PCB Heater Assembly With Reflective Plate for Targeted 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
1Object-affected harmful factors
If a heater assembly is provided to heat the ports, then the risk of water freezing is reduced, but heat is wasted being emitted to areas where it is not needed
Solution Approach 1:
The heater assembly is designed with selective heating zones that target only the critical areas around the fill port and overflow port where freezing could occur. The housing directs heat locally to these specific ports rather than heating the entire assembly uniformly, eliminating waste heat emission to non-critical areas.
Solution Approach 2:
A reflective barrier is introduced as an intermediary component between the heater and the external environment. This barrier reflects heat back toward the ports and prevents heat loss to surrounding areas, thereby reducing energy waste while maintaining effective heating of the target zones.
2Reliability
If existing heater assemblies are used, then ports are heated effectively, but the entire assembly must be replaced upon damage which increases cost and complexity
Solution Approach 1:
The heater assembly is divided into separate, modular components including the housing, heater element, and reflective barrier. This segmentation allows individual components to be replaced independently if damaged, rather than requiring replacement of the entire assembly, thereby reducing complexity and cost while maintaining heating effectiveness.
3Loss of energy
If precise assembly is required for existing heater assemblies, then heating efficiency is maintained, but assembly time and complexity increase
Solution Approach 1:
The modular segmented design allows components to be assembled in a simplified sequence without requiring precise alignment. The housing, heater element, and reflective barrier can be installed independently with tolerances that are easier to achieve, reducing assembly time while maintaining heating efficiency through the inherent design of each component.
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, directing heat only to necessary areas and enabling quick, simple assembly and component replacement, thus addressing inefficiencies and complexity of existing systems.
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
Figure 1~2
Figure 3
Figure 4~6
AI summary
A heater assembly comprising three discrete components assembled in a stack, the three discrete components comprising: a printed circuit board, pcb, (200) on which are provided electrically conductive tracks (230) which generate heat when electric power is applied to the tracks, the pcb having a first major surface (200a) and a second, opposite, major surface (200b) and a periphery joining the first and second major surfaces; a heat reflective plate (300); and a heater assembly housing (400); wherein 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.