Temperature-Dependent Switch Contact Structure Without Central Hole

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Solution Overview

Problem

Existing temperature-dependent switches face material weakening and reduced power density due to the central hole required for rivet connection between the temperature-dependent switching element and the current transfer member, impairing current conductivity and stability.

Innovation Solution

A configuration where the current transfer member has a solid, integrally formed second section that passes through the temperature-dependent switching element's opening, eliminating the need for a central hole and enhancing the overall mass and stability of the current transfer member, with a support ring for secure connection and a temperature-independent spring element to relieve the switching element.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a central hole is provided in the current transfer member for rivet connection, then the temperature-dependent switching element can be connected to the current transfer member, but the material strength and stability of the current transfer member are reduced

Engineering Contradiction:

Improveswitching element connectionVSAvoidcurrent transfer member strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The invention extracts the rivet connection from the current transfer member by providing the opening in the temperature-dependent switching element instead. This allows the switching element to be mounted without creating a hole in the current transfer member, thereby preserving its material strength and stability while still achieving reliable connection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of making the current transfer member pass through a hole in the switching element (conventional approach), the invention inverts the arrangement by having the switching element contain an opening that receives the current transfer member. This inversion eliminates the need to compromise the current transfer member's structural integrity.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If a central hole is provided in the current transfer member, then the switching element can be mounted, but the power density and current conductivity are reduced

Engineering Contradiction:

Improveswitching element mountingVSAvoidcurrent conductivity

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The invention extracts the mounting opening from the current transfer member and relocates it to the temperature-dependent switching element. This extraction preserves the full cross-sectional area of the current transfer member, maintaining its power density and current conductivity while still enabling switching element mounting.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If a rivet is used to connect the switching element, then secure connection is achieved, but material locking requires rolling or positive locking which adds manufacturing complexity

Engineering Contradiction:

Improveconnection securityVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention replaces the mechanical rivet connection system with a simplified insertion system where the current transfer member is passed through an opening in the switching element. This substitution eliminates the need for rivets, holes, and complex material locking processes like rolling, significantly simplifying manufacturing while maintaining secure connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 increases the current transfer member's stability and power density, enabling higher current conductivity and extending the switch's service life by reducing material weakening and maintaining consistent switching performance.

Implementation Method 1

a bimetallic element which is configured as a multi-layered, active, sheet metal-shaped device consisting of two, three or four interconnected components with different thermal expansion coefficients

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

the current transfer member ensures the electrically conductive connection between these two stationary contacts in the closed state or low-temperature state of the switch

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20240290562A1Temperature-dependent switch

Publication Date: 2024.08.29 HOFSAESS MARCEL P

AI summary

A temperature-dependent switch having first and second stationary contacts and a temperature-dependent switching mechanism comprising a current transfer member and a temperature-dependent switching element. The temperature-dependent switching mechanism is configured to switch in a temperature-dependent manner between a closed state, in which the current transfer member is pressed against the first and second stationary contacts so that an electrically conductive connection is established, and an open state, in which the current transfer member is held at a distance from the first and second stationary contacts and, thus, the electrically conductive connection is interrupted. The current transfer member comprises a first section which, in the closed state, is pressed against the first and second stationary contacts, and a second section which projects from the first section and is integrally connected to the first section and which is passed through an opening provided in the temperature-dependent switching element.