PTC Heater Assembly With Spring Tabs for Reliable Tube Contact
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Solution Overview
Problem
Existing heating devices for automobile passenger compartments face challenges in industrial production due to complications in the arrangement of electrode-PTC pads assembly, leading to production downtimes and inefficiencies in preloading compression springs.
Innovation Solution
A heating device design featuring a support frame with a containment tube and longitudinal housing, utilizing compression means with tabs or springs to maintain thermal and electrical contact with PTC elements, allowing for simplified assembly and reliable series production by eliminating the need for preloaded components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If preloaded compression springs are used to hold heat generating means in contact with containment tube, then thermal and electrical contact is ensured, but assembly complexity increases and production efficiency decreases due to difficulty in preloading during series production
Solution Approach 1:
The compression springs are preloaded during the molding process itself rather than requiring separate preloading operations. The molding process automatically compresses the springs to the required degree, eliminating the need for complex post-assembly preloading operations and enabling efficient series production while ensuring reliable thermal and electrical contact.
Solution Approach 2:
The mechanical preloading operation is replaced by the molding process. Instead of requiring separate mechanical compression steps to preload the springs, the molding process inherently performs the compression function through the mold cavity design, simplifying the overall assembly process and improving productivity.
2Reliability
If complex electrode-PTC pads assembly arrangement is used, then thermal contact is improved, but manufacturing complexity increases leading to production downtimes
Solution Approach 1:
The electrode and PTC pads are combined into an integrated assembly where the compression springs serve dual functions: providing electrical contact and applying compressive force for thermal contact. This merging of functions eliminates the need for separate complex arrangement steps while ensuring both thermal and electrical connectivity.
Solution Approach 2:
The compression springs perform multiple functions simultaneously: they provide mechanical compression for thermal contact, maintain electrical contact between components, and compensate for dimensional variations. This multi-functionality simplifies the overall assembly arrangement while maintaining effective thermal contact.
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 enables efficient and reliable assembly of heating devices, reducing production downtimes and complexities by ensuring proper preload and contact between heat generating means and the containment tube, facilitating effective heat dissipation and electrical connectivity.
Implementation Method 1
by applying an electric current between said containment tube and said longitudinal electrode, said heat generating means generate heat
Implementation Method 2
said tabs or springs being capable to assume a rest position and an operating position, in which said tabs or springs are in compression, such that said heat generating means are held in thermal and electrical contact
Implementation Method 3
one or more dissipation fins arranged in said support frame, suitable to dissipate the heat generated from said radiating elements
Data Source
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AI summary
The present invention concerns a heating device (1) connectable to a power supply, comprising a support frame (2), one or more radiating elements (3), each comprising a containment tube (31), having an inner surface, said containment tube (31) being capable to operate as an electrode and being connectable to said power supply, a longitudinal housing (32), made of insulating material, arranged within said containment tube (31), open at the top and having a lower base (32"), a longitudinal electrode (33), connectable to said power supply and arranged within said longitudinal housing (32), so as to be isolated from said containment tube (31), heat generating means (34), as one or more PTC (Positive Temperature Coefficient) elements, each one inserted in said containment tube (31) and arranged between, and in contact with, said longitudinal electrode (33) and said containment tube (31), so that, by applying an electric current between said containment tube (31) and said longitudinal electrode (33), said heat generating means (34) generate heat, compression means (35), located in said longitudinal housing (32), interposed between said longitudinal housing (32) and said longitudinal electrode (33), and one or more dissipation fins (4) arranged in said support frame (2), suitable to dissipate the heat generated from said radiating elements (3), characterized in that said longitudinal housing (32) comprises a plurality of seats (32') on said base (32"), and in that said compression means comprise a plate (35) on which a plurality of tabs or springs (35') are obtained, each one insertable in a respective seat (32') of said longitudinal housing (32), said plate (35) being capable to assume a rest position, in which said tabs or springs (35') are inserted in said seats (32'), and an operating position, in which said plate (35) is shifted longitudinally with respect to said longitudinal housing (32), so that said tabs or springs (35') are in compression, such that said heat generating means (34) are held in thermal and electrical contact with said inner surface of said containment tube (31) in which they are inserted, by means of the force exerted by said tabs or springs (35'). The present invention also concerns a method for mounting of a heating device (1).