Electrical Connector Temperature Indicator for Peak Heat Exposure
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Solution Overview
Problem
Existing electrical connectors lack a reliable and cost-effective method for monitoring maximum temperatures during thermal events, which can lead to damage, and existing thermal monitoring systems are often complex, expensive, and do not provide historical data for assessing the health status of the connectors.
Innovation Solution
A persistent temperature indicator system for electrical connectors that includes a thermal sensing apparatus with a temperature sensor and display, which provides a visual indication of the maximum temperature measured, using thermally reactive materials that change color permanently to indicate temperature ranges, allowing for easy assessment of the connector's health status post-event.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex thermal monitoring systems are used to monitor maximum temperatures, then measurement precision is improved, but device complexity increases and cost increases
Solution Approach 1:
The patent uses thermally reactive materials that change color in response to temperature exposure. Different substances in the material change color at different temperature thresholds, providing a visual indication of the maximum temperature reached. This eliminates the need for complex electronic sensors and processing systems while maintaining accurate temperature monitoring capability.
Solution Approach 2:
The patent replaces complex electronic thermal monitoring systems with a passive chemical/physical indicator system. The thermally reactive material directly responds to temperature through color change without requiring power, electronics, or complex mechanical components, thereby reducing device complexity while maintaining measurement precision.
2Loss of information
If persistent temperature indication is implemented, then loss of information is reduced, but device complexity increases
Solution Approach 1:
The thermally reactive material is pre-configured with specific substances that change color at predetermined temperature thresholds. When exposed to temperature, the material automatically and irreversibly changes color to record the maximum temperature reached, eliminating the need for power, memory, or complex data storage systems to preserve historical information.
3Measurement precision
If detailed temperature monitoring is implemented, then measurement precision is improved, but ease of operation worsens
Solution Approach 1:
The patent uses visually distinct color changes in the thermally reactive material to indicate different temperature ranges. Each substance changes color at specific temperature thresholds, creating a clear visual scale that allows operators to quickly assess maximum temperature exposure without complex instrumentation or data interpretation.
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 system offers a simple, efficient, and cost-effective means to monitor and record maximum temperatures, facilitating the assessment of electrical connector health without disassembly, providing historical data and enabling informed decisions on repair or replacement.
Implementation Method 1
a thermal indicator that has a plurality of changeable display characteristics; each of the plurality of changeable display characteristics may correspond to one of a plurality of ranges of temperatures; each changeable display characteristic may be configured to transition to a changed visual appearance in response to the temperature sensor measuring a temperature in the corresponding range of temperatures
Data Source
AI summary
A system includes: an electrical connector that includes: an electrically insulating housing that defines an interior region; a conductive shell on the insulating housing; and an electrical conductor in the interior region. The system also includes a thermal sensing apparatus that includes: a temperature sensor; and a temperature display visible from an exterior of the electrical connector. The temperature display is configured to provide a persistent indication of a maximum temperature measured by the temperature sensor after the temperature measured by the temperature sensor has decreased relative to the maximum.