Modular PCB Heater Assembly With Heat Reflection for Port Heating
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Solution Overview
Problem
Existing heater assemblies for water systems, such as those in aircraft, are inefficient due to wasted heat emission and require precise assembly and replacement of entire units upon damage, leading to increased costs and complexity.
Innovation Solution
A modular heater assembly comprising a printed circuit board with electrically conductive tracks, a heat reflective plate, and a flexible housing that directs heat efficiently to critical areas, allowing for easy assembly and replacement of individual components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a traditional heater assembly is used, then the ports can be heated to prevent freezing, but heat is wasted emitting in directions that do not contribute to heating the critical areas
Solution Approach 1:
The heater assembly is segmented into three distinct components: a PCB with heating tracks, a heat reflective plate, and a housing. This segmentation allows each component to be optimized for its specific function, with the reflective plate directing heat precisely to critical areas while the housing contains and directs the heat flow, reducing waste and improving heating effectiveness
Solution Approach 2:
The heat reflective plate acts as an intermediary component between the heating element and the environment. It reflects and directs heat towards critical areas that need heating, while the housing serves as another intermediary that contains and channels the heat flow, ensuring heat is delivered where needed rather than being wasted
2Ease of repair
If a traditional heater assembly is damaged, then the entire unit must be replaced, but this increases cost and complexity
Solution Approach 1:
The heater assembly is divided into three separable components: a PCB with heating tracks, a heat reflective plate, and a housing. This segmentation enables modular replacement where only the damaged component needs to be replaced rather than the entire assembly, reducing both replacement cost and complexity while maintaining ease of repair through simple component-level replacement
3Ease of operation
If a traditional heater assembly is used, then heating function is provided, but assembly and replacement of entire units is required
Solution Approach 1:
The heater assembly is segmented into three distinct components that can be assembled in a simplified stack: a PCB with heating tracks, a heat reflective plate, and a housing. This segmentation with a stackable design simplifies the assembly process compared to traditional monolithic heater assemblies, as each component can be independently manufactured and then stacked together, reducing overall device complexity while maintaining ease of 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 solution provides a more efficient and cost-effective heating solution with reduced energy consumption, simplified assembly, and the ability to replace only damaged parts, enhancing the reliability and adaptability of the heater assembly.
Implementation Method 1
a printed circuit board, pcb, on which are provided electrically conductive tracks which generate heat when electric power is applied to the tracks
Implementation Method 2
a heat reflective plate; wherein the heat reflective plate is sandwiched between the pcb and the heater assembly housing
Data Source
AI summary
A heater assembly includes three discrete components assembled in a stack. The three discrete components are: a printed circuit board, pcb, on which are provided electrically conductive tracks which generate heat when electric power is applied to the tracks, the pcb having a first major surface and a second, opposite, major surface and a periphery joining the first and second major surfaces; a heat reflective plate; and a heater assembly housing. The heat reflective plate is sandwiched between the pcb and the heater assembly housing and where the heater assembly housing is configured to fit over the heat reflective plate and the periphery of the pcb to form a closely fitted stack of the three discrete components.