Stamped Plate Heating Circuit for Solder-Free High-Temperature Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing electrical heating devices have cost-intensive circuit board manufacturing and limited adaptability for forming different heating circuits, with soldered connections that restrict temperature usage.
Innovation Solution
A plate element comprising a non-conducting carrier plate and a stamped metal plate, where the metal plate forms conductive paths and receptacles by stamping and bending, connected to the carrier plate without soldering, allowing for higher temperature usage and easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circuit board with conductive paths and soldered contact lug receptacles is used, then reliable electrical connection is achieved, but manufacturing cost increases and temperature resistance is limited
Solution Approach 1:
The patent extracts the conductive path function from a traditional circuit board and implements it directly through stamped metal plates within the housing. This eliminates the need for separate circuit boards and soldered connections, reducing manufacturing complexity while maintaining electrical connectivity through direct metal-to-metal contact between contact lugs and contact lug receptacles.
Solution Approach 2:
The patent introduces conductive paste as an intermediary substance applied to the contact lug receptacles. This paste facilitates reliable electrical connection between the contact lugs and the housing structure without requiring traditional soldering, thereby improving temperature resistance and simplifying the manufacturing process.
2Adaptability or versatility
If a circuit board with specific conductive paths is used, then heating circuits are formed, but adaptability for different heating circuit configurations is limited
Solution Approach 1:
The patent divides the heating circuit into multiple independent stamped metal plates, each representing a separate conductive path. These plates can be individually configured and positioned within the housing, allowing flexible arrangement of heating circuits without requiring a complex pre-designed circuit board layout.
Solution Approach 2:
The patent enables dynamic reconfiguration of heating circuits by allowing the stamped metal plates to be easily repositioned, removed, or modified within the housing. This provides adaptability for different heating circuit configurations while maintaining simple manufacturing processes, as the metal plates can be stamped from standard stock material.
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 and cost-reduces the manufacturing of conductive paths, allows for adaptable heating circuit formation, and enables higher temperature operation without soldering, enhancing the electrical connection efficiency.
Implementation Method 1
electrical heating device with a plurality of electrical heating elements... connected by a plate element which is provided with conductive paths... groups various contact lugs to a heating circuit
Implementation Method 2
the plate element comprises a carrier plate of a non-conducting material and a stamped metal plate
Data Source
AI summary
An electrical heating includes a plurality of electrical heating elements which are held by a housing and which abut heat conducting surfaces over which a medium to be heated flows. The electrical heating elements comprise contact lugs, arranged essentially at the same height, that are connected through a plate element. The plate element includes conductive paths and contact lug receptacles for the contact lugs. The plate element may include a carrier plate of non-conducting material and a stamped out metal plate that are joined together to form one unit. A method of manufacturing a plate element includes manufacturing the carrier plate by injection moulding and subjecting a metal plate to stamping operations to form area elements which are joined together by connecting ridges and in which the contact lug receptacles are located. The carrier plate and the metal plate are then joined, and the connecting ridges are then parted.