Plug-In Faston Coupling for Candle Resistance and Rod Thermostat
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Solution Overview
Problem
Existing connection methods between candle resistances and thermostats in electric storage water heaters are complex, costly, and prone to malfunctions due to the use of multiple components and potential for electrical wiring deterioration or mounting errors.
Innovation Solution
A plug-in coupling system using metal connectors constrained to the pins of the candle resistance, allowing axial insertion and connection with the thermostat's fastons without additional wiring or mechanical fixing means, thereby simplifying assembly and reducing the risk of malfunction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods (wiring or direct mechanical constraint) are used between candle resistance and thermostat, then electrical connection is achieved, but the number of components increases, assembly complexity increases, and reliability decreases
Solution Approach 1:
The patent combines the electrical connection function and mechanical constraint function into a single integrated faston component. The faston simultaneously provides electrical contact and mechanical retention through its U-shaped design that clamps onto the resistance element, eliminating the need for separate wiring and mechanical fastening components.
Solution Approach 2:
The faston serves multiple functions: it provides electrical connection, mechanical constraint, and structural support. This multi-functional component replaces multiple specialized components (wiring, nuts, washers, brackets) with a single universal connector that performs all necessary functions for securing and electrically connecting the resistance element to the thermostat.
2Productivity
If traditional connection methods with multiple components are used, then electrical connection is established, but assembly time increases and manufacturing costs increase
Solution Approach 1:
By merging the electrical connector and mechanical fastener into a single faston component, the patent reduces the number of assembly steps. The faston can be installed in one operation rather than requiring separate steps for wiring, securing with nuts, and adding washers, thereby significantly improving assembly speed and productivity.
Solution Approach 2:
The patent segments the connection system into modular components (faston, thermostat, resistance element) that can be independently manufactured and then quickly assembled. This modular approach with standardized fastons enables rapid assembly and facilitates parallel manufacturing processes.
3Reliability
If wiring is used for electrical connection, then electrical connection is achieved, but the risk of deterioration due to Joule effect increases
Solution Approach 1:
The patent extracts the electrical connection function from the wiring system and integrates it directly into the mechanical fastening component (faston). This eliminates the need for separate wiring that would be susceptible to Joule heating and deterioration, as the faston's metal construction provides both mechanical and electrical functions with superior thermal and electrical properties.
Data Source
Figure 1A~1B
Figure 2~3
Figure 4A~4B
AI summary
The object of the present invention is an electrical connection system between a candle resistance (R) and a rod thermostat (T). Said resistance (R) is equipped with a pair of metal connectors (1) constrained to pins (FR), shaped so as to make two female fastons (1.CR) placed in axial position with the two male fastons (CT) of such thermostat (T), in order to enable a plug-in coupling thereof.