Heating Rod Insulating Frame Plug-in Assembly
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Solution Overview
Problem
Existing heating rods face challenges in electrical safety and mechanical stability, particularly when operating at higher voltages, and require improved manufacturing efficiency and dielectric strength.
Innovation Solution
A heating rod design featuring two electrically insulated contact plates with a plug-in connection and insulating frames that completely cover the ceramic heating elements, enhancing dielectric strength and preventing accidental detachment, along with a tongue-and-groove connection for secure assembly and increased mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional heating rod design is used, then manufacturing is simpler, but electrical safety is insufficient for high voltage operation
Solution Approach 1:
The heating rod is divided into modular components: heating elements, contact plates with integrated frames, and insulating barriers. Each contact plate assembly can be pre-manufactured and tested separately, then assembled into the final product. This segmentation improves electrical safety through isolated high-voltage zones while maintaining manufacturing efficiency through standardized modules.
Solution Approach 2:
Insulating contact plate frames and barriers act as intermediary elements between high-voltage components and the tube housing. These intermediaries provide electrical isolation without requiring direct modification of the heating elements themselves, thus improving safety while maintaining design flexibility.
2Stability of the object's composition
If contact plates are not securely connected, then assembly is easier, but mechanical stability is reduced
Solution Approach 1:
The contact plate and its insulating frame are merged into a single integrated assembly. This combination ensures that the contact plate cannot detach from the frame, providing mechanical stability while the entire assembly remains easy to handle and install as one unit.
Solution Approach 2:
The contact plates and frames are pre-assembled into stable units before final installation into the tube housing. This preliminary assembly ensures mechanical stability is achieved during manufacturing, while the pre-formed units simplify the final installation process.
3Reliability
If frames do not completely cover heating elements, then manufacturing is simpler, but dielectric strength is insufficient
Solution Approach 1:
The insulating frames are designed to provide complete coverage of the heating element surfaces that require dielectric protection. This localized quality enhancement ensures maximum dielectric strength where needed, while the frame design remains simple and manufacturable through standard molding processes.
4Ease of operation
If contact plates protrude without secure connection, then insertion is easier, but accidental detachment occurs
Solution Approach 1:
The contact plate and frame are merged into an integrated assembly where the frame securely retains the contact plate. This allows the protruding contact plates to be easily inserted into the tube housing while the integrated frame prevents accidental detachment during operation.
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 design significantly enhances electrical safety, allows operation at higher voltages, improves manufacturing efficiency, and increases mechanical stability, while reducing leakage currents and manufacturing costs.
Implementation Method 1
at least one ceramic heating element arranged in the tube housing
Implementation Method 2
The frames of the two contact plates of a heating rod according to an invention are plugged into one another... increasing the dielectric strength
Data Source
AI summary
The invention relates to a heating rod comprising a tube housing, at least one ceramic heating element, which is arranged in the tube housing, a first contact plate, which in the tube housing bears against the heating element or the heating elements, and an insulating frame, which surrounds the longitudinal edges of the first contact plate. In accordance with this disclosure, a second contact plate is provided, which carries a second insulating frame, wherein the at least one heating element is arranged between the two contact plates and the two frames are plugged into one another.