Bimetal Switch Structure Without Plunger for Reliable Current Transfer
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Solution Overview
Problem
Existing temperature-dependent switches face issues with high force requirements for the bimetallic element in the open state, material weakening of the current transfer member, and complex manufacturing due to a protruding plunger, which affects switching reliability and current conductivity.
Innovation Solution
A temperature-dependent switch design where the bimetallic element is connected to the current transfer member via a separate connecting element, eliminating the need for a plunger and allowing the current transfer member to be designed with increased mass for higher conductivity, and the bimetallic element is relieved of excessive strain, with a carrier body that is ring-shaped or pot-shaped for improved mechanical and electrical shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bimetallic element is connected to the current transfer member via the carrier body in existing designs, then the switching mechanism can be implemented, but the bimetallic element experiences excessive strain and requires high force in the open state
Solution Approach 1:
The patent extracts the connecting element from the carrier body structure, making it a separate component that connects the bimetallic element to the current transfer member. This separation reduces the force burden on the bimetallic element and eliminates the need for high force in the open state, while maintaining reliable switching functionality.
2Ease of manufacture
If a plunger is used in existing designs to achieve the switching mechanism, then the switching function can be realized, but the current transfer member material is weakened and manufacturing becomes complex
Solution Approach 1:
The patent removes the plunger component from the design. Instead, the connecting element directly connects the bimetallic element to the current transfer member, eliminating the need for a plunger. This prevents material weakening of the current transfer member and simplifies the manufacturing process.
Solution Approach 2:
The patent segments the switching mechanism into distinct functional components: the bimetallic element, the connecting element, and the current transfer member. This segmentation allows each component to be optimized independently, improving manufacturability and maintaining strength without requiring a plunger structure.
3Reliability
If the current transfer member is designed with adequate mass for high conductivity, then current conductivity improves, but the device complexity increases
Solution Approach 1:
By removing the plunger and using a separate connecting element, the patent allows the current transfer member to be designed with adequate mass for high conductivity without adding unnecessary structural complexity. The simplified connection method maintains structural efficiency while enabling optimized current transfer member design.
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 design enhances switching reliability, current conductivity, and simplifies the manufacturing process by reducing material stress on the bimetallic element and eliminating the need for a plunger, leading to improved performance and reliability.
Implementation Method 1
A temperature-dependent bimetallic element, which is configured to change its geometric shape depending on its temperature
Implementation Method 2
a spring element supporting the carrier body
Data Source
AI summary
A temperature-dependent switch having a temperature-dependent switching mechanism and a housing on which first and second stationary contacts are arranged. The temperature-dependent switching mechanism is configured to switch in a temperature-dependent manner between a closed state, in which the switching mechanism establishes an electrically conductive connection between the first and second stationary contacts, and an open state, in which the switching mechanism disconnects the electrically conductive connection. The switching mechanism comprises a carrier body, a spring element, a bimetallic element and a current transfer member. The current transfer member is connected to the bimetallic element by a connecting element other than the carrier body. In the closed state, the current transfer member is pressed against the first and second stationary contacts in order to establish the electrically conductive connection, and in the open state it is lifted off the first and second stationary contacts in order to disconnect the electrically conductive connection.