Vehicle Heater Assembly Using Positioning Frames and Contact Plates
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Solution Overview
Problem
The existing vehicle heater production process is complex and costly due to the need for multiple components and intricate assembly, including soldering or gluing of contact plates to heating elements.
Innovation Solution
The use of two positioning frames that encase the heating elements, allowing for preassembly with contact plates and simplifying the assembly process, along with the use of extruded profiles for heat exchangers that reduce the number of individual parts and simplify assembly, and electrical insulation to enhance thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components (contact plates, heating elements, positioning frames) are used in the vehicle heater assembly, then the functional requirements are met, but the assembly complexity and production cost increase
Solution Approach 1:
The patent combines multiple components (contact plates, positioning frames, and heating elements) into an integrated assembly unit. The first and second contact plates are positioned with heating elements between them, forming a unified structure that reduces the number of separate components to be handled during assembly, thereby simplifying the production process while maintaining all necessary functions
Solution Approach 2:
The contact plates serve multiple functions simultaneously: they provide electrical connection, structural support, and positioning for the heating elements. The positioning frames also perform multiple roles including mechanical support, alignment, and integration with the heat exchanger mounts, reducing the need for separate specialized components
2Strength
If traditional assembly methods (soldering or gluing) are used to attach contact plates to heating elements, then the connection is secure, but the production process becomes more complex and costly
Solution Approach 1:
The patent divides the heating device into modular segments (first contact plate, heating elements, second contact plate) that can be preassembled into a unit. This segmentation allows for simplified assembly where the preassembled unit is installed as a complete module rather than requiring complex joining processes for each individual component connection
Solution Approach 2:
The contact plates and heating elements are preassembled into a unified structure before installation in the vehicle heater. This preliminary assembly is performed in an upstream production step, simplifying the final installation process and eliminating the need for complex soldering or gluing operations during the main assembly process
3Reliability
If the contact plates are electrically insulated by the positioning frame material, then the insulation is integrated, but the thermal conductivity is reduced
Solution Approach 1:
The patent introduces a separate electrically insulating layer as an intermediary component between the contact plates and the heating elements. This insulating layer specifically provides electrical insulation only where needed, while allowing thermal conduction pathways to remain open through other regions, thus resolving the conflict between electrical insulation and thermal conductivity
Solution Approach 2:
The electrically insulating layer is applied locally to specific areas of the contact plates where electrical insulation is required, rather than covering the entire surface. This localized approach maintains electrical insulation where necessary while preserving thermal conductivity pathways in other regions, optimizing both electrical and thermal performance
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 approach simplifies the production process, reduces component complexity, and enhances thermal efficiency and safety by allowing for easier handling and assembly of heating devices, while maintaining effective insulation and thermal coupling.
Implementation Method 1
PTC heating elements are arranged in a positioning frame between two contact plates
Implementation Method 2
a plurality of heat exchangers (2a, 2b, 2c) through which a fluid flow (1) to be heated can flow
Implementation Method 3
The positioning frames preferably leave free a rear side of the contact plates that faces away from the heating elements. This rear side of the contact plates is preferably covered with an electrically insulating layer
Implementation Method 4
the contact plates and the positioning frames fastened to them can advantageously be of the same design... enables cost savings
Implementation Method 5
a plurality of heat exchangers (2a, 2b, 2c) through which a fluid flow (1) to be heated can flow
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The vehicle heater has a heat exchanger (2) through which heated air stream flows, and a heating device (10) fastened to the heat exchanger. The heat exchanger has two contact plates and a heating element is provided between the contact plates, which is held by a positioning frame fitted to the contact plates. The contact plates of the heating devices carry a positioning frame in each case.