Electrical Connection Assembly With Overheat Emission Detection
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Solution Overview
Problem
Existing electrical connections in electrical panels are prone to poor tightening, leading to increased resistance and localized heating, which can cause malfunctions or accidents, and current monitoring methods are expensive or inaccurate.
Innovation Solution
An electrical connection device comprising a thermally conductive nut, core, and support that emits microparticles and/or gaseous compounds when heated beyond a threshold, allowing immediate detection of poor connections without opening the panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors are installed within the electrical panel for continuous monitoring, then connection quality can be monitored, but the cost increases significantly
Solution Approach 1:
The support structure performs self-diagnosis by automatically emitting detectable substances when overheating occurs due to poor electrical connections, eliminating the need for external temperature sensors and complex monitoring systems
Solution Approach 2:
The support material's chemical properties change in response to temperature changes, transitioning from a stable state to emitting microparticles and/or gaseous compounds when the temperature exceeds a predetermined threshold, providing passive thermal monitoring
2Measurement precision
If thermal imaging cameras are used during inspection visits, then hot spots can be detected, but the panel must be opened and the inspection is not accurate under full power operation
Solution Approach 1:
The connection device itself provides the detection function through the support's automatic emission of detectable substances when overheating occurs, eliminating the need for external inspection equipment and panel opening
Solution Approach 2:
The support is pre-configured with the property to emit detectable substances when temperature exceeds the threshold, enabling continuous monitoring during full power operation without requiring inspection visits
3Ease of manufacture
If the connection between electrically conductive member and connection pad is poorly tightened, then installation is easier, but electrical resistance increases and localized heating occurs
Solution Approach 1:
The support provides immediate feedback through emission of detectable substances when overheating occurs due to poor tightening, allowing operators to identify and correct problematic connections
Solution Approach 2:
The support material undergoes a parameter change from thermal conduction to chemical emission when the temperature threshold is exceeded, signaling connection quality issues
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
Enables immediate detection of poorly tightened connections through thermal conduction and emission of detectable substances, ensuring safety and reliability without the need for costly or disruptive monitoring.
Implementation Method 1
a core, which is thermally conductive and which is connected to the second face of the nut so as to transfer heat by conduction between the nut and the core
Implementation Method 2
the support being made of a material which emits a release containing microparticles and/or at least one gaseous compound when this material is heated beyond a predetermined temperature threshold
Implementation Method 3
If the connection between the electrically conductive member and the connection pad is poorly tightened, the electrical resistance of the connection increases, and when a current flows through this connection, localized heating occurs at this connection
Data Source
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AI summary
The present invention relates to an electrical connection device between an electrically conductive member (4A) and a connection pad (6) of an electrical appliance (3). The connection device comprises a nut (23A), adapted to receive a screw (21A) which, by screwing, tightens together the electrically conductive member and the connection pad, pressing them against the nut, a core (25A), which is thermally conductive and which is bonded to the nut so as to transfer heat by conduction between the nut and the core, and a support (27A) which supports the nut and the core so as to both hold the nut fixedly in position and to transfer heat by conduction between the core and the support. The support is made of a material which emits an emission containing microparticles and/or at least one gaseous compound when this material is heated above a predetermined temperature threshold.