Gas Safety Valve Coil Connection Without Soldering
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Solution Overview
Problem
Existing gas safety valves for cooking appliances face challenges in maintaining reliable electrical connections between the phase and ground wires, often requiring soldering that can compromise the integrity of the connections and lead to manufacturing complexities and potential gas leakage issues.
Innovation Solution
The design incorporates a reel with axial projections featuring first and second electrical contact areas that exert elastic forces to secure the phase and grounding wires to the phase connector and support, respectively, eliminating the need for soldering and simplifying assembly by ensuring constant and reliable electrical connections through compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect phase and ground wires to terminals in the reel, then electrical connections can be established, but the integrity of connections is compromised and manufacturing complexity increases
Solution Approach 1:
The patent extracts the soldering process from the connection method and replaces it with a mechanical compression connection system. The reel projection compresses the phase and ground wires against contact surfaces, eliminating the need for soldering terminals and reducing manufacturing complexity while maintaining connection reliability.
Solution Approach 2:
The patent replaces the thermal-chemical soldering process with a mechanical compression system. The reel projection acts as a compression element that mechanically secures the wires through elastic force, substituting the complex soldering operation with a simpler mechanical connection that is easier to manufacture and more reliable.
2Reliability
If soldering is used to connect wires to terminals, then electrical connections can be made, but gas leakage risks increase due to soldering-related issues
Solution Approach 1:
The patent removes the soldering process entirely from the connection method. By extracting the thermal-chemical joining process and replacing it with mechanical compression, the source of gas leakage risks associated with soldering (heat damage, seal compromise) is eliminated while maintaining reliable electrical connections.
Solution Approach 2:
The patent converts the potential harm of soldering (heat-related gas leakage) into a benefit by using a cold mechanical compression process. The reel projection's elastic compression provides reliable electrical connection without introducing heat that could compromise the gas seal, thus converting the harmful thermal process into a beneficial cold process.
3Ease of manufacture
If terminals are embedded in the reel base through insertion, then electrical connections can be established, but the connection integrity is compromised
Solution Approach 1:
Instead of inserting terminals into the reel base and then connecting wires (which compromises integrity), the patent inverts the approach: the reel projection directly compresses the wires against contact surfaces. This reversal of the connection sequence ensures wire integrity is maintained while achieving reliable electrical connection through compression rather than insertion.
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 solution enhances the reliability of electrical connections, simplifies the manufacturing process, and minimizes the risk of gas leakage by avoiding soldering-related issues, thereby optimizing the safety and efficiency of the gas safety valve.
Implementation Method 1
both electrical contact areas exerting an elastic force against the phase connector and the support, respectively, assuring the electrical connection
Data Source
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AI summary
Gas safety valve adapted for a cooking appliance, comprising an electromagnet (2) comprising a core (9), a reel (10) inserted in the core (9) and a coil (11) supported on the reel (10), the coil (11) comprising a phase wire (12) and a grounding wire (13), a support (3) of the electromagnet (2), and a phase connector (25). The reel (10) comprises a projection extending axially and comprising a first electrical contact area (A) in which a segment of the phase wire (12) is arranged and a second electrical contact area (B) in which a segment of the grounding wire (13) is arranged, wherein the first electrical contact area (A) is arranged such that it is inserted in the phase connector (25) and the second electrical contact area (B) is arranged such that it is inserted in the support (3), both electrical contact areas (A, B) exerting an elastic force against the phase connector (25) and the support (3), respectively, assuring the electrical connection between the phase wire (12) and the phase connector (25), and between the grounding wire (13) and the support (3), respectively.