Method, system, and apparatus to prevent arc faults in electrical connectivity

Abstract

A system for protection from fires and electrical shock of components used in construction of electrical systems is disclosed using a sensing degree of characteristic before an arc fault, with the purpose to detect, annunciate, and remove the hazard before an electrical arc occurs.

Claims

1. An apparatus for providing protection from an unsafe thermal condition of an electrical connectivity, that precurse unsafe events, with a maximum temperature rating, the apparatus comprising: a monitor, disposed within or on the electrical connectivity, configured to detect a change of parameters of a translucent thermomorphic substance due to heat of the electrical connectivity causing latching of a logic, the monitor comprising: the translucent thermomorphic substance selected from thermomorphic substances having one or more dimensions that change at a temperature above the maximum temperature rating of the electrical connectivity; the translucent thermomorphic substance having a first end, a second end, and a transmissivity parameter; a photon source operably coupled to the first end; and a photon measurement device operably coupled to the second end to measure an intensity of photons; wherein a change in the intensity of photons indicates a change in the one or more dimensions of the translucent thermomorphic substance at the temperature above the maximum temperature rating of the electrical connectivity causing the latching of the logic, and the monitor generates an unsafe thermal condition signal in response to the latching of the logic to indicate the unsafe thermal condition of the electrical connectivity.

2. The apparatus of claim 1, wherein the unsafe thermal condition is related to exceeding the temperature rating of an electrical connector of the electrical connectivity.

3. The apparatus of claim 1, wherein the unsafe thermal condition of the electrical connectivity is related to a precondition in an electrical arc.

4. The apparatus of claim 1, wherein the unsafe thermal condition of the electrical connectivity is consequent to ohmic heating.

5. The apparatus of claim 1, further comprising at least one indicator device configured to provide a visible indication of the unsafe thermal condition of the electrical connectivity.

6. The apparatus of claim 1, further comprising a communication device configured to provide wired or wireless communication to compatible devices in response to the unsafe thermal condition of the electrical connectivity.

7. A method for mitigation of an unsafe thermal condition in an electrical connectivity with a safety related temperature rating, that precurse unsafe events, the method comprising the steps of: placing at least one monitor in or proximal to the electrical connectivity; the monitor being configured to detect a change of parameters of a translucent thermomorphic substance due to heat of the electrical connectivity causing latching of a logic; monitoring, by said at least one monitor, a change in an intensity of photons of the translucent thermomorphic substance having a morphing point below 200 degrees Celsius yet above the safety related temperature rating of the electrical connectivity; wherein the translucent thermomorphic substance selected from thermomorphic substances having one or more dimensions that change at a temperature above the safety related temperature rating of the electrical connectivity, the translucent thermomorphic substance having a first end, a second end, and a transmissivity parameter; a photon source being operably coupled to the first end; and a photon measurement device being operably coupled to the second end to measure the intensity of photons; wherein the change in the intensity of photons indicates a change in the one or more dimensions of the translucent thermomorphic substance at the temperature above the safety related temperature rating of the electrical connectivity causing the latching of the logic, and in response to detecting the latching of the logic, said at least one monitor generates an unsafe thermal condition signal indicative of the electrical connectivity operating at a temperature above the safety related temperature rating.

8. The method of claim 7, wherein the unsafe thermal condition of the electrical connectivity is related to a precondition to an electrical arc of the electrical connectivity.

9. The method of claim 7, wherein the unsafe thermal condition signal is transmitted to a cloud computing service or a local area network by a wireless means.

