Single-Piece Heater Frame for Fast HVAC Element Assembly
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Solution Overview
Problem
Existing ventilating, heating, and air conditioning units for vehicles require complex and costly frame structures for auxiliary electric heaters, with numerous assembly operations and incompatibility with standard heating elements, making production and installation inefficient.
Innovation Solution
A single-piece, molded frame with integrated holding means on its large faces and side walls allows for easy installation of heating elements, using channels and locking members to secure them in place, facilitating the use of standard heating elements and reducing assembly operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a frame is made up of two planar frame elements assembled parallel to each other, then the heating elements can be held and positioned, but the number of parts and assembly operations increases significantly
Solution Approach 1:
The patent merges two separate planar frame elements into a single three-dimensional box-like frame structure. This single frame integrates the functions of both original frame elements (holding and positioning heating elements) while eliminating the need for assembly operations between multiple parts. The frame is formed as one piece with integrated features for securing heating elements.
2Manufacturing precision
If a complex frame structure is used to hold heating elements, then reliable positioning is achieved, but production and assembly costs increase
Solution Approach 1:
The patent combines multiple frame components into a single molded frame structure, eliminating the need for complex assembly operations. The single frame is designed with integrated features (such as recesses, ribs, or attachment points) that provide precise positioning for heating elements while being manufacturable as one piece through molding processes, thereby reducing production costs.
3Adaptability or versatility
If standard heating elements are not compatible with the frame design, then customized heating element assemblies can be created, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent designs the frame structure with universal features that can accommodate standard heating elements. The box-like frame with integrated holding mechanisms provides a standardized interface that can receive and secure conventional heating elements, allowing the system to use off-the-shelf components rather than requiring custom-made heating element assemblies.
4Manufacturing precision
If multiple assembly operations are required for heater components, then precise assembly can be achieved, but production time and costs increase
Solution Approach 1:
The patent integrates multiple assembly functions into a single frame structure that can be installed as one component. The heating elements are secured within the frame through integrated features (such as recesses, clips, or snap-fit mechanisms) that allow for rapid installation without requiring multiple separate assembly operations, thereby improving production efficiency while maintaining assembly precision.
Data Source
AI summary
A frame for receiving a heating element for an electric heater of a ventilating, heating and/or air conditioning unit of a vehicle, in particular. The frame is shaped in the form of a hollowed-out box whose large faces, intended to be traversed by airflow conveyed by the unit, are held at a distance from each other in order to create between them a space for receiving the heating element. The frame is made of a single part in which means for holding the heating element inside the space are located in the area of the large faces.