Compact Heating Element Connector for Faster Thermal Fuse Response
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Solution Overview
Problem
Existing heating elements in household appliances suffer from overheating due to lime scale buildup and excessive length, leading to reduced reliability and shorter lifespan, as well as slower heat transmission and longer reaction times for thermal fuses.
Innovation Solution
A compact heating element design with a direct connection between the heating resistor and thermal fuse via an elastic connector, reducing overall length by approximately 20% and enhancing mechanical robustness, allowing for faster heat transfer and quicker intervention times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the heating element uses a traditional arrangement with leg wire and pin connected to thermal fuse, then the element can be assembled, but the total length becomes excessive and heat transmission slows down
Solution Approach 1:
The connector integrates multiple functions into a single component: it serves as both the electrical connection element and the thermal conduction path between the heating resistor and thermal fuse. This merging eliminates the need for separate leg wires and pins, reducing total length while maintaining electrical connectivity and improving heat transmission speed through direct thermal contact.
Solution Approach 2:
The connector acts as an intermediary element that directly bridges the heating resistor and thermal fuse, providing both electrical connection and thermal conduction. This intermediary structure replaces the traditional multi-component arrangement (leg wire + pin), creating a more efficient thermal pathway while reducing overall assembly length.
2Device complexity
If the heating element uses a traditional arrangement with multiple components, then assembly is possible, but the number of component parts increases and mechanical robustness decreases
Solution Approach 1:
The connector combines multiple discrete components (leg wire, pin, and connection structure) into a single integrated element. This reduction in component count simplifies assembly while inherently improving mechanical robustness by eliminating multiple connection interfaces that could fail. The single-piece connector design removes potential weak points where separate components would join.
3Loss of time
If the thermal fuse is positioned farther from the heating resistor, then assembly is easier, but the reaction time of the thermal fuse increases
Solution Approach 1:
The connector places the thermal fuse in direct thermal contact with the heating resistor by integrating the fuse mounting structure into the connector itself. This merging of functions allows the fuse to be positioned as close as possible to the heat source, minimizing thermal response time while maintaining a compact overall design that doesn't require excessive space.
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 solution results in a more reliable, longer-lasting heating element with improved heat transfer efficiency and reduced dimensions, ensuring faster thermal fuse intervention and increased mechanical stability.
Implementation Method 1
heating electrical resistor 3
Implementation Method 2
heat is carried directly and more rapidly onto the fuse body through the specific connector
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
An electrical heating element comprising an immersed casing with an electrical heating resistor therein, fixed to a first pin, a thermal fuse and a second pin for the connection to the power supply system, wherein the electrical heating resistor and the thermal fuse are connected by a connector, having a first and a second cylindrical metallic part joining the first pin to the thermal fuse and having a third central part joining the first part to the second part.