10. The method of claim 7, wherein the unsafe thermal condition signal is transmitted via a wire to a computing device.

11. A service for providing a notification of an unsafe thermal condition in an electrical connectivity with a maximum temperature rating, that precurse unsafe events, the service comprising: one or more apparatus configured to notify the unsafe thermal condition of the electrical connectivity in response to receiving an unsafe thermal condition signal from one or more monitors installed in, or proximal to, the electrical connectivity; the one or more monitors being configured to detect a change of parameters of a translucent thermomorphic substance due to heat of the electrical connectivity causing latching of a logic; said one or more monitors comprising: the translucent thermomorphic substance having a morph point between the maximum temperature rating of the electrical connectivity and 200 degrees Celsius; wherein the translucent thermomorphic substance selected from thermomorphic substances having one or more dimensions that change at a temperature above the maximum temperature rating of the electrical connectivity, the translucent thermomorphic substance having a first end, a second end, and a transmissivity parameter; a photon source being operably coupled to the first end; and a photon measurement device being operably coupled to the second end to measure an intensity of photons; wherein the change in the intensity of photons indicates a change in the one or more dimensions of the translucent thermomorphic substance at the temperature above the maximum temperature rating of the electrical connectivity causing the latching of the logic, and said one or more monitors configured to communicate to said service the unsafe thermal condition signal in response to the latching of the logic.

12. The service of claim 11, wherein the unsafe thermal condition is a precondition to an electrical arc of the electrical connectivity.

13. The service of claim 11, wherein the notification comprises a request for mitigation of the unsafe electrical connectivity.

14. The service of claim 11, wherein the said one or more monitors estimate a risk of an electrical arc in one or more future time intervals.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) FIG. 1 depicts an unexploded side view diagram of a device with components constructed according to the teaching of this application.

(2) FIG. 2 depicts a frontal, cutaway, exploded view diagram of an electrical connector with an electrical circuit monitoring change of one or more parameters of thermomorphic substance affected by ohmic heating to detect a precondition of an unsafe event, such as DC arcing, in connectivity junctions.

(3) FIG. 3 is a top view, unexploded diagram that depicts components on the upper surface of an assembled apparatus, assembled according to the teaching of this application. The pass-through connector is depicted with a device having an exposed indicator device and a communication device for cloud communication with a protocol such as a Bluetooth™ or Wi-Fi, and an internal cavity filled with a compound that thermally decomposes to provide mitigation and/or protection from an unsafe event.

(4) FIG. 4 depicts an unexploded top-view diagram of components of the apparatus shown in FIG. 1 with visible indicator and communication device for a cloud communication device such as a Bluetooth™ or Wi-Fi on the exposed surface.

REFERENCE TO NUMERALS USED IN DRAWINGS

(5) The components identified in the figures are: (1) Conductor (2) Male Electrical Connector (3) Female Electrical Connector (4) Sensor Device (5) Indicator Device (6) Electrically Conductive Guide (7) Conductive Pin (8) Power Regulator (9) PV Module (10) Dielectric (11) Thermomorphic Substance (12) Switch (13) Monitor (14) Pass-Through Connector (15) Temperature Measurement Device (16) Junction Box (17) Cavity (18) Channel (19) Substrate (20) Antenna (21) Communication Device (22) Cloud Computing Service (23) Instrumented Connector (24) Local Area Network (25) Data Encoder (26) Unsafe Condition Signal

DETAILED DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(6) Various embodiments of the invention are disclosed in the following detailed description and accompanying drawings. Each drawing teaches how to implement the techniques and or components to effect the purposes of this patent.

(7) FIG. 1 is a side view diagram that depicts components of an exemplary sensor device (4) constructed according to the teaching of this application. The dielectric substrate (19) is depicted as supporting a thermomorphic substance (11) and additionally electrical circuit components including a power regulator (8); a switch (12), data encoder (25), antenna (20), communication device (21), monitor (13) that generates an unsafe condition signal (26), temperature measurement device (15), and an indicator device (5). The components, including the thermomorphic substance (11), could be replaced by an application specific integrated circuit (ASIC). The monitor (13) has purposes including, but not limited to, detecting parameter change of the thermomorphic substance (11) due to heat causing latching of the switch (12), which activates the indicator device (5) and generates an unsafe condition signal (26). The source of power could be scavenged, solar, mechanical, inductive, or other.

