Terminal Sensor Integration for Accurate Overcurrent Heat Detection

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Solution Overview

Problem

Existing temperature detection units for terminal connection points suffer from inaccurate heat generation temperature detection due to external temperature influences and indirect heat transfer, leading to potential damage from overcurrent energization.

Innovation Solution

A terminal with a built-in sensor fixing part and temperature sensor, where the sensor is securely locked within a cylindrical sensor fixing part, allowing direct heat transfer from the terminal contact point, enhancing detection accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the temperature detection unit is placed outside the connector to detect heat from the terminal connection point, then the detection range is extended, but the detection accuracy deteriorates due to external air temperature influence and indirect heat transfer

Engineering Contradiction:

Improvedetection rangeVSAvoidtemperature detection accuracy

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The temperature sensor is integrated directly into the terminal body, merging the detection function with the terminal structure. This eliminates the need for separate external detection units and ensures direct thermal coupling with the terminal connection point, thereby maintaining high detection accuracy while enabling effective monitoring of heat generation during overcurrent conditions

Inventive Principle:

Principle #5Merging (Combining)

2Device complexity

If the thermistor detects temperature via the connector housing from the opposite side of the terminal, then the terminal structure is simplified, but the temperature detection accuracy deteriorates due to indirect heat transfer through the housing wall

Engineering Contradiction:

Improveterminal structure simplicityVSAvoidterminal connection point temperature accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The terminal body itself serves as the thermal intermediary, directly conducting heat from the terminal connection point to the integrated temperature sensor. This eliminates the need for heat transfer through the connector housing wall, providing accurate temperature detection while maintaining structural simplicity through integration

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If the temperature sensor is integrated directly into the terminal body, then the temperature detection accuracy is improved, but the device complexity increases

Engineering Contradiction:

Improveheat generation temperature detection accuracyVSAvoidterminal structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The temperature sensor is merged with the terminal body into a single integrated structure. The sensor fixing part is formed as an integral component of the terminal body, eliminating separate assembly steps and reducing overall device complexity while achieving direct thermal coupling for accurate temperature detection

Inventive Principle:

Principle #5Merging (Combining)

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

Enables precise detection of heat generation temperature during overcurrent energization, effectively preventing damage to the terminal and electrical wire by ensuring accurate temperature measurement.

Implementation Method 1

A terminal point generates heat by energization of overcurrent, and the generated heat is transferred to a core wire 111 and the covering part 112 of the electrical wire W

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the temperature sensor has a lock part, and it is preferable that the temperature sensor is allowed to be inserted in the sensor fixing part by elastic deformation of at least either one of the lock part and the sensor fixing part, and at an insertion completion position, the lock part is locked to the sensor fixing part by restoring elastic deformation

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS9570862B2Terminal and charging connector

Publication Date: 2017.02.14 YAZAKI CORP

AI summary

In a terminal including: a terminal body that has a mating terminal contact part with which a mating terminal is brought into contact, and a sensor fixing part; and a thermistor fixed to the sensor fixing part, and a charging connector using the terminal, the sensor fixing part has a cylindrical shape in which the thermistor is inserted, the thermistor has a lock part, and is allowed to be inserted in the sensor fixing part by elastic deformation of the sensor fixing part, and at an insertion completion position, the lock part is locked to the sensor fixing part.