Connector Terminal Temperature Sensor Direct Contact
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Solution Overview
Problem
Existing connectors face challenges in accurately measuring the temperature of terminals, especially during sudden changes, due to the placement of thermistors along electric cables rather than directly on the terminals, and the use of electrically insulating and thermally conductive materials which hinder rapid temperature measurement.
Innovation Solution
A connector design featuring a temperature sensor housed in a sensor housing portion adjacent to the terminal, with a pressing rib to ensure close contact, an air layer for thermal insulation, and a pressing piece for enhanced contact, allowing direct and accurate temperature measurement of the terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thermistor measures temperature through an electrically insulating and thermally conductive material, then electrical insulation is provided, but the temperature of the terminal cannot be measured rapidly when there is a sudden change in temperature
Solution Approach 1:
A pressing rib acts as an intermediary mechanical element that applies force to press the temperature sensor directly against the terminal surface. This intermediary structure enables direct thermal contact between the sensor and terminal while maintaining electrical insulation through the sensor housing, thereby achieving both reliable electrical insulation and rapid temperature measurement response.
2Speed
If the temperature sensor is placed directly on the terminal, then rapid and accurate temperature measurement is achieved, but electrical insulation may be compromised
Solution Approach 1:
The sensor housing serves as an intermediary structure that holds the temperature sensor in direct thermal contact with the terminal while providing electrical insulation. The pressing rib within the sensor housing further mediates by applying mechanical force to ensure consistent thermal contact, thus achieving both rapid temperature measurement and maintained electrical insulation.
Solution Approach 2:
The sensor housing provides localized electrical insulation specifically at the sensor- terminal interface, while allowing direct thermal contact in the same location. This local differentiation of properties enables the temperature sensor to measure terminal temperature rapidly through direct contact while the housing maintains electrical insulation where needed.
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 precise and responsive temperature measurement of terminals even during sudden changes, minimizing external influences and improving measurement accuracy through direct contact and thermal insulation.
Implementation Method 1
the end face of the temperature sensor is exposed from the sensor housing portion and is brought into directly abutment against the terminal
Implementation Method 2
an air layer is provided around the temperature sensor except the housing space portion side in the sensor housing portion
Data Source
AI summary
A connector includes a terminal configured to be connected to an electric cable, a housing configured to contain the terminal, a terminal holder configured to be attached to the housing, and has a housing space portion configured to contain a connection part between the terminal and an end portion of the electric cable, a sensor housing portion provided in the terminal holder adjacently to the housing space portion, and a temperature sensor configured to be contain and held in the sensor housing portion. The temperature sensor has an end face which is located on a front side in a mounting direction of the terminal holder into the housing. The end face of the temperature sensor is exposed from the sensor housing portion and is brought into directly abutment against the terminal.