(8) FIG. 2 is a frontal, composite, cutaway, exploded view diagram that describes the functions and components of an apparatus constructed according to the teaching of this application. The upper section is the sensor device (4) described in FIG. 1.

(9) The lower section depicts an exposed end of the conductor (1) sufficient to pass tightly into an electrically conductive guide (6) in the pass-through connector (14). The pass-through connector (14) having an electrically conductive guide (6), that is designed to hold with conductor (1). The sensor device (4) (as shown in FIG. 1) fits into cavity (17) in the pass-through connector (14). The pass-through connector (14) is constructed of dielectric (10). Electrically conductive guide (6) is located in channel (18), which runs axially through the pass-through connector (14). The left portion of the conductive pin (7) is tightly fitted inside the electrically conductive guide (6) an exposed portion sufficient to couple securely with a female connector (not shown). Coupling a male connector (not shown) to the pass-through connector (14) which in turn couples to a female connector (not shown) forms a circuit path when electrical power is present.

(10) In addition to detecting change of parameters within the connectivity, which are a precondition to arcing, the sensor device (4) can additionally provide monitoring of voltage and or current flowing through the connectivity for efficiency, loose connectivity, and other deleterious conditions.

(11) FIG. 3 is a top view of unexploded diagram that depicts the assembled apparatus according to the teaching of the present application. Conductor (1) passing through the male electrical connector (2) is inserted into the pass-through connector (14). Electrical current conducts via an electrically conductive guide (not shown) within the pass-through connector (14). Conductive pin (not shown) exits the pass-through connector (14) coupling with female electrical connector (3). A conductor (1) exits the female electrical connector (3) to the right. The sensor device (4) has a communication device (not shown) that provides wired or wireless communication using either antenna (20) or encoded signals on the conductor (1) to communicate to compatible devices. Heat generated by ohmic resistance to the electrical current causes heating of male electrical connector (2), female electrical connector (3) and pass-through connector (14). An indicator device (5) indicates the safe/unsafe condition of the connectivity.

(12) FIG. 4 depicts an array of three PV modules (9) transmitting data to a local area network (24) and a cloud computing service (22) from instrumented connectors (23) and junction boxes (16). Insulated electrical conductors (1) are depicted as joined by instrumented connectors (23) taught according to the present application. Sensor devices (not shown) within instrumented connectors (23) perform monitoring for preconditions of unsafe conditions within connectivity of the array of PV modules (9).

(13) Still referring to FIG. 4, communication of unsafe condition data from the instrumented connectors (23), using data on conductors (1) into a junction box (16) is depicted. The data is transmitted by wireless communication circuit in junction box (16) to a local area network (24) or a cloud computing service (22), as appropriate for the situation.

DETAILED DESCRIPTION OF THE INVENTION

(14) The following is a detailed description describing exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. The scope of the invention encompasses numerous alternatives, modifications, and equivalent; it is limited only by the claims.

(15) Numerous specific details are set forth in the figures and descriptions are provided in order to provide a thorough understanding of the invention and how to practice the invention. However, the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured. A person with ordinary experience in creating connectivity would appreciate that the sensor device could be located in all or any of the pass through connector (14), male electrical connector (2), or the female electrical connector (3). Other variations of embodiment, for example, could utilize a fuse, relay, or other device to open an unsafe connectivity that could be separate from or manufactured integral to the male electrical connector (2) or the female electrical connector (3).

(16) References are cited that provide detailed information about electrical systems, unsafe conditions of electrical systems, and approved techniques for implementing protection systems. However, a person with ordinary experience in instrumenting systems would understand the application applies to steam and chemical piping systems that overheat.

(17) The embodiments of the invention set forth herein relate to detection, notification, mitigation, and isolation of unsafe connectivity that incorporates the present invention for purposes of properly disconnecting the flow of electricity within in the connectivity.

