strength is improved, but the device complexity increases
Solution Approach 1:
The patent merges multiple fixing functions into a single integrated fastener assembly that includes clamp parts, connecting rods, and mounting structures. By combining these elements into one unified component rather than separate parts, the design achieves strong mechanical retention of the leading wire while minimizing the number of discrete components that would increase complexity
Solution Approach 2:
The fastener system is designed with multi-functionality to address several requirements simultaneously: the clamp parts provide mechanical retention, the connecting rods transmit and distribute forces, and the overall structure anchors the leading wire to the substrate. This multi-functional design achieves high connection strength without requiring multiple separate components, thereby controlling device 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
The solution ensures a secure connection between the leading wire and heating layer, preventing detachment and improving the service life of the heating pad by distributing the force and enhancing mechanical strength, thus effectively preventing ice formation in water tanks.
Implementation Method 1
an adhesive layer is arranged at a surface of the heating layer, the protecting layer is arranged on the adhesive layer, and the protecting layer may be removed when the electric heating pad for the water tank is used. The adhesive layer arranged on the surface of the heating layer makes the first and second fixed parts be firmly fixed
Implementation Method 2
The electric heating pad heats the water tank and prevents the water tank from ice formation after the electric heating is electrified
Data Source
AI summary
An electric heating pad for a water tank includes a substrate, a heating layer paved on the substrate, a leading wire that is electrically connected to the heating layer, and a fastener that fixes the leading wire. The substrate is configured with a first through hole that latching to the leading wire. The fastener includes a first fixed part and a second fixed part that are arranged on two faces of the substrate. The second fixed part is configured with a clamp part, and a second through hole matching to the leading wire is arranged at the clamp part. The fastener further includes a connecting rod that connects the first fixed part to the second fixed part, the substrate is configured with a third through hole, and the connecting rod passes through the third through hole to make the substrate be clamped between the first fixed part and the second fixed part.