Induction Cooktop Polymeric Support Assembly for PCB Insulation
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Solution Overview
Problem
Induction cooking appliances face challenges in mounting printed circuit boards on metal trays without insulation issues, particularly with the use of metal trays which require efficient and cost-effective solutions for assembly and packaging.
Innovation Solution
The use of polymeric support elements with snap-engagement mechanisms and elastic hooks allows for quick and tool-free mounting of printed circuit boards and coil trays on metal trays, ensuring proper insulation and easy assembly, which can be automated for increased reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal trays are used for mounting printed circuit boards, then electrical insulation problems occur, but using insulating materials increases assembly complexity
Solution Approach 1:
The patent introduces polymeric support elements as intermediary components between the metal tray and the printed circuit board. These support elements serve as mediators that provide electrical insulation while maintaining a simple assembly structure, eliminating the need for complex insulating arrangements.
Solution Approach 2:
The patent employs inexpensive polymeric support elements with snap-engagement mechanisms that are designed for easy assembly and potential replacement. These disposable-like components provide reliable insulation without requiring complex permanent installation procedures.
2Productivity
If traditional mounting methods are used, then assembly time increases, but automated assembly requires simple mounting mechanisms
Solution Approach 1:
The patent implements self-service mounting through snap-engagement mechanisms where the support elements automatically engage with the metal tray and secure the printed circuit board without requiring additional fastening operations. This self-securing mechanism enables rapid manual and automated assembly.
Solution Approach 2:
The patent replaces traditional mechanical fastening systems (screws, clips, adhesives) with a simplified snap-engagement mechanism that relies on elastic deformation and geometric interlocking. This substitution reduces assembly steps and enables automated assembly while maintaining secure mounting.
3Reliability
If insulation measures are added to metal trays, then manufacturing cost increases, but cost-effective solutions are needed
Solution Approach 1:
The patent uses polymeric support elements as cost-effective intermediary components that provide the necessary electrical insulation. These support elements are manufactured separately and attached to the metal tray, avoiding the need for expensive modifications to the metal tray itself while ensuring reliable insulation.
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 enables efficient, cost-effective, and reliable assembly of induction cooking appliances by ensuring proper insulation and easy mounting of components, enhancing the quality and simplicity of the assembly process.
Implementation Method 1
Each support element is provided, at distal ends thereof, with an elastic hook portion designed to cooperate, in a snap-engaging assembling movement, with corresponding slots in the metal tray
Data Source
AI summary
An induction cooking appliance comprises a bottom metal tray containing a printed circuit board and electronic components mounted thereon, and also a pair of polymeric support elements configured to be fastened to the metal tray and interposed between the tray and the printed circuit board in order to define a predetermined distance between the tray and the printed circuit board. The polymeric support elements may have an integral intermediate polymeric frame which provides a predetermined relative position thereof.