(18) This exemplary embodiment uses change of parameter of a thermomorphic substance at a temperature above the rating of the connectivity as means to cause an unsafe condition signal. There are extensive, publically available scientific papers and technical reports on the subject of thermal mitigated changes. There are many compounds, materials, and substances that change properties and composition due to temperature. A few of many examples of temperature-dependent phenomena are thermal runaway of semiconductors, change of translucence, change of composition, and melting.

(19) Other embodiments of the present invention could additionally include at least one device configured to perform monitoring of temperature within the electrical connectivity. The purpose of the device to confirm exceeding a thermal rating indicative of an unsafe thermal condition and generate an unsafe condition signal. In this augmented embodiment, the electrical circuit is configured to: 1) measure temperature of a connectivity junction; 2) utilize logic to infer an unsafe condition by observing significant change in temperature; and 3) output an unsafe condition signal which causes disconnection of the offending electrical circuit by causing an associated device to open the connectivity.

(20) According to another embodiment of the present invention, a method of detecting an unsafe condition includes analog or digital comparison of voltage and/or current data of measurement of intensity of light from a translucent conductor coupled to a photon detector detecting exceedance of a threshold value, which initiates operation of a current disrupter in order to isolate that portion of the connectivity associated with the unsafe condition. The step of controlling operation of a disrupter device further includes causing the circuit to open and remain open.

(21) According to another embodiment, the device could employ an integrated circuit rated to change state above 85 degrees Celsius complemented by a circuit with 125 degrees Celsius rating for detecting unsafe conditions in connectivity with 85 degrees Celsius. Malfunction of the integrated circuit would indicate an unsafe condition. An 85 degrees Celsius rated integrated circuit (IC) in a monitor circuit will malfunction above its rating and usually recover when the temperature lowers. When the 85 degree Celsius IC is functioning properly, a 125 degree Celsius rated IC monitors the functionality and encodes an unsafe condition signal (safe). From time to time, the 125 degree Celsius rated IC monitor sends the unsafe condition signal to a cloud computing service or by wire or wireless to a computer via a local area network or the condition can be encoded and delivered by wired connection. When overheat causes the 85 degree Celsius rated IC to malfunction (thermal runaway), the 125 degree Celsius IC encodes the unsafe condition signal as true, which alerts of a hazardous condition at that location.

(22) According to still yet another embodiment of the present invention, the device is able to alert an unsafe condition by operating an indicator lamp on the module with the unsafe condition; lighting a lamp located at a distance; or sending an alert signal over a wired or wireless data link to a control station.

(23) In a broad embodiment, the present invention extends to use in other equipment, which is subject to risk of damage, fire, and loss of property due to aging and manufacturing defects.

(24) For example, in the case of manufacturing a connector for use in establishing connectivity, the device could be constructed in connectivity components meeting the appropriate regulatory requirements.

(25) In another example, in the case of manufacturing a PV system component, such as, but not limited to a DC to AC inverter, the embodiment would be situated in connectivity proximal to components and wiring therein that could have an unsafe condition. The device would generate an unsafe condition signal to cause interruption of current flow by opening a circuit or short-circuiting power as appropriate to mitigate the unsafe condition.

(26) Best Embodiment

(27) In a best embodiment, the apparatus is constructed with thermomorphic material or substance selected for properties that will optimize detection of unsafe conditions, and signal for correction and/or mitigation such as but not limited to, communicating to a local area network or a cloud computing service that provides facility monitoring; or causing a switch, relay, or circuit breaker to open the circuit. In a best embodiment, the device produces a repeated or continuous unsafe condition signal at a temperature below the temperature that causes an arc to happen. The reason being, if the warning is ignored, continued increase in corrosion will result progressively and will eventually result in a high temperature arc that would cause conflagration of the insulating material, with collateral fire. A raging fire could cause significant damage and risk of human injury.

