Unitary Heater Support Frame for Reliable PTC Element Positioning
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Solution Overview
Problem
Existing ventilation, heating, and air conditioning systems for vehicles require complex and costly frames for auxiliary electric radiators, which complicate assembly and hinder the use of standardized heating elements.
Innovation Solution
A simplified, unitary frame with molded retaining means and passages for easy installation of heating elements, allowing for individual reception and positioning within a single manufacturing operation, reducing assembly operations and enabling the use of standard elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex multi-part frame structure is used to hold heating elements, then the structural integrity and positioning reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple frame components into a single unitary frame structure that integrates support functions, positioning features, and mounting capabilities into one monolithic component, eliminating the need for separate support elements and reducing assembly complexity while maintaining structural integrity
Solution Approach 2:
The unitary frame is designed to perform multiple functions simultaneously: providing structural support, positioning heating elements through integrated features, enabling mounting to the housing, and facilitating air flow management, thereby replacing multiple specialized components with a single multi-functional element
2Reliability
If a complex multi-part frame structure is used, then the positioning reliability of heating elements is improved, but the assembly operations and manufacturing cost increase
Solution Approach 1:
The patent integrates positioning features, support structures, and mounting elements into a single unitary frame that is manufactured as one piece, eliminating the need for multiple assembly operations to combine separate components while ensuring precise positioning through integrated design features
Solution Approach 2:
The unitary frame is pre-manufactured with all necessary positioning features, support structures, and mounting elements already integrated in their correct positions and orientations, allowing heating elements to be installed directly without requiring complex assembly sequences or intermediate positioning steps
3Ease of manufacture
If a unitary frame structure is used, then the manufacturing cost and assembly operations are reduced, but the adaptability for different heating element configurations may be limited
Solution Approach 1:
The unitary frame incorporates locally varied features including recesses, protrusions, and positioning elements at specific locations that can accommodate different heating element sizes, shapes, and configurations, allowing a single frame design to serve multiple application requirements through strategic local modifications
4Adaptability or versatility
If multiple separate components are used for the frame, then the adaptability for different configurations is improved, but the assembly operations and time increase
Solution Approach 1:
The patent consolidates multiple separate frame components into a single unitary structure that is manufactured as one piece, eliminating the time required for assembling multiple components while maintaining configuration adaptability through integrated design features that accommodate various heating element arrangements
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 allows for cost-effective production and easy installation of heating elements, ensuring reliable positioning and connection, while maintaining structural integrity and adaptability for different heating power requirements.
Implementation Method 1
The additional electric radiators comprise a chassis carrying electric elements
Data Source
Figure 1
Figure 2
AI summary
The frame is shaped in the form of a hollowed-out box whose large faces (2,2'), intended to be traversed by an airflow (A) conveyed by a ventilating, heating or air-conditioning unit, are held at a distance from each other in order to create a heating-element receiving space between them. The frame is made of a single part in which retainers (15) for holding heating elements (3) e.g. positive temperature coefficient (PTC) resistors inside the space are located in the area of the large faces. An independent claim is also included for an electric-heater assembling method.