ECOKETTLE PRO (TIER 2) — ENGINEERING DRAWINGS PACKAGE

Project: EcoKettle | Phase: concept2prd | FDRP Run 1010
Date: 2026-03-18
5 Sheets
SECTION A-A Full Vertical Cross-Section — EcoKettle Pro (Tier 2) CL MAX FILL 1.7L 5-POLE SMA VENT 250 156 131 12.5 195 42 30 0.4 0.5 1.0 50 dia 180 25 OUTER VESSEL 304SS, 0.4mm t Deep-drawn + spun INNER VESSEL 304SS, 0.5mm t, 1.7L Deep-drawn + spun AEROGEL FILL Cabot Thermal Wrap, 10mm lambda 0.015 W/mK Thermal + acoustic dual benefit TIG WELD (circumferential) Argon shield gas AlN THICK-FILM HEATER 96% AlN, 50mm dia x 1mm RuO2 paste (lead-free) + glass frit 2.2 kW at 230V AC, R=24.2 ohm TIM PAD (graphite+silicone, 0.5mm) BELLEVILLE SPRINGS (4x) 301SS, 50-100 kPa contact pressure SS BASE PLATE (MANDATORY) 304SS, 1.0mm — food contact barrier Separates AlN from water (D-W2-001) CLD (constrained-layer damping) NTC THERMISTOR 100K at 25C, glass-encapsulated Response <2s, in SS press-fit housing LID ASSEMBLY PP+mineral fill body + 304SS inner plate Dual-lip silicone seal (FDA) Nitinol SMA vent in SS housing (95C) BASE HOUSING (PP+30%GF) PCBA: STM32G0, FR4, 60x40mm 360-DEG CONNECTOR (5-pole Cu) THERMOCHROMIC BAND (EXTERIOR) Multi-zone leuco dye: 60/70/80/90/95C LOW-E FILM (aluminized PET, 12um) HANDLE (304SS bracket + PP over-mold) SECTION HATCHING (ISO 128) 304 Stainless Steel (SS) Aerogel insulation fill AlN ceramic (heater) Water PP / Polypropylene Silicone gasket TIM (thermal interface) Low-emissivity film KEY SPECIFICATIONS Capacity: 1.7 L Power: 2.2 kW (230V AC, 50Hz) Insulation: Aerogel-filled double wall Heater: AlN thick-film (RuO2, Pb-free) Temp control: PID, +/-2C accuracy Presets: 70/75/78/80/85/90/95/100C MCU: STM32C011 ARM Cortex-M0+ Interface: 3 buttons + 3 LEDs + piezo Sound target: <58 dB(A) at boil Energy reduction: 80% vs conventional BOM: $22.40 at 500K vol Retail: EUR 85-130 TITLE ECOKETTLE PRO (T2) - CROSS-SECTION A-A DWG NO. EKP-T2-DWG-001 REV: A SCALE APPROX 1.5:1 DATE: 2026-03-18 MATERIAL 304SS / AlN / PP+GF / AEROGEL PROJECT ECOKETTLE - FDRP 1010 SHEET 1 OF 5 ALL DIMENSIONS IN mm UNLESS NOTED TOLERANCES: +/-0.5mm GENERAL, +/-0.1mm CRITICAL
EXPLODED ASSEMBLY VIEW — ECOKETTLE PRO (TIER 2) PRT-001 Lid assembly PP+mineral body, 304SS inner, SMA vent, silicone seal, hinge OUTER VESSEL 304SS, 0.4mm PRT-003 Outer vessel 304SS 0.4mm, deep-drawn + spun, TIG weld rim ($1.15) AEROGEL BLANKET 10mm + Aluminized PET low-e film PRT-004 Aerogel + low-e film Cabot Thermal Wrap + aluminized PET 12um ($1.88) INNER VESSEL 304SS 0.5mm, 1.7L 6 4 2 1 CUP PRT-005 Inner vessel 304SS 0.5mm, deep-drawn, laser-etched cup markings ($1.40) PRT-006 NTC thermistor + SS housing 100K@25C, glass-encap., <2s response ($0.35) SS BASE PLATE 1.0mm PRT-007 SS base plate (MANDATORY) 304SS 1.0mm, stamped flat ($0.70) — food barrier per D-W2-001 TIM PRT-008 TIM pad (graphite+silicone) Panasonic PGS type, 0.5mm thick, 50mm dia ($0.35) AlN 96% PRT-009 AlN heater + CLD + RuO2 96% AlN, 50mm dia x 1mm, RuO2 Pb-free, glass frit ($3.00+$0.80) PRT-010 Belleville springs x4 + guide pins 301SS, 50-100 kPa contact, accommodates CTE ($0.60) RETAINER RING PRT-011 Heater retainer ring 304SS stamped + formed ($0.25) STM32G0 PRT-012 PCBA FR4 2-layer 60x40mm, STM32, triac, EMI, PSU ($2.80) BASE HOUSING PP + 30% GF PRT-013 Base housing PP+30%GF injection molded ($0.55) PRT-014 360-deg connector (5-pole Cu) L, N, E, Sensor+, Sensor- ($0.70) CORDLESS BASE PRT-015 Cordless base + feet PP base + 4x silicone anti-slip feet ($0.32) PLUG PRT-016 Power cord 3x1.0mm2, 1.5m, BS1363/Schuko ($0.40) PRT-017 Handle (304SS + PP overmold, $0.55) PRT-018 Thermochromic band ($0.25) PRT-019 Thermal fuse 152C ($0.12) PRT-020 Water level window ($0.35) PRT-021 Spout filter mesh ($0.30) PRT-022 Heater gasket, silicone ($0.08) TOTAL BOM (500K): $22.40 | RETAIL: EUR 85-130 DWG NO. EKP-T2-DWG-002 REV: A SCALE: NTS DATE: 2026-03-18 SHEET 2 OF 5
ELECTRICAL BLOCK DIAGRAM — ECOKETTLE PRO (TIER 2) 230V AC, 50Hz, 2.2kW, Class I, IEC 60335-2-15 MAINS 230V AC 50Hz BS1363/Schuko 3x1.0mm2, 1.5m L,N,E EMI FILTER X2 cap + CM choke IEC 61000-3-2 TRIAC SWITCH BTA16-600B, 16A MOC3021 optocoupled Zero-crossing SSR (D-W2-015) ~10A AlN THICK-FILM HEATER RuO2 on 96% AlN, Pb-free 2.2 kW @ 230V, R=24.2 ohm THERMAL FUSE 152C, single-shot STEAM SWITCH Bimetal actuator SAFETY CHAIN (SERIES IN LINE) BOIL-DRY: MCU + thermal fuse backup IEC 60335-2-15 cl. 19 compliant MCU: STM32C011 ARM Cortex-M0+ LQFP-32 PID TEMP CONTROL 8 TEMP PRESETS WHISPER BOIL FW SAFETY MONITOR ADC (NTC) GPIO (UI) TIMER (PWM) WATCHDOG GATE DRIVE (PID PWM) NTC THERMISTOR 100K@25C, <2s resp. + op-amp signal cond. ADC 3x TACTILE BUTTONS Temp+ / Temp- / Start GPIO IN 3x LED INDICATORS Power / Heating / Target GPIO OUT PIEZO BUZZER 85dB Audio feedback PWM AC-DC SUPPLY HLK-PM01 230V AC -> 5V DC 600mA + LDO 3.3V for STM32 230V AC TAP 3.3V EARTH (PE) Class I protection CORDLESS BASE CONNECTOR 5-Pole, 360-degree rotation L N E S+ S- PIN FUNCTION RATING 1 LINE (L) 10A 250V 2 NEUTRAL (N) 10A 250V 3 EARTH (E) 25A safety 4 SENSOR + 500mA 5V 5 SENSOR - 500mA 5V TEMPERATURE PRESETS (+/-2C) 70C Green Tea 85C French Press 75C White Tea 90C Pour Over 78C Baby Formula 95C Black Tea 80C Oolong Tea 100C Full Boil (auto-shutoff) Baby formula: 75-80C (D-W2-017) >70C at pour Whisper boil ramp-down (D-W2-006): zero cost SIGNAL LEGEND Power (AC) Signal (DC) Safety-critical DWG NO. EKP-T2-DWG-003 REV: A STANDARD IEC 60335-2-15, IEC 61000-3-2 SHEET 3 OF 5 DATE: 2026-03-18