(28) In a best embodiment, the device repeatedly sends an unsafe condition signal when a first threshold is exceeded lower than a temperature that indicates imminent arc formation.

(29) In a best embodiment, pre-detection of an emerging unsafe condition with a device would be continuous when electrical current is carried by the conductivity. This approach would also detect heating due to an arc or external fire. Should such conditions occur, the device would send an unsafe condition signal, which results in an alarm and the associate connectivity system component being de-energized by disconnecting the flow of electricity according to the teaching herein.

(30) Construction of Embodiments

(31) The US National Electric Code (2014 Edition) requires that components and conduits used in solar systems must operate at temperatures up to 85 degrees Celsius. The degree of heat generated by flow of electricity in connectivity is represented by Ohm's Law. The relationship means that either increased resistance of the connectivity, such as caused by corrosion, or increased current, such as caused by increasing the number of PV modules, could eventually result in a DC arc with the hazards that the DC arc entails. A temperature of around 200 degrees Celsius is identified as sufficient for sustained arcing in PV connectors and is documented by B. Yang, et al, in reference #5 in the List of Non-Patent Documents, which is incorporated in its entirety by reference.

(32) An instrumented device can be produced by placing a portion of translucent thermomorphic substance that changes optical transmissivity above 85 degrees Celsius which is the rated temperature for PV connectivity. The substance, such as, but not limited to High Density Polyethylene (HDPE), is positioned in close proximity to the components that exhibit resistive electrical heating phenomena, also known as ohmic heating, in a junction of electrical connectivity of an electrical system and can result in localized elevated heating loosening bonds or dielectric insulation breakdown that results in arcing.

(33) In order to produce a device according to the teaching of this patent, select from substances that produce a measurable change in parameter above the maximum specified operating temperature but sufficiently below the temperature where debonding or dielectric breakdown resulting in arcing is expected to occur. For example, if the maximum operating temperature of a connectivity component is 80 degrees Celsius, according to the American Society of Test and Measurement Engineers (ASTME), translucence of HDPE decreases above 104 degrees Celsius; a point the ASTME calls, “T.sub.m”. Further, HDPE melts at 150 degrees Celsius, a point the ASTME calls, “Ta”. Alternatively, the substance, for example, could be a semiconductor material which becomes a conductor (or non-conductor) above a certain temperature based on its composition.

(34) Embodiments, without limitation, can be constructed without an electronic circuit, or with a digital circuit, or an analog circuit, or a combination. The device should, according to need to communicate, be able to send and receive analog and digital input signals. The circuitry should be designed with the ability to be unaffected by the electrical current on the conductors.

(35) Other embodiments of the design could, according to need to take pre-action, also have analog and/or digital outputs to provide actuation such as, but not limited to a status indicator light or semaphore, or a means for sending data and information such as, but not limited to, coded modulation onto the electrical current carried by the conductor within the connectivity; or wireless means, for sending information using approved protocols such as, but not limited to, Bluetooth™ or Ethernet.

(36) If the thermomorphic substance is a semiconductor, the substance should be selected to change output above the thermal rating of the component and well below the temperature associated with an arc fault.

(37) If the thermomorphic substance is translucent, the photon source to detect change in translucence can be, for example without limitation, a light emitting diode (LED). The photon source should be selected so as to produce wavelengths that are compatible with an associated photon measurement device. The photon intensity measurement device can be selected from, but is not limited to, a photodiode, phototransistor, or photo resistor, which receives photons and produces a measurable voltage or current output. The photon measurement means should be selected for ability to reliably generate an output signal for the limited amount of the frequency of light that will be conducted by the translucent material. The photon detector device should be appropriately biased, if necessary, to operate in the full range of expected illumination. There are a plethora of commercially available devices that serve the purpose. Reliability, stability, and durability are key parameters to be considered in making a selection.

