PTC Heating Element Assembly With Integrated Holding Webs
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Solution Overview
Problem
The existing heat-generating elements in electrical heating devices for motor vehicles face challenges in ensuring precise positioning and secure electrical connections during assembly, particularly when aiming to standardize components across different layers for cost-effective production.
Innovation Solution
The heat-generating element features integrally formed holding webs on a positioning frame, which are plastically deformed to securely fix conductor tracks and PTC elements, creating a preassembled unit that can be easily handled and inserted into the housing, ensuring proper thermal and electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductor tracks are separately assembled to PTC heating elements, then electrical connections can be established, but positioning precision and assembly reliability deteriorate due to manual placement requirements
Solution Approach 1:
The patent combines the conductor track and positioning frame into a single integrated component. The holding webs are directly formed on the positioning frame, eliminating the need for separate assembly steps. This merging ensures that conductor tracks are automatically positioned with high precision relative to PTC heating elements while significantly improving assembly reliability through the unified structure.
Solution Approach 2:
The conductor tracks are pre-formed with holding webs that are integrally formed on the positioning frame before assembly. This preliminary action of integrating the positioning and electrical connection functions into one component ensures precise positioning is built-in from the start, eliminating subsequent adjustment needs and improving overall assembly reliability.
2Ease of manufacture
If standardized components are used across different layers, then production costs decrease, but assembly complexity increases due to predetermined positioning requirements
Solution Approach 1:
The integrated positioning frame with holding webs serves multiple functions simultaneously: it positions PTC heating elements, provides electrical connections through conductor tracks, and ensures proper alignment. This multi-functionality allows the same standardized component to be used across different layers without increasing assembly complexity, as all positioning and connection requirements are met by the single unified structure.
Solution Approach 2:
By merging positioning and electrical connection functions into one standardized component, the patent enables universal use across layers. The integrated design eliminates the need for separate positioning and connection components, reducing part numbers and simplifying assembly procedures while maintaining low production costs through standardization.
3Manufacturing precision
If holding webs are separately attached to positioning frame, then assembly flexibility is maintained, but manufacturing precision and connection reliability deteriorate
Solution Approach 1:
The holding webs are integrally formed on the positioning frame as a single unified component. This merging eliminates the need for separate attachment steps, ensuring high connection precision between conductor tracks and PTC heating elements. The integrated structure guarantees consistent positioning and electrical connection reliability while simplifying manufacturing by reducing the number of assembly operations required.
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 enables easier assembly, prevents misplacement of components, and allows for standardized parts usage across different layers, facilitating assembly even by inexperienced personnel while maintaining reliable electrical connections.
Implementation Method 1
the conductor tracks are plastically deformed across the board by forming
Implementation Method 2
a plurality of PTC heating elements which are provided one above the other in one plane and are arranged between conductor tracks
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present invention relates to a heat-generating element of an electric heating device comprising a positioning frame (28) made of an insulating material, which forms adjacent receptacles (32) for at least one PTC heating element (30) each, arranged between conductor tracks (34, 36) against which the PTC heating elements (30) are electrically conductive. A heat-generating element according to the present invention, which facilitates the assembly of the electric heating device, has a positioning frame comprising retaining webs surrounding and delimiting the conductor tracks, which overlap the conductor tracks on the outside.