Control Module Skirt Connection for Higher Power Heating
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Solution Overview
Problem
The existing control modules for electric heating devices in motor vehicles face limitations in using high electrical powers due to reduced contact between the conductive rod and the connecting member, and inadequate mechanical retention, restricting the power output to less than 1000 Watts.
Innovation Solution
A control module design that incorporates a skirt on the periphery of the orifice for the conductive rod, increasing the contact surface and ensuring better mechanical connection, allowing higher power usage up to 1200 Watts, with a radial shoulder and annular groove for improved positioning and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple orificial connection between the rod and the connecting member is used, then the device complexity is reduced, but the electrical power transmission capability deteriorates due to reduced contact surface
Solution Approach 1:
The invention transitions from a point-contact or minimal surface-contact connection to a multi-dimensional contact interface by adding the skirt structure. The skirt extends radially outward from the orifice, creating a circumferential contact surface around the rod, thereby increasing the contact area from a simple linear interface to a three-dimensional annular interface that encompasses the rod's circumference.
Solution Approach 2:
The skirt is pre-formed as an integral part of the connecting member before assembly. This preliminary structuring ensures that when the rod is inserted, the contact surface is already optimized and positioned correctly, eliminating the need for additional contact-enhancing components or complex assembly steps.
2Power
If the contact surface between the rod and the connecting member is increased, then the electrical power transmission capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The skirt is merged with the connecting member as a single integral component. This combining of the skirt structure with the main body of the connecting member eliminates the need for separate manufacturing of the skirt and subsequent assembly operations, thereby maintaining manufacturing simplicity while achieving enhanced contact surface area.
Solution Approach 2:
The skirt serves multiple functions simultaneously: it increases the electrical contact surface area for power transmission, provides mechanical retention for the rod, and maintains structural integrity of the connection. This multi-functionality eliminates the need for additional separate components, simplifying the overall manufacturing process.
3Reliability
If a simple orificial connection is used, then the mechanical retention is insufficient, but adding complex retention mechanisms increases device complexity
Solution Approach 1:
The skirt structure performs dual functions: it enhances electrical contact surface area and simultaneously provides mechanical retention for the rod. The radial extension of the skirt creates frictional engagement and physical barriers that prevent rod displacement, eliminating the need for separate mechanical retention components like clips, retainers, or locking mechanisms.
Solution Approach 2:
The mechanical retention function is merged into the electrical connection structure itself. The skirt, which is part of the electrical conductor, also serves as the mechanical retention element, thereby achieving reliable rod retention without adding separate retention mechanisms or increasing overall device complexity.
4Power
If the contact surface is increased to allow higher power, then the control precision is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The skirt is pre-formed with precise dimensions and geometry during the manufacturing of the connecting member. This preliminary precision work ensures that during assembly, the rod insertion encounters consistent and predictable resistance, allowing for better control of insertion force without requiring high precision during the assembly operation itself.
Solution Approach 2:
The skirt's geometric parameters (radius, height, thickness) are optimized to provide the desired contact surface area while maintaining appropriate mechanical compliance. By carefully selecting these parameters, the design achieves a balance between providing sufficient contact area for high power transmission and maintaining insertion forces that are easy to control during assembly.
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
Enables efficient transmission of higher electrical power and enhanced mechanical stability, allowing for better control and operation of higher power electrical appliances.
Implementation Method 1
one end of a conductive metal rod, the other end of which is placed in contact with the positive terminal of the battery
Implementation Method 2
resistive elements of the positive temperature coefficient (PTC) type
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a control module for an electric appliance, comprising a connection body (46) consisting of an electrically conductive material and a rod (59) for the power supply of the body, one end of the rod (59) being inserted into an opening (58) of the body (46), characterised in that the rod (59) is forcibly inserted into a cylindrical skirt of the conductive body, formed on the periphery of the opening (58).