Angled High-Voltage Connector with Threaded Wall Mount

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Solution Overview

Problem

Connecting high-voltage conductors poses challenges such as ensuring tightness and functional reliability, particularly when reconnecting external conductors to high-voltage boxes, where internal connections can lead to contamination or leaks, and external connections result in high contact resistance due to limited spring contact force, causing heating and failure.

Innovation Solution

A high-voltage connector with an angled housing featuring a socket made of insulating material like glass fiber reinforced polyamide, which securely connects to the wall of an electrical component through a threaded shaft, allowing for reliable and compact line connections by using a nut and screw mechanism, and a sealing ring to prevent leaks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If internal connections are used to connect high-voltage conductors inside the high-voltage box, then the connection is compact and protected, but contamination or leaks occur and the box must be opened for external connections

Engineering Contradiction:

Improveconnection reliabilityVSAvoidcontamination and leaks

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The device divides the connection system into two separate modules: a high-voltage box for power distribution and an external connector for line connections. This segmentation allows the connector to be opened and closed independently without affecting the high-voltage box integrity, eliminating contamination risks while maintaining compact internal connections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An intermediate connector module is introduced between the high-voltage box and external conductors. This mediator contains the connection mechanism outside the high-voltage box, allowing secure connections to be made externally without opening the high-voltage box, thus preventing contamination and leaks.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If external connections are made via a plug, then the high-voltage box remains sealed, but high contact resistance occurs due to limited spring contact force

Engineering Contradiction:

Improvetightness and sealingVSAvoidcontact resistance and heating

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The device replaces weak spring contacts with a robust screw connection mechanism. The threaded shaft and nut provide mechanical advantage, enabling high clamping force to be applied to the conductor, thereby eliminating high contact resistance and heating issues while maintaining external connectivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If the high-voltage box is opened to make external line connections, then connections can be made, but the tightness and functional reliability of the high-voltage box are compromised

Engineering Contradiction:

Improveaccessibility for connectionsVSAvoidtightness and functional reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system is segmented into a sealed high-voltage box and an external connector module. The connector can be independently accessed and operated without opening the high-voltage box, maintaining the box's tightness and reliability while providing easy access for making external line connections.

Inventive Principle:

Principle #1Segmentation

4Device complexity

If spring contacts are used for external connections, then the connection is simple, but excessive heating and failure occur due to limited contact force

Engineering Contradiction:

Improveconnection simplicityVSAvoidheating and failure

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The simple spring contact mechanism is replaced with a screw connection system. The threaded shaft and nut provide mechanical advantage, enabling high clamping force to be applied to the conductor, thereby eliminating excessive heating and failure while maintaining ease of operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3807959B1Device for connecting high-voltage conductors

Publication Date: 2022.12.07 EUGEN FORSCHNER

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AI summary

The invention relates to a device for connecting a first high-voltage conductor (20) and a second high-voltage conductor (30) by means of a high-voltage connector (100), which has an angled housing (110) with a first housing part (111) for introducing the first high-voltage conductor (20) and a second housing part (112) for introducing the second high-voltage conductor (30), wherein a cover (115) for releasing or closing an assembly opening (113) is arranged on at least one of the housing parts (111, 112). The device according to the invention is characterised in that the first conductor (30) can be guided through a through-opening (14) in a wall (12) of an electrical component (10) for connecting to the electrical component (10), and in that the first housing part (111) of the high-voltage connector (100) accommodating the first conductor (30) is provided with means (140, 148, 150, 152) for connecting to the wall (12) of the electrical component (10).