Heating Element Terminal Pin Connection Insert
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Solution Overview
Problem
Existing water-immersed heating elements face issues with reliable connections between copper terminal pins and resistance wires, particularly in fully compacted designs, leading to detachment and electrical arcing, which compromises heat transfer and safety during dry start conditions.
Innovation Solution
A connection insert, such as a steel sleeve, is securely affixed to the terminal pin, allowing the resistance wire to be welded to it, providing a robust mechanical, electrical, and thermal connection, even during compaction, and enabling the use of copper terminal pins for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a copper terminal pin is used for enhanced electrical and thermal conductivity, then heat transfer efficiency is improved, but the connection reliability between the terminal pin and resistance wire deteriorates due to welding difficulty
Solution Approach 1:
A steel insert is introduced as an intermediary component between the copper terminal pin and the resistance wire. The steel insert serves as a mediator that is compatible with both copper (for attachment) and resistance wire (for welding), thereby resolving the incompatibility issue. The copper pin attaches to the steel insert, and the resistance wire welds to the steel insert, enabling reliable connections without direct copper-to-wire welding.
Solution Approach 2:
The terminal assembly uses a composite structure combining copper and steel materials. The copper terminal pin provides superior electrical and thermal conductivity, while the steel insert provides mechanical strength and weldability. This composite approach allows each material to contribute its optimal properties to the overall connection system.
2Reliability
If the heating element is fully compacted to improve heat transfer and flexibility, then thermal efficiency is improved, but the connection between terminal pin and resistance wire deteriorates leading to detachment and electrical arcing
Solution Approach 1:
The terminal assembly is segmented into distinct functional components: the copper terminal pin, the steel insert, and the resistance wire attachment point. This segmentation allows each component to be optimized for its specific function while maintaining overall connection integrity during compaction. The steel insert acts as a structural backbone that maintains connection strength through the compaction process.
Solution Approach 2:
The steel insert serves as a mediator that maintains mechanical strength and connection integrity during the compaction process. It provides a stable structural foundation that prevents detachment between the terminal pin and resistance wire, even when the heating element is fully compacted to improve heat transfer efficiency.
3Ease of manufacture
If a steel terminal pin is used for ease of welding, then manufacturing ease is improved, but the thermal conductivity and heat transfer efficiency deteriorate
Solution Approach 1:
The terminal assembly uses a composite structure where copper provides superior thermal and electrical conductivity, while steel provides ease of welding and mechanical strength. The copper terminal pin ensures efficient heat transfer to the steel insert, which then conducts heat to the resistance wire, combining the advantages of both materials in the heat transfer path.
Solution Approach 2:
The steel insert acts as an intermediary in the heat transfer path between the copper terminal pin and the resistance wire. While copper provides the primary thermal conductivity, the steel insert maintains thermal continuity and ensures efficient heat transfer to the wire, bridging the gap between the two materials.
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 configuration ensures a stable and efficient thermal energy transfer from the resistance wire to the thermal protection device, preventing damage from excessive temperatures and improving the reliability and lifespan of the heating element.
Implementation Method 1
a resistance wire and a terminal pin in electrical and thermal contact
Implementation Method 2
stable and efficient thermal energy transfer from the resistance wire to the thermal protection device
Data Source
AI summary
An improved construction for a heating element for an appliance is disclosed. A coiled resistance wire extending coaxially along the length of an elongate sheath is surrounded by an electrically insulating, high thermally conductive material that fills the sheath around the wire. The resistance wire is secured to a terminal pin at a connection comprising a connection insert that is securely affixed to the terminal pin, intermediate the terminal pin and resistance wire. The resistance wire is then able to be welded to the connector to provide a superior mechanical connection between a terminal pin and the resistance wire, even though the terminal pin is made from copper. The disclosed construction, therefore, provides good electrical and thermal conductivity and resists the tendency to separate during manufacture.