Flame-Resistant Electrical Connector with Ceramic Insert
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Solution Overview
Problem
Thermoplastic electrical connector inserts soften or melt under high temperatures, leading to potential short-circuits in flame-hazard environments, while fire-retardant thermoset inserts are non-recyclable, contradicting environmental protection trends.
Innovation Solution
An electrical connector with a thermoplastic insert featuring a ceramic protection element that maintains a constant distance between electrical contacts, preventing shorting and being environmentally friendly by allowing recyclability.
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 reliability at high temperatures deteriorate
Solution Approach 1:
The insert is constructed as a composite structure combining thermoplastic material (for ease of manufacture and recyclability) with ceramic material (for flame resistance and high-temperature stability). The ceramic protection element is integrated within the thermoplastic insert, creating a multi-material system that leverages the advantages of both materials while mitigating their individual disadvantages.
2Reliability
If thermoset material is used for the insert, then flame resistance is improved, but recyclability and environmental friendliness deteriorate
Solution Approach 1:
The insert uses a composite structure where thermoplastic material (which is recyclable) forms the base structure, and ceramic material (which provides flame resistance) is integrated as a protection element. This allows the insert to achieve flame resistance without sacrificing recyclability, as the thermoplastic portion can be separated and recycled.
Solution Approach 2:
The insert is divided into distinct functional zones: the thermoplastic portions (front and rear insulators) that can be recycled, and the ceramic protection element that provides flame resistance. This segmentation allows different materials with different properties to be used in different regions, optimizing both recyclability and flame resistance.
3Adaptability or versatility
If the number of contacts is increased, then connectivity is improved, but distance between contacts is reduced, worsening shorting risk
Solution Approach 1:
The ceramic protection element provides rigid structural support that maintains spacing between contacts even as the number of contacts increases. The ceramic material's high-temperature stability ensures that contact spacing is preserved under thermal stress, preventing shorting in high-density connector configurations.
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 protection element ensures electrical insulation and mechanical protection, preventing shorting even at high temperatures, while being recyclable and environmentally neutral.
Implementation Method 1
a protection element placed between the front part and the rear part and made of a flame-insensitive material capable, under the effect of high temperature, of maintaining a predefined distance between the electrical contacts
Implementation Method 2
a thermoplastic insert subjected to a flame or to a high temperature close to its melting temperature will tend to soften or even to melt
Data Source
AI summary
An electrical connector includes at least one insert (10), the insert including:a front part (13) and a rear part (16) at least partially made of thermoplastic material, anda plurality of cavities (20) passing through from one side to the other of the front part and the rear part of the insert, each cavity being capable of receiving an electrical contact (30),a protection element (18) placed between the front part (13) and the rear part (16) and made of a flame-insensitive material capable, under the effect of high temperature, of maintaining a predefined distance between the electrical contacts.