Electrical Connection Assembly With Passive Overheat Detection

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Solution Overview

Problem

Existing electrical connections between conductive members and terminal blocks in electrical units are prone to malfunctions due to incorrect tightening, leading to localized heating and potential accidents, and current monitoring methods are expensive or inaccurate.

Innovation Solution

An electrical connection device comprising a thermally conductive nut, core, and support that transfers heat by conduction, emitting microparticles and/or gaseous compounds when heated above a threshold, allowing for immediate detection without opening the distribution board.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If temperature sensors are installed in the distribution board for continuous monitoring, then connection quality can be monitored, but the system becomes expensive

Engineering Contradiction:

Improveconnection quality monitoringVSAvoidsensor installation cost

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces expensive electronic temperature sensors with a passive thermochromatic indicator that changes color in response to temperature changes. This substitution eliminates the need for complex sensor installation, wiring, and power supply systems while providing continuous visual temperature monitoring of electrical connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The thermochromatic indicator is self-powered and requires no external energy source or complex installation. It automatically responds to temperature changes through its material properties, providing self-service monitoring without requiring additional sensors, power supplies, or complex control systems.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If thermal camera images are taken during inspection visits, then hot spots can be detected, but the distribution board must be opened which cools the units and prevents accurate detection

Engineering Contradiction:

Improvehot spot detection accuracyVSAvoidinspection accessibility

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The thermochromatic indicators are pre-installed on the electrical connections inside the distribution board before operation. They continuously monitor temperature during normal operation, so when inspection is needed, the indicators already show the temperature history without requiring the board to be opened, eliminating the cooling effect and providing accurate readings.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The indicators provide continuous temperature monitoring during normal operation, maintaining the monitoring function without interruption. This eliminates the need to open the distribution board for inspection, as the indicators remain in place and continue to accurately reflect connection temperatures during full-power operation.

Inventive Principle:

Principle #20Continuity of useful action

3Loss of information

If the distribution board is opened for inspection, then thermal images can be captured, but air movements cool the electrical units and images do not reflect normal operation

Engineering Contradiction:

Improvethermal inspection capabilityVSAvoidelectrical unit temperature during inspection

Core Design Contradiction:

Loss of informationVSTemperature

Solution Approach 1:

The thermochromatic indicators act as intermediaries between the electrical connections and the inspector. They are positioned directly on the connections and provide visual temperature information that can be read through the closed distribution board, eliminating the need to open the board and avoiding the cooling effect on the electrical units.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Provides immediate and cost-effective detection of improperly tightened connections by emitting detectable gases and particles, ensuring safety and reliability without disrupting the electrical system.

Implementation Method 1

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 above a predetermined temperature threshold

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 2

a core, which is thermally conductive and is bonded to the second face of the nut so as to transfer heat by conduction between the nut and the core

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250246823A1Electrical connection device, and associated electrical unit and distribution board

Publication Date: 2025.07.31 SCHNEIDER ELECTRIC IND SAS

AI summary

This invention relates to an electrical connection device between an electrically conductive member (4A) and a terminal block (6) of an electrical unit (3). The connection device comprises a nut (23A), adapted to receive a screw (21A) which, by screwing, clamps together the electrically conductive member and the terminal block, 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 both to hold the nut securely in position and to transfer heat by conduction between the core and the support. The support is made of a material that emits a release containing microparticles and/or at least one gaseous compound when that material is heated above a predetermined temperature threshold.