(38) The thermomorphic substance for constructing the device can be, for example and without limitation, loops, strips, pieces, or strands of any length, axial, and longitudinal dimension. The thermomorphic substance can be selected of polymers such as, but not limited to, polyethylene, that produce measurable change in transmissivity spanning temperatures sufficiently below the temperature where an electrical arc forms yet above the maximum temperature rating of the connectivity component, which is monitored. The thermomorphic substance should be selected for having appropriate characteristics such as, but not limited to, thickness, melting point, change in transmissivity, toxicity of any byproducts when heated, and tensile strength. If coated, the coating should be appropriate for the application. If a translucent thermomorphic substance is used, it should not substantially discolor or occlude light over time for so long as the operational life of a system component wherein the sensor is installed. Another property affecting selection could be how the thermomorphic substance conducts or does not conduct light when affected by temperature.

(39) Means for determining an unsafe condition includes, but is not limited to, using an electronic circuit rated above the rating of the components to measure temperature indirectly. For example, indirect means could be accomplished by measuring change in a voltage parameter affected by temperature.

(40) The energy source for a circuit incorporated into the device design, could be, but is not limited to, a tap of energy carried by the conductor, an inductive coil surrounding the conductor, or a solar cell. The energy source, if any, should be selected for operating as long as possible and to hold sufficient charge for as long as the system component wherein the sensor is installed.

(41) Digital or analog information, including but not limited to, unsafe condition signals, temperature measurements, and alerts produced by the device, can be delivered to a remote transceiver located in a junction box or a combiner box, that relays the information to an electrical system health monitoring and control center. The information could be used, for example, to produce an estimate of risk for future time intervals that an arc will likely occur by using an algorithm based on parameters including, but not limited to, the rate of increase in temperature sensed and time. The means to deliver the information could be wireless using a protocol such as but not limited to Bluetooth or Wi-Fi (such as, for example only, a modulation on the conduit DC or AC signal).

(42) The device should operate to produce an unsafe condition signal when a temperature trigger below the temperature associated with a sustained arc is produced due to temperatures within electrified connectivity. (B. Yang, et al, cited previously as #5 in the List of Non-Patent Documents above, found the temperature sufficient to sustain a DC arc is 200 degrees Celsius.)

(43) In accordance with yet another aspect of the present invention, the material used to produce the packaging should be reliable and stable for the expected service life of the connectivity.

(44) In accordance with a third aspect of the present invention, the apparatus could include features such as, but not limited to, a self-test function, ability to annunciate, to be interrogated by wired or wireless means, and interrupt current flow by opening the circuit to stop the flow of electricity.

(45) To test the functionality of the system, create an apparatus for performing a series of measurement tests that produce data to determine the response characteristics of the thermomorphic substance at a range of temperatures. Testing in an instrumented thermal test chamber is one means. Increasing the resistance can be accomplished by placing the corrodible test article in a salt-air environment at an elevated temperature to quicken the corrosion and thus the resistance.

(46) In yet another test configuration, additionally include a comparator logic means (such as a differential amplifier) settable at a preferred temperature with the purpose to generate an unsafe condition signal such as illumination of a warning light, release of a semaphore, or transmission of a wireless or wired signal. The unsafe condition criteria could include, but is not limited to, one or more of a threshold value, a range of threshold values, or a predetermined signature.

(47) In accordance with another aspect of the present invention, if the comparator logic requires electricity to operate, it is connected to electricity carried by the connectivity or electricity from another source, such as a battery or capacitor energized by kinetic energy or solar energy.

