Vehicle heating system
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing vehicle heating systems are complex and costly to manufacture due to the need for multiple components and intricate assembly processes, particularly in attaching heating elements to contact plates and heat transfer devices.
Innovation Solution
The system employs two positioning frames to hold heating elements, allowing for pre-assembly with contact plates and simplifying the assembly process by reducing the number of components, using injection-molded or clicked frames that provide insulation and clamping mechanisms, and utilizing extruded profiles for heat transfer devices with staggered arrangements for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate components (heating elements, contact plates, positioning frames) are used, then the system can be assembled flexibly, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the positioning frame and contact plate into a single integrated component. The contact plate serves dual functions as both an electrical contact element and a positioning structure for the heating element, eliminating the need for separate positioning frames and reducing assembly steps.
Solution Approach 2:
The contact plate is designed to perform multiple functions simultaneously: providing electrical contact, positioning the heating element through its geometric shape, and serving as a structural support. This multi-functionality reduces the total number of components needed in the system.
2Manufacturing precision
If intricate assembly processes are used to attach heating elements to contact plates, then precise positioning is achieved, but manufacturing time and cost increase
Solution Approach 1:
The positioning features are pre-formed into the contact plate geometry during manufacturing. The geometric shape of the contact plate inherently provides positioning guidance for the heating element, eliminating the need for complex assembly operations to achieve precise positioning.
Solution Approach 2:
The contact plate's geometric shape automatically provides positioning and alignment functions without requiring additional positioning mechanisms or complex assembly procedures. The heating element is positioned simply by placing it onto the contact plate, where the geometry itself performs the positioning function.
3Reliability
If separate insulation components are added to contact plates, then electrical insulation is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The insulation function is merged with the contact plate by applying an insulating coating directly to the contact plate surface. This integrated approach provides electrical insulation without requiring separate insulation components or additional assembly steps.
Solution Approach 2:
The contact plate utilizes composite material properties by combining conductive material for electrical contact with an insulating coating layer. This composite structure allows the same component to provide both electrical conduction where needed and electrical insulation where required.
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 manufacturing process, reduces costs, and enhances thermal and electrical insulation while ensuring efficient heat transfer and safety through reduced component complexity and efficient assembly methods.
Implementation Method 1
PTC heating elements are arranged in a positioning frame
Implementation Method 2
The positioning frames can be made of plastic or polymer ceramic
Data Source
AI summary
The description relates to a vehicle heating system having at least one heat transfer device through which air can flow to be heated and at least one heating device which is attached to the heat transfer device and which each involves at least one heating element arranged between two contact plates, said heating element being held by a positioning frame which is attached to one of the contact plates. The contact plates of the heating devices are each held in a positioning frame to which they are attached.