Sealed Temperature Switch Housing Against Solder and Varnish Ingress

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Solution Overview

Problem

Temperature-dependent switches face challenges in achieving effective mechanical sealing, particularly due to issues with insulating foils curling or folding, which can lead to leaks and contamination, and existing solutions like enclosures or resin hoods are perceived as complex and inefficient.

Innovation Solution

The introduction of a sealing ring on the upper side of the cover part, which is in sealing contact with the bent upper section of the wall, provides enhanced mechanical sealing without the need for insulating foils, ensuring the switch is sealed before connecting leads are attached, and can be easily integrated into the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If insulating foils are used to electrically insulate housing parts, then electrical insulation is achieved, but the foils curl or fold causing sealing failures and contamination

Engineering Contradiction:

Improveelectrical insulationVSAvoidsealing failure and contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a sealing ring as an intermediary component between the insulating foil and the housing parts. This sealing ring prevents the insulating foil from curling or folding by providing a mechanical constraint, thereby maintaining both electrical insulation and effective sealing without contamination

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs a flexible sealing ring that can adapt to the housing structure while maintaining continuous contact to prevent foil displacement. The sealing ring acts as a thin film barrier that constrains the insulating foil in its proper position, preventing sealing failures

Inventive Principle:

Principle #30Flexible shells and thin films

2Object-affected harmful factors

If enclosures or resin hoods are used for sealing, then mechanical sealing is improved, but the device complexity increases

Engineering Contradiction:

Improvemechanical sealingVSAvoidsealing structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent segments the sealing function into a separate, dedicated sealing ring component rather than using complex enclosures or resin hoods. This segmentation allows the sealing ring to be a simple, standalone element that provides effective mechanical sealing without increasing overall device complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sealing ring is designed as a simple, inexpensive component that can be easily manufactured and replaced if needed. Rather than using complex resin hoods or enclosures, the patent employs a straightforward sealing ring that achieves effective sealing at low cost and low complexity

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If the switch is sealed after connecting leads are attached, then assembly is simplified, but solder or varnishes can enter the interior causing contamination

Engineering Contradiction:

Improveassembly simplicityVSAvoidcontamination from solder or varnishes

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent implements preliminary sealing by installing the sealing ring and sealing the switch housing before the connecting leads are attached and soldered. This preliminary action prevents solder or varnishes from entering the interior during the soldering process, while the sealed unit can still be easily assembled as a complete component

Inventive Principle:

Principle #10Preliminary action

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 significantly improves the mechanical sealing of the switch, preventing solder or varnishes from entering the interior and simplifies production by eliminating the need for complex sealing methods, while being cost-effective and easy to automate.

Implementation Method 1

a bi-metal disc fitted over the movable contact part

Methodology Applied

Scientific EffectBi-metallic strip effect: Bi-Metallic Strip

Implementation Method 2

The spring snap disc presses the movable contact member against a stationary counter contact

Methodology Applied

Scientific EffectElastic force: Elasticity

Implementation Method 3

the switch is, for example, brought into thermal contact with the device to be protected via one of its outer surfaces, so that the temperature of the device to be protected influences the temperature of the switching mechanism

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11901144B2Temperature-dependent switch

Publication Date: 2024.02.13 HOFSAESS MARCEL P

AI summary

A temperature-dependent switch with a housing, which comprises a cover part having an upper side and a lower part having a raised peripheral wall, the upper section of which is bent onto the upper side of the cover part and thereby holds the cover part on the lower part, wherein two contact surfaces are provided outside at the housing and a switching mechanism is arranged in the housing, wherein the switching mechanism is configured to switch, depending on its temperature, between a closed state, in which the switching mechanism establishes an electrically conductive connection between the two contact surfaces, and an open state, in which the switching mechanism interrupts the electrically conductive connection between the two contact surfaces. A sealing ring is arranged on the upper side of the cover part, which sealing ring is in sealing contact with the bent upper section of the wall.