Heat-Sensing Plastic

Temperature indicator in generic baby spoons, bottle and straws.

What is this?

It is normally impossible to know the temperature of an object without touching it, which makes thermochromic materials fascinating because they make visible what is normally invisible. The colorful electrical plugs and wiring in the picture (on the photo of the sample) make clever use of thermochromic technology – excessive, possibly dangerous, heat is marked by a change of color in the plug casing and cable jacket. The process is reversible, so the color reverts to the original hue once the equipment cools down. In addition to heat, the technology can also provide other sensory signals of over-heating wiring such as a foul smell or deformation.

Color-changing electrical equipment is useful in every industry where heavy use of plug and cord sets creates the potential for a significant fire hazard, or down-time. Thermochromic materials have many other applications. Existing uses include battery-testing labels, heat sensing for microwaveable foods, and temperature sensors for chilled beverages. And virtually any reversible color combination (cold and hot) can be ordered along with trigger temperatures from 10F to 170F and in most low temperature polymers. Also consider an irreversible color change to notify manufacturers of warranty voids or where visual inspections occur periodically.

How does the wire coating detect malfunctions? What different elements can the wire detect?

Thermochromic materials are encapsulated pigments which react to heat by temporarily and reversibly losing their ‘cold’ color. Once the heat source is removed the thermochromic material reverts to its original ‘cold’ color again.

Are there limits to the effect colors?

The thermochromic material can be ordered in almost any color ‘cold and hot’.

What are usual wire applications?

-Extension Cords
-Power Cords
-Surge Protectors
-Retractile Cords
-Coil Cords
-Flexing-type Cords
-Continuous Charge Cords
-Welding Cables
-Emergency and Temporary Power Cords
-Outdoor & Garden Cable
-Battery Charging Cords
-Spark and Glow Plug Wire
-Motor, Relay and Solenoid Wire
-Portable GFCI Hook-ups
-Thermocouple Cable
-Wiring Harnesses
-Festoon Cables
-Composite Cables

What are typical device applications?

-Kitchen Appliances (Toasters, electric fry pans, coffee makers)
-Bathroom Appliances (Hair dryers, curlers)
-Heating Appliances (Irons, Infrared and Space Heaters)
-Power Tools (Power drills, saws, air compressors, other job-site equip.)
-Electric Motors (Blowers, HVAC, people-movers, garage door motors)
-Transformers/Relays (Utility meters, transmission lines, breaker boxes,
-Portable Generators (Temporary back-ups, Mobile/RV parks)
-Welding Equipment (Power Supply cords, welding leads)
-Battery cabling (jumper cables, charging devices, starting motor wiring)
-Temporary Lighting (emergency, outdoor events, holiday displays)
-Electric Appliances (PC’s, office HW, stereo/TV, gaming equip.)
-Vacuum Cleaners (retractile cords, rough /commercial use)
-Freeze-proofing Cable (roof and window de-icers, pipe defrosters)