PCB Contact Pin Alignment for Electric Heater Control Housings
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Solution Overview
Problem
Existing control devices for electric heating systems in motor vehicles with ceramic PTC elements face challenges in precise alignment and electrical safety during assembly, particularly with high-voltage power currents, leading to potential misalignment and mechanical stress on the printed circuit board.
Innovation Solution
The introduction of an alignment element with a funnel-shaped passage and ramp surface on the printed circuit board allows for precise insertion of contact pins, reducing the need for exact positioning of power switches and distributing mechanical stress, while an electrically insulating film ensures safe heat conduction without direct electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If exact positioning of power switch relative to printed circuit board is required, then electrical connection precision is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent introduces an alignment element as an intermediary component between the power switch and printed circuit board. This alignment element features a funnel-shaped passage with a ramp surface that guides the contact pin into proper alignment with the plug-in slot, eliminating the need for precise manual positioning while ensuring reliable electrical connection.
Solution Approach 2:
The alignment element is pre-installed on the printed circuit board before the power switch is positioned. The funnel-shaped passage and ramp surface are prepared in advance to guide the contact pin during insertion, performing the alignment function before the actual connection is made, thus simplifying the assembly process.
2Reliability
If forceful insertion of contact pin is used to ensure good contact, then electrical connection reliability is improved, but mechanical stress on printed circuit board increases
Solution Approach 1:
The alignment element acts as a mediator that distributes the insertion force through its ramp surface. Instead of concentrating force directly on the printed circuit board, the ramp surface gradually guides the contact pin into the plug-in slot, reducing peak stress while ensuring reliable contact.
Solution Approach 2:
The funnel-shaped passage with ramp surface provides a cushioning effect during insertion. The gradual slope of the ramp surface allows the contact pin to be guided in smoothly, preventing sudden forceful impacts that could damage the printed circuit board, while still ensuring firm electrical connection.
3Temperature
If cooling element is thermally coupled with power switch, then heat dissipation is improved, but electrical insulation requirements increase
Solution Approach 1:
The patent introduces an electrically insulating film as an intermediary layer between the cooling element and power switch. This thin film provides thermal conduction pathway while maintaining electrical insulation, allowing heat dissipation without compromising electrical safety.
Solution Approach 2:
The solution uses a composite structure combining the cooling element, insulating film, and power switch. The insulating film serves dual functionality by providing both thermal conduction and electrical insulation properties, simplifying the overall design compared to using separate components for each function.
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 solution simplifies the manufacturing process by allowing rough alignment of contact pins, ensuring precise electrical connections and reducing mechanical stress on the printed circuit board, while maintaining effective heat conduction and electrical safety.
Implementation Method 1
The alignment element (90) has a funnel-shaped passage (92, 100) extending from its insertion side, i.e. from the side of the alignment element opposite the printed circuit board (40). This passage (92, 100) has sides (102) which are inclined inwardly towards the passage (92, 100) in the form of a ramp surface (102).
Implementation Method 2
The power switch can also be contacted with the printed circuit board such that the body of the power switch is provided next to the printed circuit board and abuts against a cooling element there.
Data Source
AI summary
A control device for an electric heating device has a control housing which surrounds a printed circuit board and which accommodates a power switch. The power switch makes contact with the printed circuit board via a contact pin. An alignment element is penetrated by the contact pin is attached to the printed circuit board, and is formed with at least one passage for the contact pin. The passage is aligned with a plug-in slot of the printed circuit board and has a widened opening on its side opposite the printed circuit board. The widened opening tapers in the direction of the passage via a ramp surface. In the manufacturing method, the power switch is approached to the plug-in slot of the printed circuit board and the alignment element. As part of this approach, the contact pin is aligned with the plug-in slot by sliding on the ramp surface.