Heating Rod with Segmented Contact Sheets for Power Control
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Solution Overview
Problem
Existing heating rods for vehicles require complex controllers to adjust heating power due to their design, which only allows for all elements to be activated or none, limiting control and efficiency.
Innovation Solution
A heating rod design with three terminals, featuring two contact sheets and an insulation layer, allowing selective activation of heating elements by applying voltage to either the first or second contact sheet, enabling partial or full heating power adjustment with reduced control effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If voltage is applied to all heating elements simultaneously, then heating power is maximized, but control complexity increases and energy efficiency decreases
Solution Approach 1:
The heating rod is divided into multiple independent heating element groups, each group being controllable through separate contact sheets. This segmentation allows the controller to activate only the necessary heating zones rather than all elements simultaneously, reducing overall controller complexity while maintaining heating power when needed.
Solution Approach 2:
The contact sheets are designed to be movable relative to the heating elements, allowing dynamic reconfiguration of which heating elements are activated. This dynamic adjustment capability enables efficient control without requiring complex electronic switching circuits for each individual element.
2Power
If voltage is applied to all heating elements, then heating power is maximized, but energy efficiency decreases when full power is not needed
Solution Approach 1:
By dividing the heating elements into multiple independently controllable groups via separate contact sheets, the system can activate only the necessary heating zones. This selective activation reduces energy consumption when full heating power is not required, while still providing maximum heating power when all contact sheets are activated simultaneously.
Solution Approach 2:
The system allows changing the activation state of different heating element groups independently. By controlling which contact sheets receive voltage, the system can adjust the total heating power output to match actual thermal demands, improving energy efficiency across varying operating conditions.
3Adaptability or versatility
If multiple contact sheets are used to control heating elements, then heating power adjustment is improved, but device structure becomes more complex
Solution Approach 1:
Multiple contact sheets are merged into a single integrated structure that can simultaneously contact multiple heating element groups. This combined contact sheet design provides versatile heating power adjustment capability while avoiding the complexity of managing entirely separate control structures for each heating zone.
4Reliability
If insulation layer is added between contact sheets, then electrical isolation is improved, but manufacturing complexity increases
Solution Approach 1:
The insulation layer is integrated into the contact sheet assembly as a unified component rather than a separate addition. This merging of the insulation function into the existing contact sheet structure ensures reliable electrical isolation between contact sheets while avoiding the increased manufacturing complexity that would result from adding entirely separate insulation components.
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 design simplifies the control of heating rods by allowing for adjustable heating power with fewer control inputs, enhancing efficiency and ease of use.
Implementation Method 1
a first contact sheet electrically contacts only a first part of the plurality of the heating elements of the heating rod, whereas a second contact sheet contacts a second part of the plurality of heating rods. Hence, when a voltage is applied only to the first contact sheet, only some of the heating elements are activated, i.e., have a current flow through them, and generate heat.
Data Source
AI summary
A heating rod having a plurality of ceramic heating elements, a first strip-shaped contact sheet, a second strip-shaped contact sheet, and a housing in which the plurality of heating elements and the contact sheets are arranged. The first contact sheet electrically contacts only a part of the plurality of the heating elements, and the second contact sheet electronically contacts a second part of the plurality of the heating elements.