Isolated temperature sensing for hems contacts

1. A method of detecting temperature of an electrical terminal comprising:

applying a material patch to a surface of the electrical terminal, the material patch containing a polymer matrix with a polymeric positive temperature coefficient material which contains a mixture of electrically conductive magnetic particles, whereby the material patch does not appreciably increase the electrical resistance or thermal capacitance of the electrical terminal;

exciting the electrically conductive magnetic particles with an AC magnetic field to cause eddy currents to flow within the electrically conductive magnetic particles;

remotely sensing a change in the material patch with an electrically isolated circuit which is external to the electrical terminal to determine if the electrical terminal is operating at a safe temperature to optimize current flow across the electrical terminal.

2. The method of claim 1 , comprising:

generating a magnetic field based on the thermal expansion of the polymer matrix, the magnetic field is a non-linear function of temperature.

3. The method of claim 2 , wherein below a designed transition temperature, the polymer matrix does not expand or has minimal expansion and the electrically conductive magnetic particles are in close mechanical contact.

4. The method of claim 2 , wherein above a designed transition temperature, the polymer matrix expands causing the electrically conductive magnetic particles to move apart and form individual islands.

5. The method of claim 2 , wherein current flow across the terminal and the material patch results in ohmic heating of the polymer matrix of the material patch, wherein excess current flow causes the polymer matrix to rise above its designed transition temperature, causing the polymer matrix to expand wherein the electrically conductive magnetic particles move apart, breaking the flow of current across the material patch.

6. The method of claim 1 ,

wherein when the polymer matrix is above the designed transition temperature the eddy currents will flow only within each of the electrically conductive magnetic particles and the electrical loss will be relatively low;

wherein when the polymer matrix is below the designed transition temperature and the electrically conductive magnetic particles are in close mechanical contact the eddy currents will flow through the electrically conductive magnetic particles and the polymer matrix and the losses will be significantly higher.

7. The method of claim 6 , comprising:

detecting the change in the polymer matrix dissipative loss by an external circuit that is magnetically coupled to the polymer matrix.

8. The method of claim 7 , wherein an oscillator whose inductive element is magnetically coupled to the polymer matrix is used to detect the change in the polymer matrix dissipative loss.

9. The method of claim 7 , wherein an inductor is located near the material patch, sufficiently closely that some or all of the inductor's magnetic field flows through the material patch, the inductor forms part of a resonant system whose quality is a function of the magnetic properties of the material patch, wherein as the material patch rises above the designed transition temperature the electrically conductive magnetic particles of the polymer matrix separate, the eddy current losses drop, and the quality of the resonant circuit or system rises.

10. A method of detecting temperature of an electrical terminal comprising:

applying a polymer matrix with a polymeric positive temperature coefficient material which contains a mixture of electrically conductive magnetic particles to a surface of the electrical terminal;

exciting the electrically conductive magnetic particles with an AC magnetic field to cause eddy currents to flow within the electrically conductive magnetic particles;

remotely sensing a change in the material with an electrically isolated circuit which is external to the electrical terminal to determine if the electrical terminal is operating at a safe temperature to optimize current flow across the electrical terminal.

11. The method of claim 10 , wherein thermal expansion of the polymer matrix results in a magnetic field which is a non-linear function of temperature, wherein below a designed transition temperature, the polymer matrix does not expand or has minimal expansion and the electrically conductive magnetic particles are in close mechanical contact and above the designed transition temperature, the polymer matrix expands causing the electrically conductive magnetic particles to move apart and form individual islands.

12. The method of claim 10 , wherein current flow across the electrical terminals and the material results in ohmic heating of the polymer matrix, wherein excess current flow causes the polymer matrix to rise above a designed transition temperature, causing the polymer matrix to expand, wherein the electrically conductive magnetic particles move apart, breaking the flow of current across the material.

13. The method of claim 10

wherein when the polymer matrix is above a designed transition temperature the eddy currents will flow only within each of the electrically conductive magnetic particles and the electrical loss will be low;

wherein when the polymer matrix is below the designed transition temperature and the electrically conductive magnetic particles are in close mechanical contact the eddy currents will flow through the electrically conductive magnetic particles and the polymer matrix and the losses will be higher.

14. The method of claim 13 , comprising:

detecting the change in the polymer matrix dissipative loss by an external circuit that is magnetically coupled to the polymer matrix.

15. The method of claim 14 , wherein an oscillator whose inductive element is magnetically coupled to the polymer matrix is used to detect the change in the polymer matrix dissipative loss.

16. The method of claim 14 , wherein an inductor is located near the material, wherein some or all of the inductor's magnetic field flows through the material, the inductor forms part of a resonant system whose quality is a function of the magnetic properties of the material, wherein as the material rises above the designed transition temperature the electrically conductive magnetic particles of the polymer matrix separate, the eddy current losses drop, and the quality of the resonant circuit or system rises.

17. The method of claim 10 , wherein a thermal mass of the material is less than 25 percent of a thermal mass of the electrical terminal.

18. A method of detecting temperature of an electrical terminal comprising:

applying a material which contains a mixture of electrically conductive magnetic particles to a surface of the electrical terminal;

exciting the electrically conductive magnetic particles with an AC magnetic field to cause eddy currents to flow within the electrically conductive magnetic particles;

remotely sensing a change in the material with an electrically isolated circuit which is external to the electrical terminal to determine if the electrical terminal is operating at a safe temperature to optimize current flow across the electrical terminal.

19. The method of claim 18 , wherein thermal expansion of the material results in a magnetic field which is a non-linear function of temperature, wherein below a designed transition temperature, the material does not expand or has minimal expansion and the electrically conductive magnetic particles are in close mechanical contact and above the designed transition temperature, the material expands causing the electrically conductive magnetic particles to move apart and form individual islands.

20. The method of claim 18

wherein when the material is above a designed transition temperature the eddy currents will flow only within each of the electrically conductive magnetic particles and the electrical loss will be low;

wherein when the material is below the designed transition temperature and the electrically conductive magnetic particles are in close mechanical contact the eddy currents will flow through the electrically conductive magnetic particles and the losses will be higher.