Thermoplastic Connector Insert with Ceramic Flame Barrier
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Solution Overview
Problem
Thermoplastic electrical connector inserts soften or melt under high temperatures, leading to potential short circuits in environments at risk of flames, while thermoset inserts, though flame-resistant, are non-recyclable and environmentally unfavorable.
Innovation Solution
An electrical connector with a thermoplastic insert featuring a ceramic protective element that maintains contact spacing under high temperatures, preventing short circuits and being recyclable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic material is used for the insert, then ease of manufacture and recyclability are improved, but flame resistance and ability to maintain contact spacing under high temperature deteriorate
Solution Approach 1:
The insert is constructed as a composite structure combining thermoplastic material (for ease of molding and recyclability) with ceramic material (for flame resistance and structural stability). The ceramic element is integrated within the thermoplastic insert to provide the necessary thermal and mechanical properties that thermoplastic alone cannot achieve.
2Reliability
If thermoset material is used for the insert, then flame resistance is improved, but environmental sustainability and recyclability deteriorate
Solution Approach 1:
The solution uses a composite where the majority material is recyclable thermoplastic, while a localized ceramic component provides the flame-resistant properties. This allows the insert to achieve the required fire safety standards without sacrificing the recyclability of the main body material.
Solution Approach 2:
Instead of making the entire insert from flame-resistant thermoset material, the ceramic material is strategically placed only in the critical areas where flame resistance and contact spacing maintenance are most needed. This localized approach provides the necessary protection while minimizing the amount of non-recyclable material.
3Ease of manufacture
If thermoplastic insert is used in high temperature environment, then ease of manufacture is maintained, but ability to maintain contact spacing and prevent short circuits deteriorates
Solution Approach 1:
The ceramic element integrated in the thermoplastic insert provides dimensional stability and maintains contact spacing under high temperature conditions, compensating for the thermoplastic material's tendency to deform when heated.
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 ceramic protective element ensures electrical insulation and mechanical protection, preventing short circuits and maintaining environmental sustainability by being recyclable and resistant to high temperatures and flames.
Implementation Method 1
a protective element (18) made of a material insensitive to flame, capable of maintaining, under the effect of a high temperature, a predefined distance between the electrical contacts
Implementation Method 2
capable of maintaining, under the effect of a high temperature, a predefined distance between the electrical contacts
Implementation Method 3
a thermoplastic insert subjected to a flame or to a high temperature close to its melting point will tend to soften or even melt
Data Source
Figure 1~2
AI summary
The connector has an insert (10) including a front part (13) having a front insulator (11), and a rear part (16) having a rear insulator (15), where the front and rear parts are made of thermoplastic material. Cavities (20) pass through the front and rear parts of the insert, where each cavity receives an electrical contact (30). A protective element (18) is positioned between the front and rear parts, where the protective element is made of a flame insensitive material i.e. ceramic, to maintain a predetermined distance between the electrical contacts under the effect of high temperature.