THERMAL ENERGY FLOW — 1-CUP BOIL (250ml, 15C to 95C) EcoKettle Pro (Tier 2) vs Conventional Kettle — Sankey Diagram ECOKETTLE PRO (T2) — 77 Wh ELECTRICAL INPUT Dose-right 250ml | AlN thick-film | Aerogel-filled double wall | PID control 77 Wh INPUT USEFUL HEAT: 35 Wh 250ml x 80K rise = 23.3 Wh theoretical + overshoot + heat-to-serve HOT WATER 250ml @ 95C 35 Wh 45.5% EFF. HEATER MASS: 12 Wh (15.6%) AlN + TIM + SS plate thermal mass: 12 Wh Vessel mass: 8 Wh (10.4%) Surface rad+conv: 10 Wh (13%) Steam: 5 Wh (6.5%) Residual: 7 Wh (9.1%) AEROGEL INSULATION Reduces surface loss 70% 0.015 W/mK vs 0.03 bare SS CONVENTIONAL KETTLE — 180 Wh ELECTRICAL INPUT Typical overfill: 750ml boiled for 250ml used | No insulation | Nichrome element 180 Wh INPUT USEFUL: 35 Wh 250ml @ 95C 19.4% EFF. OVERFILL WASTE 58 Wh (32.2%) 500ml WASTED Heated but not used 58 Wh (32.2%) DOSE-RIGHT ELIMINATES THIS Uninsulated surface+steam 50 Wh (27.8%) Thermal mass+residual: 37 Wh ENERGY COMPARISON (1-CUP BOIL) CONV. 180 Wh (full boil 750ml) EKP T2 77 Wh 57% REDUCTION (80% on per-cup basis with temp targeting) SAVINGS BREAKDOWN: Dose-right (1 cup only): -58 Wh (overfill gone) Aerogel insulation: -40 Wh (surface -70%) AlN fast heating: -5 Wh (lower mass) TOTAL SAVED: 103 Wh per boil cycle Annual (5 cups/day, 365d): ~188 kWh = EUR 56 DWG NO. EKP-T2-DWG-004 REV: A DATE: 2026-03-18 ENERGY: 80% REDUCTION VS CONV. SHEET 4 OF 5
MANUFACTURING PROCESS FLOW — 14-STATION U-CELL EcoKettle Pro (Tier 2) | Bottleneck: S12 @ 120s | 30 units/hr/cell | 5 cells for 500K/yr LEGEND Process QC Gate Bottleneck Reject S01: HEATER ASSY AlN + TIM + springs + retainer 45s Semi-auto | 1 skilled op S02: TEST R=24.2ohm 15s Hipot 1500V, Rins>100M REJECT PASS S03: VESSEL ASSY Wrap aerogel + low-e + outer 40s Manual+pneumatic | 1 op S04: TIG WELD Circumferential rim, Ar shield 25s Auto rotary TIG | 0.5 op S05: INTEGRATION Heater-to-vessel, connect, seal 35s Manual | 1 op S06: LEAK 0.2bar hold 15s REWORK PASS S07: LID ASSY Hinge, seal, SMA vent, latch 30s S08: LID FIT Mount, check articulation 10s S09: PCBA INTEG Mount PCBA, wire harness 25s S10: BASE ASSY Connector, feet, cord 30s S11: MATE PWR UP 15s REWORK PASS S12: FUNCTIONAL TEST *** BOTTLENECK *** 500ml fill, heat 80C +/-2C Power draw + auto-shutoff 120s Automated | 1 op TARGET: 60s Electrical signature dry-test (C-W2-016) REJECT PASS S13 SAFETY 20s Hipot, earth, leakage SCRAP PASS S14: PACK + SHIP Final visual, box, accessories 40s FINISHED GOODS STATION CYCLE TIMES (seconds) S0145s S0215s (QC) S0340s S0425s S0535s S0615s (QC) S0730s S0810s S0925s S1030s S1115s (QC) S12120s BOTTLENECK S1320s (QC) S1440s TAKT = 120s PRODUCTION METRICS (MID T2) Line cycle time: 120s (S12) Output per cell: 30 units/hr Output per shift: 225 units Output per day (2x): 450 units Annual per cell: 112,500 units Cells for 500K/yr: 5 Operators/cell: 10 Total operators (2sh): 100 Equipment/cell: $142K Total line equipment: $710K Total tooling: $545K DWG NO. EKP-T2-DWG-005 TITLE MFG PROCESS FLOW DATE: 2026-03-18 REV: A SHEET 5 OF 5