Terminal Block Transparent Probe Thermochromic Overheat Detection
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Solution Overview
Problem
Existing terminal blocks face issues with delayed overheating detection due to high thermal resistivity between the metallic contact terminal and discoloration unit, and are prone to mechanical damage, which can lead to fires if the overheat condition is not promptly indicated.
Innovation Solution
A terminal block design featuring a transparent and insulating temperature probe with a thermochromic discoloration layer positioned close to the conductive linking bar, allowing for rapid color change indication of overheating, and a screw connection terminal with low thermal resistance to enhance sensitivity and visibility of the color change.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the discoloration unit is arranged on the insulating cap, then the discoloration unit is protected from mechanical damage, but the thermal insulation between the metallic contact terminal and discoloration unit delays overheating detection
Solution Approach 1:
The patent introduces a transparent temperature probe as an intermediary component between the metallic contact terminal and the discoloration unit. This probe conducts heat rapidly from the contact terminal to the discoloration layer while its transparent material allows optical signals to pass through, thus resolving the thermal insulation problem while maintaining the protective function.
Solution Approach 2:
The discoloration layer is nested within or on the temperature probe structure, which itself is positioned within the insulating cap. This nested arrangement allows the discoloration unit to be close to the heat source while still being protected by the insulating cap structure.
2Loss of time
If the discoloration unit is placed close to the conductive linking bar, then overheating detection is rapid and sensitive, but the discoloration unit is exposed to mechanical damage
Solution Approach 1:
The temperature probe acts as a mediator that allows the discoloration layer to be positioned close to the conductive linking bar for rapid heat detection, while the probe structure itself protects the discoloration layer from direct mechanical damage.
Solution Approach 2:
The discoloration layer is applied as a thin film on the temperature probe surface, allowing it to be close to the heat source while the probe structure provides mechanical protection. The thin film configuration enables thermal coupling without requiring thick protective layers.
3Reliability
If the insulating cap material is used, then electrical insulation is provided, but the high thermal resistivity prevents rapid heat transfer to the discoloration unit
Solution Approach 1:
The transparent temperature probe serves as a thermal intermediary with low thermal resistivity, conducting heat rapidly from the metallic contact terminal to the discoloration layer without compromising the electrical insulation provided by the insulating cap material.
Solution Approach 2:
The solution uses a composite structure combining the high electrical resistivity insulating cap material with a low thermal resistivity transparent probe material, achieving both electrical insulation and rapid heat transfer through different materials in the same system.
4Loss of information
If the discoloration layer is made visible through the transparent temperature probe, then the fault indication is observable, but the optical path may be interrupted or obscured
Solution Approach 1:
The discoloration layer undergoes color changes in response to temperature, creating a visible optical signal that can be observed through the transparent temperature probe. This color change mechanism ensures reliable fault indication while maintaining optical path integrity.
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 provides rapid and sensitive detection of overheating conditions, ensuring timely indication of faults and reducing the risk of mechanical damage, thereby enhancing safety and reliability.
Implementation Method 1
a discoloration layer arranged at the first end of the temperature probe having at least a thermochroic layer
Implementation Method 2
a temperature probe received by the duct and made of transparent and insulating material having a first end and a second end... the discoloration layer arranged at the first end of the temperature probe is closer to the conductive linking bar
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
It is therefore an objective of the invention to provide a terminal block including: an insulating body with a duct and at least one hole formed through a wall of the insulating body, a conductive linking bar in the insulating body for connecting at least one wire respectively passing through the at least one hole, a temperature probe received by the duct and made of transparent and insulating material having a first end and a second end, and a discoloration layer arranged at the first end of the temperature probe having at least a thermochroic layer. At least a portion of the temperature probe is arranged to pass through the duct towards the conductive linking bar so that the discoloration layer at the first end of the temperature probe is closer to the conductive linking bar than the second end of the temperature probe. By having such configuration, the discoloration layer will be heated rapidly thereby in the event of the bar overheating to provide a rapid colour change indicating a fault condition. This makes it more sensitive to the temperature of the conductive linking bar. Besides, the lights reflecting the colour change of the discoloration layer will propagate to the external of the insulating body through the optical path provided by the transparent temperature probe and arrives at the second end portion of the probe, which makes it visible to the eyes of the observer from an external point of view. This allows the image of discoloration layer to be viewed by the observer perceiving a fault occurring.