One-Piece Heater Frame for Faster Vehicle Auxiliary Heating Assembly
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Solution Overview
Problem
Existing electrical auxiliary heating devices for motor vehicles require complex and costly multi-part frames for electrical heating elements, which complicate assembly and increase production costs, especially in consumption-optimized vehicles where additional heating is necessary at low ambient temperatures.
Innovation Solution
A one-piece frame design for electrical auxiliary heating devices that securely holds and fastens electrical heating elements without additional components, allowing for simplified assembly and reduced production costs through injection molding, enabling easy adaptation to different structural requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-part frames are used to hold electrical heating elements, then the heating device can be assembled with separate components, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent merges multiple frame parts (first frame half and second frame half) into a single one-piece frame structure. This eliminates the need for separate components and assembly steps, directly resolving the contradiction by simplifying the frame structure while improving ease of assembly. The one-piece frame is produced via injection molding, which maintains manufacturing feasibility while eliminating complexity.
Solution Approach 2:
The patent segments the frame design into a modular one-piece structure that can be easily integrated into the heating system. While the frame itself is unified, the design allows for easy insertion and positioning of heating elements, maintaining ease of manufacture through standardized injection molding processes while reducing overall assembly complexity.
2Ease of manufacture
If multi-part frames are used for electrical heating devices, then components can be manufactured separately, but production costs and logistics complexity increase
Solution Approach 1:
The patent combines multiple frame components into a single one-piece structure produced by injection molding. This eliminates the need for separate manufacturing of frame halves and their subsequent assembly, reducing production costs through a single molding process and simplifying logistics by eliminating handling of multiple small parts. The one-piece frame maintains all necessary functional features while reducing component count.
3Ease of operation
If electrical heating elements are held by separate frame components, then the frame can be assembled from parts, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
The patent merges the frame components into a single one-piece structure that is ready for immediate assembly of heating elements. This eliminates the time-consuming process of assembling frame halves and aligning them, directly reducing assembly time while improving ease of operation. The injection-molded one-piece frame provides precise geometry for easy integration of heating elements without requiring intermediate assembly steps.
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 one-piece frame simplifies the construction and assembly of electrical auxiliary heating devices, reducing production and logistics costs while ensuring reliable and efficient heating performance, particularly in scenarios where main heating systems fall short, such as at low ambient temperatures.
Implementation Method 1
an electrical heating element (4), in particular a PTC heating element
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
The device has an electrical heating element i.e. positive temperature coefficient heating element (4), directly fastened to a one-piece frame (2) in a form-fit manner. A holding unit (18) is positioned at the frame for holding the electrical element, and a locking element (19) comprising a locking nose is integrated in the frame. The frame is arranged in a receiver of a heating system. Two holding arms (7, 8) are arranged lateral to an electrical connection device (3), where the holding arm (8) is provided in a frame collar (9). An independent claim is also included for a method for manufacturing a frame for receiving an electrical heating element.