PTC Thermistor Insulating Plate Design

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Solution Overview

Problem

Conventional PTC thermistors have inadequate insulation between electric conducting plates with different electrodes, leading to potential short circuits and instability of PTC thermal resistance members due to insufficient separation and uneven locking, posing safety risks.

Innovation Solution

Incorporation of an intermediate insulating plate with openings corresponding to PTC thermal resistance members, securely separating and stabilizing the electric conducting plates and enhancing insulation by engaging the PTC thermal resistance members within these openings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If only PTC thermal resistance members are used to separate conducting plates, then the structure is simple, but the insulation effect is insufficient and short circuits may occur

Engineering Contradiction:

Improvestructure simplicityVSAvoidinsulation reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

An intermediate insulating plate is introduced between the two conducting plates as a mediator to provide reliable insulation. This insulating plate with through-holes serves as the primary insulation barrier, preventing short circuits between the conducting plates while the PTC thermal resistance members pass through it to maintain thermal contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If locking members are tightened unevenly, then assembly is easier, but the distance between conducting plates decreases causing loss of insulation and short circuits

Engineering Contradiction:

Improveassembly easeVSAvoidinsulation safety

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The intermediate insulating plate acts as a mediator that maintains the proper distance between conducting plates regardless of locking member tightness. Its rigid structure prevents the plates from coming into contact even when locking members are tightened unevenly, eliminating the insulation loss problem.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The intermediate insulating plate provides beforehand cushioning by pre-establishing a reliable insulation barrier before any potential short circuit can occur. This protective measure ensures that even if locking members are tightened unevenly, the insulation is already in place to prevent short circuits.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If positioning recesses are shallow, then manufacturing is easier, but PTC thermal resistance members are not firmly fixed and may slip off

Engineering Contradiction:

Improvemanufacturing easeVSAvoidPTC member stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The intermediate insulating plate serves as an intermediary fixation structure that provides through-holes for the PTC thermal resistance members. These through-holes act as positioning features that firmly hold the PTC members in place, preventing them from slipping off while maintaining ease of manufacturing.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Volume of moving object

If conducting plates are positioned close to each other, then the device is more compact, but insulation effect decreases and short circuits become more likely

Engineering Contradiction:

Improvedevice compactnessVSAvoidinsulation effectiveness

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The intermediate insulating plate is positioned between the conducting plates as a mediator that maintains adequate spacing while allowing the device to remain compact. Its presence ensures insulation effectiveness even when the overall device size is reduced, preventing short circuits between the closely positioned conducting plates.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Ensures effective insulation and stable fixation of PTC thermal resistance members, preventing short circuits and ensuring safe operation by maintaining a consistent insulation gap between the electric conducting plates.

Implementation Method 1

the opposite sides of the PTC thermal resistance members 10 will immediately be heated to form a heat source

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

an intermediate insulating plate 26 clamped between the two electric conducting plates 21 and 22... able to surely separate and insulate the two electric conducting plates 21 and 22

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS7880581B2PTC thermistor

Publication Date: 2011.02.01 CHANG CHUNG TAI

AI summary

A PTC thermistor includes two electric conducting plates connected with different electrodes and an intermediate insulating plate clamped between the two electric conducting plates. The intermediate insulating plate has its surface bored with openings at locations respectively corresponding with those of each PTC thermal resistance member for the PTC thermal resistance member to be engaged therein. The intermediate insulating plate can surely separate and insulate the two different-electrode electric conducting plates and stably fix the PTC thermal resistance members in position.