Temperature-Dependent Switch with Segmented Connecting Lugs
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Solution Overview
Problem
Existing temperature-dependent switches have complex designs and assembly processes, particularly with plug-type connections, which are time-consuming and prone to mechanical deformations and insufficient soldered joints, limiting their reliability and ease of use.
Innovation Solution
The use of connecting lugs with plug-type connections and a sintered insulating protective layer that encases the inner ends of the lugs, eliminating the need for riveting and providing a structurally stable connection that withstands mechanical loads while ensuring electrical insulation and protection against dirt and moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If feed lines are connected by material-connecting engagement (soldering or welding) to connecting surfaces, then electrical connection is established, but the assembly process becomes time-consuming and complex
Solution Approach 1:
The feed line is divided into two distinct parts: a first connecting portion for material connection to the connecting surface, and a second connecting portion formed as a plug-type connection. This segmentation allows different connection methods to be applied to different parts, enabling automated assembly while maintaining reliable electrical connections through the material-connected first portion.
Solution Approach 2:
The insulating protective layer acts as an intermediary that encases the first connecting portion of the feed line, providing structural stability and protection to the soldered or welded connection. This protective layer shields the material connection from mechanical loads and environmental factors, ensuring connection reliability while allowing the second portion to remain accessible for automated plug-type connection.
2Strength
If riveting is used to connect feed lines to housing, then mechanical strength is improved, but the risk of housing deformation increases
Solution Approach 1:
The insulating protective layer serves as an intermediary between the feed line and the housing, providing mechanical support and stress distribution. By encasing the first connecting portion, it reinforces the connection without requiring rivets that could deform the housing, thus maintaining both mechanical strength and housing precision.
Solution Approach 2:
The solution combines the insulating protective layer material with the feed line and housing structure to create a composite assembly. This composite structure provides the necessary mechanical strength through the combined properties of the materials, eliminating the need for riveting while preventing housing deformation.
3Reliability
If insulating caps are added to protect switches electrically, then electrical insulation is improved, but the device complexity and assembly steps increase
Solution Approach 1:
The insulating protective layer performs multiple functions simultaneously: it provides electrical insulation, protects the material connection from mechanical loads, and offers structural stability. By merging these functions into a single integrated component rather than adding separate caps and shields, the solution improves insulation reliability while reducing overall device complexity.
Solution Approach 2:
The insulating protective layer is designed as a multi-functional element that combines electrical insulation, mechanical protection, and structural support in one component. This universal approach eliminates the need for multiple separate protective elements, reducing assembly steps and simplifying the overall device structure while maintaining high insulation reliability.
4Ease of operation
If connecting lugs are threaded through slots in caps, then plug-type connection is enabled, but the risk of galvanic connection damage and lug bending increases
Solution Approach 1:
The feed line is segmented into a first connecting portion enclosed by the insulating protective layer for material connection, and a second connecting portion exposed as a plug-type connection. This segmentation allows the second portion to be easily installed through automated plug-type connection without threading through slots, while the first portion remains protected, eliminating the risk of connection damage and lug bending.
Solution Approach 2:
The insulating protective layer acts as an intermediary that protects the first connecting portion from mechanical stresses during installation. By providing this protective enclosure, the layer prevents bending and damage to the material connection while allowing the second portion to be easily connected via automated plug-type connection, thus maintaining both installation ease and connection integrity.
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 simplifies assembly, enhances mechanical stability, and prevents damage to connections, allowing for reliable and efficient installation of temperature-dependent switches with plug-type connections, reducing the risk of deformations and ensuring high-quality electrical connections.
Implementation Method 1
the insulating protective layer is a sintered protective layer
Implementation Method 2
a bimetallic part is provided in the switching mechanism, said bimetallic part being deformed suddenly from its low-temperature position into its high-temperature position when its switching temperature is reached
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A temperature-dependent switch (10) has, on the outside on its housing, a first and at least a second connecting surface (22, 23) for directly connecting feed lines and, in the housing, a temperature-dependent switching mechanism, which depending on its temperature produces or opens an electrically conducting connection between the two connecting surfaces (22, 23). The feed lines are directly connected, at their inner ends (27, 28), to the connecting surfaces (22, 23), the switch (10) being encased by an insulating protective layer (32), and the feed lines, at their free ends (29, 31) which are remote from the inner ends (27, 28), are free of the protective layer (32). The feed lines are in the form of connecting lugs (25, 26), which are connected in material-connecting engagement, at their inner ends (27, 28), to the connecting surfaces (22, 23) and, at their free ends (29, 31), are directly forms as plug-type connections. The insulating protective layer (32) is configured such that it brings about a structurally stable connection between the housing, the connecting surfaces (22, 23) and the inner ends (27, 28) of the connecting lugs (25, 26) (Fig. 2).