Ceramic Connector Housing with Integrated Fire Suppression

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Solution Overview

Problem

Electrical connectors and installations are vulnerable to fires caused by electrical surges, overloads, and environmental factors, leading to rapid temperature increases and material degradation, which existing solutions do not adequately address.

Innovation Solution

A ceramic or composite housing for electrical connectors incorporating a microcapsule-based extinguishing agent that releases a non-flammable gas mixture when temperatures exceed 120°C, displacing oxygen and cooling the environment to prevent ignition and re-ignition, while maintaining structural integrity and airtightness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional electrical connector housings are used, then the structure is simple and cost-effective, but the housing is vulnerable to fire from electrical surges and overloads

Engineering Contradiction:

Improvefire resistanceVSAvoidhousing structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The microcapsule extinguishing agent is nested within the housing structure itself. The housing contains integrated microcapsules filled with fire-extinguishing agent, creating a nested configuration where the protective agent is embedded within the structural component, eliminating the need for separate fire suppression systems

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The housing is constructed as a composite structure combining the structural housing material with embedded microcapsule extinguishing agent. This composite approach integrates fire protection functionality directly into the housing material, simultaneously achieving fire resistance and structural integrity

Inventive Principle:

Principle #40Composite materials

2Reliability

If fire protection measures are added to electrical connectors, then fire resistance improves, but the manufacturing complexity increases

Engineering Contradiction:

Improvefire suppression capabilityVSAvoidhousing production

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The manufacturing process merges the housing formation and microcapsule integration into a single unified process. The microcapsule extinguishing agent is incorporated during the housing manufacturing step, combining two production operations (housing fabrication and fire protection application) into one simultaneous process, thereby simplifying overall manufacturing

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If the housing is made of ceramic or composite material, then heat resistance and structural integrity improve, but the manufacturing difficulty increases

Engineering Contradiction:

Improvestructural integrityVSAvoidhousing fabrication

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The microcapsule extinguishing agent provides self-activating fire suppression when temperature exceeds 120°C. The system serves itself by automatically detecting thermal conditions and releasing the extinguishing agent without external control systems, sensors, or power sources, thereby simplifying manufacturing while maintaining high heat resistance

Inventive Principle:

Principle #25Self-service

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 effectively isolates electrical connectors from overvoltages, suppresses fire initiation, and prevents damage by rapidly releasing an extinguishing agent, ensuring early-stage fire suppression and reducing the risk of ignition and self-ignition in electrical installations.

Implementation Method 1

the microcapsules consisting of closed halocarbons in a polymeric shell of polyurea and/or polyurethane... when the refrigerant is heated above 110 °C, when the microcapsules break

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 2

The fire is extinguished by halocarbon vapors, which are liberated abundantly when the refrigerant is heated above 110 °C

Methodology Applied

Scientific EffectGas expansion: Thermal Expansion

Implementation Method 3

The fire is extinguished within 10 to 20 seconds after ignition, preventing the protected objects from being damaged

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Data Source

PatentEP4160830A1Housing of electrical connectors with an autonomous fire prevention system and protection method of electrical connectors

Publication Date: 2023.04.05 BINDA URSZULA

Figure 1~3
Figure 4~6
Figure 7~9

AI summary

An electrical connector housing is made of ceramic and / or composite material, which has an elongated, hollow shape formed by at least two parts (a and b) connected to each other by means of a connecting element (4), the housing (1) has openings (2) at its ends, whose shape corresponds to the ends of the connector (9), the inside of the housing (1) contains the extinguishing agent (3). The method of securing the electrical connector comprises placing the connector in a sealed housing (1) made of ceramic material and / or composite material in which the extinguishing agent (3) is placed.