Arc-Resistant Power Terminal with Insulated Tongue Bosses
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Solution Overview
Problem
The aerospace industry faces challenges with arcing and shorting between electrical terminals due to increased electrical voltages and frequencies, as well as environmental factors like humidity, which can lead to damage and system shutdowns, and existing methods to prevent arcing are insufficient.
Innovation Solution
An arc-resistant electrical terminal design featuring a conductive tongue with raised bosses and a dielectric insulation layer, where the insulation material covers the tongue except for the bosses, providing a conductive path while preventing arcing, and optionally incorporating a conversion coating to reduce conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If terminals are positioned close to one another to address space constraints, then space utilization is improved, but the likelihood of accidental shorting and arc tracking increases
Solution Approach 1:
A dielectric material is introduced as an intermediary substance between adjacent conductive terminals. This dielectric layer prevents direct electrical contact and arc tracking while allowing the terminals to remain in close proximity, thus maintaining space utilization while eliminating the harmful arcing effect.
Solution Approach 2:
The dielectric material is applied selectively to specific surfaces of the terminals where arc tracking is most likely to occur. This localized application provides protection exactly where needed while minimizing the impact on overall terminal functionality and space requirements.
2Object-affected harmful factors
If mechanical dividers are used to isolate terminals, then arc tracking is reduced, but device complexity increases
Solution Approach 1:
The patent replaces mechanical dividers with a dielectric coating or layer applied to the terminal surfaces. This substitution eliminates the need for complex mechanical separation structures while providing effective electrical isolation and arc tracking prevention through the insulating properties of the dielectric material.
3Object-affected harmful factors
If separation distances between terminals are increased, then arc tracking is prevented, but space utilization deteriorates
Solution Approach 1:
Instead of increasing physical separation distance, a dielectric material is introduced as an intermediary layer between terminals. This allows terminals to maintain minimal physical spacing while the dielectric layer provides the necessary electrical isolation to prevent arc tracking.
4Ease of operation
If terminals are exposed for making electrical contact, then ease of operation is improved, but the risk of electrocution and arcing increases
Solution Approach 1:
The dielectric material is applied selectively to specific surfaces of the terminals, leaving contact surfaces exposed for electrical connection while covering other surfaces where arc tracking could occur. This localized differentiation maintains operational ease while providing protection against electrocution and arcing.
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 terminal significantly reduces arcing and associated damage, preventing arcing for up to eight hours in humid conditions, compared to conventional terminals which experience arcing within minutes, thereby enhancing safety and reliability.
Implementation Method 1
A layer of insulation material is formed on at least a portion of the tongue for preventing arcing at a connection point
Implementation Method 2
a conversion coating layer is formed on the electrically conductive material of at least a portion of the tongue for reducing the conductivity of the tongue portion
Data Source
AI summary
An arc-resistant electrical terminal (100) includes a mount portion (104) and a wire receiving portion (102) formed of an electrically conductive material. The wire receiving portion (102) is configured to be crimped onto a wire. The mount portion (104) includes a solid tongue (116) having opposing face surfaces. An aperture (126) is formed between the opposing face surfaces for connecting the terminal to a connection point. A layer of insulation material (230) is formed on at least a portion of the tongue for preventing arcing at a connection point. A raised boss (220a, 220b) is formed to surround the aperture (126) on at least one of the opposing face surfaces of the tongue (116), the raised boss providing an electrically conductive surface of the terminal (100) free from the layer of insulation material for connection to a connection point.