Thermal Detection Plug for Appliance Interface Safety

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Solution Overview

Problem

Conventional current sensing circuit interrupters are ineffective in detecting heat build-up at the interface between appliances and power supplies, particularly in high amperage devices like space heaters, as they rely on amperage and voltage thresholds, missing gradual heat increases that do not exceed predetermined limits.

Innovation Solution

A thermal detection plug is placed at the power interface to directly measure temperature, using a thermocouple and thermal cut-off mechanism to interrupt power flow when temperatures exceed safe limits, independent of current flow, thus addressing the heat build-up issue.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional current sensing circuit interrupters are used, then amperage and voltage faults can be detected, but gradual heat build-up at the power interface cannot be detected

Engineering Contradiction:

Improvedetection capabilityVSAvoidtemperature detection accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent replaces conventional current sensing mechanisms with a thermal sensing mechanism. A thermocouple is positioned at the power interface to directly measure temperature, substituting the indirect electrical measurement approach with direct thermal measurement. This allows detection of gradual heat build-up that current sensing devices miss.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The thermocouple acts as an intermediary element positioned between the power interface components. It directly contacts or proximity-senses the thermal field at the critical interface, translating thermal energy into electrical signals that trigger the thermal protection device when temperature thresholds are exceeded.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermal detection plug is used, then temperature can be directly detected, but device complexity increases

Engineering Contradiction:

Improvesafety detectionVSAvoidplug structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The thermal detection elements (thermocouple, thermal protection device) are nested within the existing plug housing structure. The thermocouple is positioned inside or at the interface of the plug, and the thermal protection device integrates with the plug's electrical contacts, embedding the safety functionality within the conventional plug form factor.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The plug design incorporates multiple functions: power transmission through contacts, thermal sensing via thermocouple, and automatic circuit interruption through the thermal protection device. This multi-functional integration allows a single device to perform both electrical connection and safety protection without requiring separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If higher temperature thresholds are used in conventional devices, then false interruptions are reduced, but actual heat damage occurs before detection

Engineering Contradiction:

Improveoperational continuityVSAvoidheat damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The thermal protection device is positioned to detect temperature at the power interface before heat can propagate to surrounding components. By placing the sensing element at the earliest point of heat generation, the system takes preliminary protective action by interrupting power flow before thermal damage can occur to the plug housing, wiring, or adjacent materials.

Inventive Principle:

Principle #10Preliminary action

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 thermal detection plug enhances safety by halting electricity flow at lower temperature thresholds than conventional devices, preventing overheating and structural compromise, while being cost-effective and compatible with standard plug sizes, thus improving safety for high amperage appliances.

Implementation Method 1

A thermal detection plug is placed at the power interface to directly measure temperature, using a thermocouple

Methodology Applied

Scientific EffectSeebeck effect: Seebeck Effect

Implementation Method 2

using a thermocouple and thermal cut-off mechanism to interrupt power flow when temperatures exceed safe limits

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS9843145B2Thermal safety plug for an electric appliance

Publication Date: 2017.12.12 LASKO OPERATION HOLDINGS LLC

AI summary

A thermal detection plug for use with an electrical apparatus is provided. The thermal detection plug includes: a housing, a thermal cut-off, contact prongs, and supporting structures to effectively interrupt the flow of electrical power at the point of interface of between the power cord of an appliance and power receptacle. The thermal detection plug interrupts power based on a temperature detected at the interface point.