Composite Flameproof Terminal Block Cover for Heat and Ignition Resistance
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Solution Overview
Problem
Terminal blocks and their covers, used in commercial aircraft engines, face challenges in withstanding extreme temperatures and improving flame resistance and self-extinguishing performance, as current materials do not adequately resist ignition and have limitations in extreme conditions.
Innovation Solution
A flameproof terminal block design featuring a base portion made from an electrically-insulative flame-resistant material and an outer shell from a flame-resistant or metal material, which shields the body and enhances self-extinguishing properties, with mechanical fasteners, adhesive, or molded attachment, and textured surfaces for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal blocks are made from single electrically insulative material, then electrical insulation is provided, but flame resistance and self-extinguishing performance are insufficient
Solution Approach 1:
The terminal block cover is constructed from composite materials consisting of a flame-resistant base material (such as polyamide-imide) combined with a flameproof outer shell material (such as metal, ceramic, or flame-resistant polymer). This composite structure provides both electrical insulation from the base material and superior flame resistance and self-extinguishing properties from the flameproof outer shell, resolving the contradiction between maintaining simple single-material construction and achieving high flame resistance performance.
2Temperature
If flame-resistant materials are used, then heat resistance is improved, but ignition resistance and self-extinguishing time are still inadequate for extreme environments
Solution Approach 1:
The terminal block cover employs local quality by applying different material properties to different regions: the base material provides general electrical insulation and moderate heat resistance, while the outer shell is specifically engineered with superior flameproof properties and self-extinguishing characteristics. This localized differentiation of material qualities ensures that the critical outer surface has maximum ignition resistance and flame suppression capability, addressing the inadequate ignition resistance of uniform flame-resistant materials.
3Reliability
If outer shell is added for flame shielding, then flame resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The terminal block cover is segmented into two distinct components: a base material portion and an outer shell portion. This segmentation allows each component to be manufactured separately using optimized processes for their respective materials, then assembled together. The base material can be molded using standard plastic molding techniques, while the outer shell can be separately fabricated from metal, ceramic, or flame-resistant polymer, and then attached to the base. This segmented approach simplifies manufacturing compared to creating a single complex multi-material component, while still achieving superior flameproof performance.
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 solution significantly improves the resistance to heat and ignition, reducing the time for self-extinguishing and enhancing the safety and reliability of electrical connections in extreme environments.
Implementation Method 1
an outer shell, connected to the body, formed from a flame resistant or flameproof material, and adapted and configured to shield the body from flame
Implementation Method 2
An inner surface of the outer shell can be textured to enhance adhesion with the body
Data Source
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AI summary
A flameproof terminal block has a base portion adapted and configured to hold and electrically insulate a lower portion of one or more electrical terminals from a surrounding area, and a cover portion having a body (110) formed from an electrically-insulative flame-resistant material, the body formed to substantially surround and insulate an upper portion of one or more electrical terminals from a surrounding area, and an outer shell (720), connected to the body, formed from a flame resistant or flameproof material, and adapted and configured to shield the body from flame.