Arc Suppression Element for Electrical Connectors
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Solution Overview
Problem
Conventional electrical connectors face damage and arcing issues during disconnection in high voltage applications, requiring complex and costly solutions to prevent arcing, which are not suitable for many applications.
Innovation Solution
An electrical connector with an arc suppression element that increases resistance after disconnection, using a variable resistive material like positive temperature coefficient materials, to prevent arcing by maintaining an electrical connection through a secondary channel until the current falls below the arcing threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional electrical connectors are disconnected while carrying current, then the connectors can be separated, but electrical arcing occurs causing damage to terminals and connector components
Solution Approach 1:
An arc suppression element is introduced as an intermediary component between the male and female terminals. This element provides a controlled path for current during disconnection, preventing uncontrolled arcing. The element is positioned in a secondary channel and makes sequential contact - establishing connection after the female terminal disconnects from the male terminal, and maintaining connection until the male terminal fully disengages from the housing.
Solution Approach 2:
The arc suppression element is pre-positioned in the secondary channel such that it automatically engages in the correct sequence during disconnection. The element's position ensures it contacts the male terminal after the female terminal disconnects but before the male terminal leaves the housing, preparing a safe current path in advance of potential arcing conditions.
2Object-affected harmful factors
If complex locking features or current shut-off circuits are added to prevent arcing, then arcing is suppressed, but device complexity and cost increase
Solution Approach 1:
The arc suppression element operates automatically based on the mechanical sequence of disconnection alone, without requiring external control circuits, sensors, or active components. The element's position and the natural movement of the male terminal during disconnection provide all necessary control, making the system self-regulating and eliminating complex control mechanisms.
Solution Approach 2:
The arc suppression element is designed as a simple, inexpensive passive component that can be easily manufactured and integrated into the connector housing. Rather than using expensive active components or complex circuits, a simple conductive element provides the necessary arc suppression function at minimal cost.
3Reliability
If the arc suppression element maintains low resistance during disconnection, then current can flow through the bypass path, but arcing may still occur
Solution Approach 1:
The arc suppression element's resistance is made dynamic rather than static. The element exhibits low resistance when contacting the male terminal to provide a current bypass path, but transitions to high resistance after the male terminal disconnects. This dynamic resistance change is achieved through material properties or mechanical design that responds to the disconnection state, automatically adapting the electrical characteristics to the operational phase.
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
Enables safe and reliable disconnection of live electrical connections without arcing, making the connectors hot swappable and reducing the risk of damage, while simplifying the design and reducing costs.
Implementation Method 1
using a variable resistive material like positive temperature coefficient materials
Data Source
AI summary
An electrical connector matable to and unmatable from a separable mating electrical connector includes a housing having a terminal channel and a secondary channel. The electrical connector also includes a female terminal received in the terminal channel. The female terminal is matable with and unmatable from a mating male terminal of the mating electrical connector. An arc suppression element is received in the secondary channel. The arc suppression element configured to electrically couple between the female terminal and the male terminal immediately after the female terminal is disengaged from the male terminal, the arc suppression element providing a bypass between the female terminal and the male terminal so that arcing does not occur when the female terminal is disconnected from the male terminal of the mating electrical connector.