Thermocouple Connector Design for Minimizing Thermal Gradient Errors
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Solution Overview
Problem
Existing thermocouple connectors with intermediate connections or joints can lead to accuracy loss due to temperature differences between joints, even when using conductors made from the same dissimilar metals as the thermocouple wires.
Innovation Solution
A thermocouple connector design featuring an elongate male member made of high thermal conductivity material and a female member made of low thermal conductivity material, with direct contact terminals and an optional temperature sensor to minimize temperature differences and errors, allowing for a compact, space-saving configuration that can pass through small gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If connectors with intermediate connections or joints are used, then disconnectable connections can be provided, but accuracy is lost due to temperature differences between joints
Solution Approach 1:
The invention removes intermediate connections and joints from the thermocouple circuit by implementing direct contact between terminals. The male and female connectors establish direct electrical contact without intermediate conductors, eliminating the source of thermal gradient errors while preserving disconnectability.
Solution Approach 2:
The invention introduces a temperature sensor as an intermediary element that measures the actual temperature at the connector location. This measured temperature is then used to compensate for any errors in the thermocouple measurement, allowing disconnectable connections without sacrificing accuracy.
2Ease of manufacture
If conventional connector materials are used, then ease of manufacture is improved, but thermal gradients between terminals increase causing measurement errors
Solution Approach 1:
The invention changes the thermal conductivity parameter of the connector material from conventional low thermal conductivity materials to high thermal conductivity materials (such as metals). This ensures that the entire connector body, including both terminals, remains at a uniform temperature, eliminating thermal gradient errors while maintaining manufacturability.
3Strength
If the connector has a large cross-sectional area, then structural strength is improved, but the connector cannot pass through small gaps in complex assemblies
Solution Approach 1:
The invention divides the connector into separate male and female components that can be assembled together. This segmentation allows each component to have a compact size suitable for passing through small gaps, while the assembled connector maintains the required structural strength for reliable electrical and thermal connection.
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 design minimizes errors in temperature measurement by reducing thermal gradients between terminals and eliminating intermediate joints, maintaining accuracy within specified tolerance bands while enabling precise temperature calculation using the cold junction temperature.
Implementation Method 1
one of the first and second members is formed of a thermally conducting material having a thermal conductivity of at least 75 W/mK
Implementation Method 2
The circuit generates a voltage due to the diffusion of electrons along the temperature gradient (the Seebeck effect)
Data Source
AI summary
A thermocouple connector has a first member and a second member which couples to the first member. The first member carries two first terminals for electrically joining to the respective ends of a pair of thermocouple wires. The second member carries two corresponding second terminals for electrically joining to the respective ends of a pair of thermocouple extension wires. Each first terminal contacts a respective second terminal when the first and second members are coupled.