Fireproof Separator Board for Plug-Based Circuit Interrupter

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Solution Overview

Problem

Plug-based circuit interrupters face issues with high temperature arcs and oxidation of contact terminals, leading to casing deformation, melting, and potential fires, especially during long-term use and lightning strikes.

Innovation Solution

Incorporation of a fireproof separator board made from flame retardant, high temperature resistant materials like epoxy board, asbestos board, mica plate, or ceramic material within the insulating casing to prevent heat conduction from contact terminals to the casing, effectively blocking heat and protecting the casing from combustion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the insulating casing is made of plastic to reduce cost and weight, then the device becomes more economical and lighter, but the contact terminals generate high temperature arcs that can cause the plastic casing to deform, melt, and burn

Engineering Contradiction:

Improvefire safetyVSAvoidheat conduction to casing

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A fireproof separator board is introduced as an intermediary component between the contact terminals and the plastic casing. This separator board blocks the heat conduction path, preventing high temperature arcs from reaching and damaging the plastic casing, thus resolving the contradiction between using plastic for cost/weight benefits and protecting against thermal damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The internal structure of the circuit interrupter is segmented into distinct thermal zones by introducing the fireproof separator board. This segmentation isolates the high-temperature arc generation zone from the plastic casing, allowing the plastic casing to maintain its cost and weight advantages while being protected from thermal exposure.

Inventive Principle:

Principle #1Segmentation

2Duration of action of moving object

If the contact terminals are used for long time electrical conduction, then the device provides continuous service, but the surface of the contact terminals becomes burned or oxidized, increasing resistance and temperature

Engineering Contradiction:

Improveservice lifeVSAvoidcontact terminal temperature

Core Design Contradiction:

Duration of action of moving objectVSTemperature

Solution Approach 1:

The fireproof separator board acts as a thermal barrier that mediates between the contact terminals and the surrounding environment. As contact terminals undergo oxidation and temperature increases during long-term use, the separator board prevents this heat from propagating to the casing, enabling extended service life without compromising structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the PCB contains numerous electrical components including varistors for lightning protection, then the device provides comprehensive protection, but if the plug is struck by lightning, the varistor may combust and burn the casing

Engineering Contradiction:

Improvelightning protectionVSAvoidcombustion risk from varistor

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The fireproof separator board serves as a protective intermediary between the varistor and the plastic casing. When lightning strikes and the varistor combusts during overload protection operation, the separator board blocks the combustion and heat from reaching the casing, maintaining the lightning protection function while preventing catastrophic failure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The fireproof separator board provides beforehand cushioning against the potential combustion of the varistor. By pre-installing this thermal barrier, the design anticipates and mitigates the risk of varistor combustion during lightning strikes, protecting the casing before damage can occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 fireproof separator board significantly reduces the risk of casing melting and burning by isolating heat from contact terminals, ensuring the casing remains protected from high temperatures and lightning-induced fires, while being cost-effective, safe, and easy to assemble.

Implementation Method 1

a fireproof separator board, formed of a flame retardant, high temperature resistant material, disposed within the insulating casing, for preventing heat generated by the first and second contact terminals from being conducted to the insulating casing

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Data Source

PatentUS9713273B2Fireproof separator board and plug-based circuit interrupter employing the fireproof board

Publication Date: 2017.07.18 LI CHENGLI

AI summary

This invention provides a fireproof separator board, which is made of a flame-retardant, high temperature resistant material and disposed within an insulating casing of an electrical device, for preventing the heat generated by the electrical components of the electrical device from being conducted to the insulating casing. This invention also provides a plug-based circuit interrupter that includes the fireproof separator board. The fireproof separator board and the plug-based circuit interrupter of this invention can effectively prevent high temperature and fire caused by the electrical components that could melt the casing.