Temperature-Sensitive Connector With Parallel Thermal Cutoff and Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical systems face challenges in effectively managing over-temperature and over-current faults, which can lead to system instability and damage.
Innovation Solution
The implementation of a temperature-sensitive connector with an integrated thermal switching device, comprising a thermally activated switch element and a thermal sensor element in parallel, which generates status signals to an electrical thermal control device upon temperature thresholds being exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal cutoff device is used to protect against over-temperature faults, then system safety is improved, but the ability to provide detailed temperature information and enable precise control is lost
Solution Approach 1:
The patent combines a thermal cutoff device and a thermal sensor into a single integrated connector assembly. The thermal cutoff (TCO) provides safety protection by opening the circuit at high temperatures, while the thermal sensor (thermistor) simultaneously provides continuous temperature monitoring data to the control device, resolving the contradiction between safety and information availability.
Solution Approach 2:
The connector is designed to perform multiple functions: electrical connection, thermal protection via TCO, and temperature sensing via thermistor. This multi-functional design allows the system to both protect against overheating and gather precise temperature information for control decisions, eliminating the need for separate protective and sensing components.
2Reliability
If separate thermal protection and sensing components are used, then functional reliability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent integrates the thermal cutoff device, thermal sensor, and electrical connector into a single unified component. This consolidation maintains the reliability of thermal protection while reducing the number of separate parts, simplifying the overall system architecture and reducing installation complexity.
Solution Approach 2:
The connector assembly serves multiple purposes simultaneously: providing electrical connectivity, housing a thermal cutoff for protection, and incorporating a thermal sensor for monitoring. This multi-functional design eliminates the need for multiple discrete components, thereby reducing device complexity while maintaining protection reliability.
3Measurement precision
If a thermal sensor is always connected in parallel with the thermal cutoff, then temperature monitoring capability is improved, but current flow characteristics and switching accuracy are affected
Solution Approach 1:
The patent employs a dynamic configuration where the thermal sensor is connected in parallel with the thermal cutoff, but the system adaptively adjusts its operation based on temperature conditions. At normal temperatures, the TCO remains closed with minimal impact from the parallel sensor. At fault temperatures, the TCO opens while the sensor continues monitoring, allowing the system to maintain both monitoring accuracy and switching reliability through conditional operational modes.
Solution Approach 2:
The thermal sensor provides continuous temperature feedback to the control device, enabling the system to monitor temperature trends and distinguish between normal operational heating and actual fault conditions. This feedback mechanism allows the thermal cutoff to switch accurately based on genuine thermal threats rather than transient temperature variations, maintaining switching reliability while enabling precise monitoring.
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
This solution enables accurate temperature monitoring and fault detection, allowing for timely interventions such as disconnecting the thermally controlled electrical component from a power source, thereby preventing damage and ensuring system safety.
Implementation Method 1
a thermally activated switch element connected mechanically and electrically in parallel by a pair of internal conductors to a thermal sensor element
Implementation Method 2
a thermal sensor element having a variable resistance
Data Source
AI summary
A temperature-sensitive connector is disclosed. The connector can include a connector body and a first terminal to connect to a terminal of an electronic component being thermally controlled and a second terminal to connect to a terminal of an electronic thermal control device. The connector can include at least one conductor mounted in the connector body to convey a signal from the electronic component being thermally controlled to the electronic thermal control device. A thermal switching and sensing device can be integrated into the connector body to electrically connect to the first terminal and the second terminal. The integrated thermal switching and sensing device can include a thermally activated switch element connected in parallel with a thermal sensor.