Elastic Holder for Thermal Fuse Height Adjustment

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Solution Overview

Problem

The conventional field coil assembly for an electromagnetic clutch faces damage to the thermal fuse during the injection molding process due to uneven height and pressure from the molding apparatus, leading to potential malfunction.

Innovation Solution

A field coil assembly with a holder featuring an elastic member, such as an elastic support plate or rubber plate, to adjust the height of the thermal fuse, preventing damage by allowing elastic deformation and maintaining uniform exposure during molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the thermal fuse is rigidly fixed to the holder, then the positioning is stable, but the thermal fuse is damaged during injection molding due to height variations

Engineering Contradiction:

Improvepositioning stabilityVSAvoiddamage during injection molding

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The support plate is designed with elastic deformation capability, allowing it to dynamically adjust its position during injection molding. The plate bends under molding pressure to accommodate height variations, preventing damage to the thermal fuse while maintaining stable positioning after the molding process completes.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The elastic support plate provides beforehand cushioning by absorbing the impact and pressure from the injection molding process. The plate's flexibility acts as a buffer that protects the thermal fuse from direct damage during the molding operation, while still providing stable support during normal operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Device complexity

If the thermal fuse height is fixed, then the structure is simple, but the thermal fuse cannot adapt to height variations caused by electromagnetic coil winding differences

Engineering Contradiction:

Improvestructure simplicityVSAvoidheight adaptability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The support plate's key parameter is its flexibility or elastic modulus, which allows it to change its effective height through elastic deformation. This single parameter change enables the structure to adapt to different electromagnetic coil heights without requiring complex adjustable mechanisms or multiple components.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The support plate is designed as a thin, flexible structural element that can elastically deform to accommodate height variations. This flexible plate provides adaptability similar to flexible shells and films, allowing the thermal fuse to maintain proper positioning despite variations in electromagnetic coil winding heights.

Inventive Principle:

Principle #30Flexible shells and thin films

3Measurement precision

If the thermal fuse is exposed during injection molding, then temperature sensing accuracy is maintained, but the thermal fuse is pressed down and damaged by the molding apparatus

Engineering Contradiction:

Improvetemperature sensing accuracyVSAvoidthermal fuse integrity

Core Design Contradiction:

Measurement precisionVSStrength

Solution Approach 1:

The elastic support plate provides beforehand cushioning by being positioned between the injection molding apparatus and the thermal fuse. During molding, the plate deforms elastically under pressure, absorbing the impact before it reaches the thermal fuse, thus protecting the fuse's integrity while allowing the fuse to remain exposed for accurate temperature sensing.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The support plate acts as an intermediary element between the injection molding apparatus and the thermal fuse. It mediates the interaction by providing a flexible interface that allows the molding process to proceed while protecting the thermal fuse from direct contact and damage with the molding apparatus.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 adjustable thermal fuse height ensures it is not damaged by the molding process, maintaining its functionality and accuracy in temperature sensing.

Implementation Method 1

an elastic member (320), for elastically supporting the thermal fuse (60)

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS8022800B2Field coil assembly for electromagnetic clutch

Publication Date: 2011.09.20 HANON SYST CO LTD

AI summary

A field coil assembly for an electromagnetic clutch, which includes an electromagnetic coil body formed by winding an electromagnetic coil; a bobbin for supporting the electromagnetic coil body; a field core for receiving the bobbin and the electromagnetic coil body; a holder mounted to the electromagnetic coil body; and a thermal fuse installed to the holder to be connected to the electromagnetic coil body, wherein the holder having the thermal fuse installed thereto is provided with an elastic member for elastically supporting the thermal fuse upwards. Thus, the height of the thermal fuse installed to the holder can be adjusted.