Removable electric grill controller with mount
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Solution Overview
Problem
Existing electric grill controllers fail to withstand high heat and harsh outdoor environments, and they often require expensive insulation that can degrade, while also potentially impeding the controller's ability to act as an electrical ground.
Innovation Solution
A removable electronic controller with a mounting bracket made of conductive metal, featuring a thermal barrier that protects internal electronics from heat and allows the controller to act as an electrical ground, eliminating the need for traditional insulation materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional heat insulation materials (such as fiberglass) are used to protect the controller from heat, then the controller is protected from high temperatures, but the insulation materials may degrade from heat or environmental conditions and potentially impede the controller's ability to act as an electrical ground
Solution Approach 1:
The mounting bracket is divided into two distinct functional sections: an outer bracket portion made of insulating material that provides thermal protection, and an inner bracket portion made of conductive material that provides electrical grounding. This segmentation allows each portion to perform its specific function without interfering with the other, resolving the contradiction between heat protection and electrical grounding capability
Solution Approach 2:
Different portions of the mounting bracket are assigned different material properties: the outer portion uses insulating material for thermal protection, while the inner portion uses conductive material for electrical grounding. This local differentiation of material qualities allows the single mounting bracket structure to simultaneously provide both heat protection and electrical grounding without degradation or interference
2Temperature
If high-temperature plastic and high-temperature rated electronics are used to manufacture the controller, then the controller can withstand high temperatures, but the manufacturing cost increases and the controller loses removability
Solution Approach 1:
The thermal protection function is extracted from the controller itself and relocated to the mounting bracket. The mounting bracket's insulating outer portion provides the thermal barrier, allowing the controller to be manufactured with standard, lower-cost materials and components that do not require high-temperature ratings, while still achieving the necessary heat resistance when mounted
Solution Approach 2:
The mounting bracket acts as an intermediary thermal barrier between the heat source (grill housing) and the controller. This intermediary structure provides the necessary thermal protection, allowing the controller to use conventional materials and electronics that are easier and less expensive to manufacture, while still withstanding the high-temperature environment through the bracket's insulation
3Temperature
If traditional insulation materials are used, then heat protection is provided, but the controller's ability to act as an electrical ground is impeded
Solution Approach 1:
The mounting bracket is segmented into an insulating outer portion for thermal protection and a conductive inner portion for electrical grounding. This segmentation allows the structure to simultaneously provide thermal insulation while maintaining electrical conductivity for safety grounding, resolving the contradiction between heat protection and electrical safety
Solution Approach 2:
The mounting bracket uses a composite structure combining insulating material (for thermal protection) and conductive material (for electrical grounding). This composite approach allows both thermal insulation and electrical conductivity to coexist in a single mounting structure, eliminating the need to choose between heat protection and electrical safety
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 effectively shields the controller from heat, ensures electrical safety by grounding the grill housing, and reduces manufacturing costs by using sheet metal for the mounting bracket, which conducts heat rather than providing insulation.
Implementation Method 1
a mounting bracket forming a thermal barrier between the housing and the controller... the mounting bracket... are made of a metal, and the spring elements may connect to an electric ground via a power cord
Implementation Method 2
The first and second spring elements may be made of electrically conductive metal... Establishing an electrical ground is an important safety feature because stray or leaked currents in the electric grill's housing present a danger to a user
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An electric grill comprising a housing (300), a controller (100), and a mounting bracket (200) which mounts the controller to the housing. The mounting bracket (200) is generally hollow and forms a thermal barrier between the controller and the housing, wherein the thermal barrier protects the controller from heat generated in the housing. As a result, the controller (100) does not require insulation and may include lower temperature rated components. Moreover, the mounting bracket may have metallic tabs (280, 281) which interface with spring elements (190, 195) on the controller, thereby fastening the controller to the bracket. These spring elements and metallic tabs may be in electric communication with the housing, thereby allowing the controller to act as an electric ground with respect to the housing.