(48) Reduction to Practice

(49) In April 2014, under an appropriate non-disclosure agreement, Sandia National Laboratories (SNL) was commissioned to explore the temperature at which a DC arc initiates in a single conductor connector of the type used in PV connectivity. This SNL research resulted in Sandia Laboratory Technical Report SAND2015-0883, February 2015, (Not for public release—For Official Use Only), which determined that a first arc in a PV connector occurs in PV connectors at around 200 degrees Celsius. In this research, SNL also explored whether melting of translucent thermomorphic substances could be applied successfully to detect arc-faults in PV connectors. The concept being that in the event of hot spots, which are known to precede arc-faults, a proximal translucent polymer strand operationally coupled to a photon detector and a light emitter would melt and the light signal from the light emitter would diminish or cease to reach the photon detector, causing a logic circuit to signal a pre-arc condition. An alternative is an illuminated proximal translucent polymer strand coupled to a photon detector would exhibit reduced transmissivity and the reduced light signal reaching the photon detector would cause a logic circuit to signal an interrupter device to open the connectivity and stop the flow of current.

(50) We, the inventors, explored using the phenomena of thermal response to develop a method based on temperature affects that could be applied to predict and prevent an arc-fault in connectivity above 100 degrees Celsius and below the 200 degrees Celsius at which SNL research found that a DC arc initiates. The concept being that in the event of increased resistive heating caused by conductor corrosion within a connector, the temperature within the connector body would measurably change and reflect degree of risk. When the amount of change increases significantly, a signal would be produced to an integral interrupter means to disconnect the connector and stop the flow of current.

(51) We, the inventors, explored thermal effects on translucent polymers at temperatures under 200 degrees Celsius. We, the inventors, found several translucent polymers, according to the ASTME, that exhibit the property to melt at a temperature below 200 degrees Celsius. The inventors experimented with polymers including low density polyethylene (LDPE) which melts at 125 degrees Celsius and high density polyethylene (HDPE) which, according to the ASTME, melted at 150 degrees Celsius.

(52) We, the inventors, also explored utilizing semiconductor circuits which are known to become unstable above 125 degrees Celsius based on its composition as temperature affects the energy band gap. (This property is documented by D. Wolpert and P. Ampadu, “Managing Temperature Effects in Nanoscale Adaptive Systems”, DOI 10.1007/978-1-4614-0748, cited as #8 in the List of Non-Patent Documents.)

(53) We, the inventors, modified commercial, injection-molded, PV connectivity connectors to incorporate an integrated circuit with thermal rating of 85 degrees Celsius coupled to a circuit rated at 100 degrees Celsius. Examples of corroded PV connectivity electrically conductive guides and pins were created to produce exemplary heating caused by corrosion at electrical current typical of that of PV connectivity at the present time. The test example was assembled. The test example worked as described herein establishing that resistive heating within a connector well below the 200 degree Celsius that produces an arc can be accomplished.

(54) Another prototype device was constructed consisting of an LED positioned on a thumbnail-size circuit board to illuminate a strip of translucent Low Density Polyethylene (LDPE) and a photon detector positioned at the opposing end of the LDPE received the photons emitted by the LED. The output of the photon detector was connected to a comparator logic circuit biased to produce an output signal when the voltage from the photo detector exceeds a threshold value. LDPE was chosen for the property of decreasing transmissivity above 100 degrees Celsius and melting above 150 degrees Celsius. The device was calibrated by adjusting the bias of comparator circuit so as to produce an output signal at the voltage generated by the photo detector at its rating of 125 degrees Celsius. When power was applied, the photons from the LED were transported through the strip of LDPE to the photo detector which produced a measureable signal proportional to the loss of transmissivity of the LDPE. The device was tested in a thermostatically controlled oven.

(55) CONCLUSIONS, RAMIFICATIONS, AND SCOPE

(56) The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications (aside from those expressly stated), are possible and within the scope of the appending claims.

(57) While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. A person with ordinary experience in creating electrical connectivity would appreciate that the sensor device could be located in the wiring as well as all or any of the pass-through connector (4), male electrical connector (2), or the female electrical connector (3) in the figures.

(58) A person with ordinary experience would appreciate that the connectivity can be within a junction box, a panel, or electronic assembly. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention.

(59) The previous description of specific embodiments is provided to enable any person skilled in the art to make or use the present invention. The various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without the use of the inventive faculty.