Bimetal Temperature Switch with Segmented Movable Plate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional bimetal temperature switches have issues with responsiveness to heat, complex assembly processes, high skill requirements for caulking ceramic substrates, and limited degrees of freedom in shaping and positioning due to the need for multiple parts and intricate assembly steps, which complicates their use in applications like hair irons and hot plate heaters.
Innovation Solution
A temperature switch design featuring a movable plate with U-shaped pawl parts and cut-out portions on the substrate, allowing for easy attachment and sliding engagement, reducing the number of components and assembly steps, and utilizing a bimetal thermally actuated element for efficient heat detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bimetal temperature switch configuration is used with multiple parts and intricate assembly steps, then the switch can be mounted on ceramic substrate, but the assembly process becomes complex and requires high skill levels
Solution Approach 1:
The patent merges multiple separate components (bimetal plate, support structure, contact elements) into an integrated temperature switch assembly that can be mounted as a single unit on the ceramic substrate, eliminating complex multi-step assembly processes and reducing the need for specialized caulking skills
Solution Approach 2:
The temperature switch is designed with a universal mounting structure that can be attached to ceramic substrates using simple adhesive bonding rather than requiring specialized caulking procedures, making the assembly process accessible to general manufacturing operations
2Reliability
If conventional temperature switch design is used, then the switch structure is stable, but the responsiveness to heat detection is poor
Solution Approach 1:
The temperature switch incorporates a segmented design where the bimetal plate is divided into functional zones with different thermal masses, allowing the detection portion to respond quickly to temperature changes while the support structure maintains structural stability
Solution Approach 2:
The patent applies local quality by making the bimetal plate thin and lightweight in the heat detection area to improve responsiveness, while maintaining a robust support structure and mounting features in other areas to ensure structural stability and reliable operation
3Adaptability or versatility
If multiple components are used in the temperature switch, then the functionality is complete, but the degrees of freedom in shaping and positioning are limited
Solution Approach 1:
The temperature switch incorporates a movable contact element that can dynamically adjust its position in response to thermal expansion and bimetallic deformation, providing adaptability in positioning while maintaining a simple overall structure with fewer components
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 design enhances heat detection responsiveness, simplifies assembly, reduces the need for specialized skills, and increases the degrees of freedom in substrate shaping and positioning, making the temperature switch more cost-effective and suitable for ceramic substrates.
Implementation Method 1
a thermally actuated element that is loosely attached to the movable plate and whose warping direction is inverted at a prescribed temperature for electrically opening and closing a line
Implementation Method 2
A collar 16 of the pin 12 is disposed between the contact spring 8 and the bimetal plate 15 in order to serve as a spacer and to provide thermal insulation between the contact spring 8 and the bimetal plate 15
Data Source
AI summary
In a temperature switch, a cut-out portion of the substrate is formed of a first cut-out portion and a second cut-out portion which are made from the side part toward the center. At a fixation part of a movable plate in the temperature switch, a pawl part and an elastic locking part having an L-shaped cross section are formed adjacent to the pawl part on the upstream side in the sliding direction. When the pawl part is fitted in the second cut-out portion, a tip of the elastic locking part abuts an end portion-top surface of the substrate and the elastic locking part reversibly warps upwardly.