High-Current Thermostat Rivet Structure for Stable Electrical Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermostat terminals experience loosening and poor electrical contact due to torsion forces from circular rivets, and materials like brass terminals have low bending strength and high resistivity, while steel terminals can lead to heat rise issues.
Innovation Solution
A thermostat design featuring polygonal-shaped rivet holes and solid rivets, combined with a multi-layer metal terminal structure, including layers of steel and copper, to enhance torsion resistance and temperature performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circular rivets are used to attach terminals to thermostat housings, then the installation process is simple, but torsion forces cause the rivets and rivet holes to slide and loosen, resulting in poor electrical contact
Solution Approach 1:
The patent changes the rivet and rivet hole shape from circular (symmetrical) to polygonal (asymmetrical). This asymmetry prevents rotational movement and sliding between the rivet and rivet hole, eliminating the loosening problem caused by torsion forces during installation and use.
2Reliability
If brass terminals are used for electrical connection, then the terminals have good electrical conductivity, but they have low bending strength and cannot withstand high temperatures
Solution Approach 1:
The patent employs a multi-layer terminal structure combining different metal materials (such as steel and copper layers). The steel layers provide high bending strength and temperature resistance, while the copper layers ensure good electrical conductivity. This composite structure resolves the contradiction between electrical performance and mechanical/thermal strength.
3Strength
If steel terminals are used for electrical connection, then the terminals have high bending strength, but they have high resistivity which causes heat rise and poor thermostat performance
Solution Approach 1:
The multi-layer terminal structure combines steel layers (providing high bending strength) with copper layers (providing low resistivity and good electrical conductivity). This composite approach allows the terminal to simultaneously achieve high mechanical strength and low energy loss, preventing heat rise while maintaining structural integrity.
4Device complexity
If single-layer metal terminals are used, then the terminal structure is simple, but the terminals exhibit poor bending strength and high temperature resistance
Solution Approach 1:
The patent uses a multi-layer metal construction where different metal layers (steel and copper) are combined to achieve superior bending strength and temperature resistance. While the structure becomes more complex, the performance benefits in strength and temperature resistance significantly outweigh the increased structural complexity.
Data Source
AI summary
The disclosure provides a construction for a high-current thermostat including a thermostat housing, a rivet hole arranged in the thermostat housing, and a rivet matched with the rivet hole. The terminal is connected to the thermostat housing by the rivet. The rivet hole and rivet each have a polygonal shape and the rivet can be solid. The terminal includes a multi-layered metal structure. The polygonal-shaped rivet hole and solid rivet improve the rivet torsion force of the thermostat. The multi-layer metal construction of the terminal exhibits improved bending strength and high temperature resistance to reduce the terminal heat rise of the thermostat.