Power Plug Over-Temperature Protection via Thermal Switch
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Solution Overview
Problem
Electrical power plugs and receptacles face issues with overheating and fire hazards due to poor electrical contact, humidity, and over-current conditions, which can cause the copper alloy plates to melt the insulating housing, leading to safety risks.
Innovation Solution
Incorporating a temperature-controlled switch and solenoid mechanism that disconnects the input and output lines when the conductor plates exceed a predetermined temperature, ensuring real-time temperature monitoring and rapid disconnection to prevent overheating and fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If copper alloy contact plates are used in plugs and receptacles, then good electrical conductivity is achieved, but high temperature generation under over-current or poor contact conditions can melt the insulating housing and cause fire
Solution Approach 1:
The temperature-controlled switch is pre-positioned and thermally coupled to the copper alloy contact plates. When temperature rises due to over-current or poor contact, the switch automatically opens to disconnect the circuit before the insulating housing melts or fire occurs, preventing the harmful effect in advance
Solution Approach 2:
The temperature-controlled switch acts as an intermediary safety device between the copper alloy contact plates and the insulating housing. It monitors the temperature of the contact plates and interrupts the current flow when excessive heat is detected, preventing the heat from melting the housing and causing fire
2Object-affected harmful factors
If temperature-controlled switch and solenoid mechanism are added for over-temperature protection, then safety against fire hazards is improved, but device complexity increases
Solution Approach 1:
The temperature-controlled switch is self-actuating based on thermal contact with the copper alloy plates. When the plates exceed the safe temperature threshold, the switch automatically opens the circuit without requiring external control systems, microprocessors, or complex sensing electronics, thereby providing safety functionality with minimal added complexity
Solution Approach 2:
The patent uses a thermal-mechanical temperature-controlled switch and solenoid mechanism instead of electronic temperature sensing and control systems. This mechanical/thermal approach simplifies the device structure by eliminating the need for complex electronic temperature monitoring circuits, microcontrollers, and software control logic
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 effectively prevents overheating and fire hazards by quickly disconnecting power when abnormal temperatures are detected, enhancing safety and reducing the risk of damage to the plug or receptacle.
Implementation Method 1
at least one temperature-controlled switch, disposed in direct or indirect thermal contact with at least one of the electrical conductor plates
Implementation Method 2
a solenoid mechanically couplet to the reset switch, wherein when a current flows through the solenoid, the solenoid operates the reset switch to disconnect the input side phase and neutral lines from the output side phase and neutral lines
Data Source
AI summary
An electrical power plug or receptacle with an over-temperature protection function, including a reset switch operated by a solenoid that electrically connects and disconnects the input side and output side electrical lines, and an temperature-controlled switch disposed in thermal contact with one or more electrical conductor plates on the input or output side. The temperature-controlled switch is connected in series with the solenoid between the output side phase and neutral lines. When the temperature of the temperature-controlled switch is within a normal range, the switch is open and does not form a current path with the solenoid. When the temperature is at or above a threshold temperature, the temperature-controlled switch is closed, a current flows through the switch and the solenoid between the output side phase and neutral lines, and the solenoid operates the reset switch to disconnect the input side from the output side.