Ring Heater Contact Assembly With Arc Contacts and Spring Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air treatment chemical dispensers with ring-type PTC heating elements face inefficiencies in electrical charge distribution, alignment challenges during assembly, and increased complexity and cost due to riveting, which can lead to short circuits and suboptimal heat transfer.
Innovation Solution
A heater design featuring arc-shaped electrical contacts with a PTC heating element sandwiched between them, where the contacts are kept far apart to prevent short circuits, and a spring for alignment and thermal expansion accommodation, with a welded housing for assembly and improved heat transfer, using conductive and heat-conductive materials like aluminum and steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two ring-shaped electrical contacts are positioned in close proximity all the way around the ring, then electrical charge can be delivered to the heating element, but there is a theoretical potential for charge to be directed inefficiently and risk of short circuiting if parts are not precisely assembled
Solution Approach 1:
The patent divides the continuous ring-shaped electrical contacts into arc-shaped segments with gaps between them. This segmentation prevents short circuiting by ensuring that adjacent contacts are not in continuous proximity, eliminating the risk of electrical discharge while maintaining effective heating through the arc-shaped contact surfaces.
2Manufacturing precision
If parts are installed inside the housing to ensure proper alignment for optimal function, then heating efficiency is improved, but the installation process becomes awkward and complex
Solution Approach 1:
The patent employs asymmetric design features including a non-circular cross-section of the housing and asymmetric positioning of internal components. This asymmetry creates natural alignment references that guide proper installation without requiring complex alignment procedures, simplifying the assembly process while maintaining optimal heating efficiency.
Solution Approach 2:
The housing design incorporates self-aligning features where the asymmetric geometry automatically positions components correctly during installation. The shape and positioning of internal elements guide them into proper alignment without requiring external tools or complex procedures, allowing the structure to self-align during assembly.
3Strength
If the housing is assembled using rivets to secure parts, then structural integrity is achieved, but cost and complexity increase
Solution Approach 1:
The patent integrates the electrical contacts directly into the housing structure, merging previously separate components into a unified design. This integration eliminates the need for rivets and separate assembly steps, reducing complexity and cost while maintaining structural integrity through the combined design.
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 enhances electrical and thermal efficiency, reduces the risk of short circuits, simplifies assembly, and eliminates the need for riveting, ensuring optimal heat and energy transfer to the wick while accommodating thermal expansion.
Implementation Method 1
A PTC heating element is typically in the form of a pill-shaped tablet formed from pressed conductive granular material. Its resistivity to electrical charge generates heat
Implementation Method 2
The generated heat is then carried back along the contact to spread the heat around the through bore, and then to the wick
Implementation Method 3
a spring for thermal expansion accommodation
Implementation Method 4
A wick dips into the liquid, and then extends upward out of the bottle
Implementation Method 5
Heating of the upward end of the wick causes air treatment chemical to be volatized from the wick, and thus the bottle, to the surrounding area
Data Source
AI summary
Disclosed herein are heaters for dispensing volatile air treatment chemicals. Semi-circular electrical contacts are provided in a ring-type heater, and alignment and anchoring features are provided to facilitate use of a spring to accommodate thermal expansion.