Liquid Heating Vessel Control Mount Plate with Tension-Locking Tabs
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Solution Overview
Problem
Existing liquid heating vessel controls lack sufficient strength to withstand transit forces, leading to potential detachment of the main control moulding from the mount plate, and current strengthening methods increase manufacturing costs.
Innovation Solution
A control for liquid heating vessels featuring a metal mount plate attached to a moulded plastics unit using metal tabs with a pillar and arm structure that applies tensile force, creating a 'tension locking' mechanism without additional components, enhancing attachment strength and allowing for a compact design without screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws are added to pass through the mount plate and moulding to hold them together, then the strength of the control is improved, but the manufacturing cost increases due to additional components and assembly steps
Solution Approach 1:
The patent combines the mounting tab and the mount plate into a single integrally formed metal component. The tab extends from the mount plate and includes a bent portion that engages with the molded unit, eliminating the need for separate screws or fasteners. This integration reduces component count and assembly complexity while maintaining attachment strength.
Solution Approach 2:
The patent employs a plastically deformable tab structure that can be bent during assembly to create a secure mechanical engagement. The tab is initially in a first configuration during assembly, then deformed to a second configuration that locks the mount plate to the molded unit. This dynamic deformation process creates a strong attachment without requiring additional fastening components.
2Strength
If the control is strengthened by adding screws, then the attachment strength is improved, but the device complexity increases due to additional components
Solution Approach 1:
The mounting tab and mount plate are merged into a single integrally formed metal component, reducing the number of parts from multiple separate components (mount plate, tabs, screws) to fewer integrated parts. This simplification reduces device complexity while maintaining the necessary attachment functionality.
Solution Approach 2:
The patent extracts the fastening function from separate screw components and integrates it directly into the mount plate structure through the bent tab design. The tab itself performs the fastening function through its deformation and engagement with the molded unit, eliminating the need for external fasteners.
3Strength
If larger controls are used to accommodate traditional mounting methods, then the attachment is sufficient, but the size of the liquid heating vessel increases
Solution Approach 1:
The plastically deformable tab structure allows for a compact mount plate design that achieves strong attachment through deformation during assembly. The tab can be bent to create a secure mechanical lock within a smaller form factor, eliminating the need for larger controls required by traditional non-deformable mounting methods.
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 provides a robust attachment that increases the strength of the control while reducing manufacturing costs and enabling the production of smaller, more efficient liquid heating vessels with improved thermal diffuser plate thickness and base size.
Implementation Method 1
the mount plate is plastically deformed next to the metal tab so as to form a stiffened shape at the base of the pillar that creates a tensile force acting along the pillar
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
The present invention relates to controls for liquid heating vessels. In particular, a control (2) comprising a moulded plastics unit (4) which houses at least one switch for controlling an electrical power supply to the liquid heating vessel, and a metal mount plate (6) attached to the moulded plastics unit (4), wherein the metal mount plate (6) comprises one or more metal tabs (22) arranged to attach the mount plate (6) to the moulded plastics unit (4) in a tension locking arrangement.