Medium Voltage Connector With Conical Elastomeric Interface
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Solution Overview
Problem
Existing medium voltage distribution stations face complexity in connecting electrical equipment due to the need for compact and reliable connections, which are often compromised by high voltages and maintenance challenges, particularly when using flat compressible interfaces that require uniform technological solutions.
Innovation Solution
A connector system featuring a frustoconical connection end piece with a flexible elastomeric material and a rigid shell, combined with a deformable insulating support and conductive insert, allows for secure and compact connections by expelling air during injection and utilizing a compressible material to form a funnel-shaped connection zone, ensuring electrical continuity and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid bars with plug-in connectors are used for medium voltage connections, then connection reliability is improved, but device complexity and maintenance difficulty increase
Solution Approach 1:
The patent changes the physical state of the connection interface by introducing a compressible elastomeric material that transforms the rigid connection into a flexible, self-adjusting connection. The elastomer's compressibility parameter allows the connection to accommodate dimensional variations while maintaining reliable electrical contact, thereby reducing complexity without sacrificing reliability
Solution Approach 2:
The invention combines rigid conductive cores with flexible elastomeric materials to create a composite connection structure. The rigid shell provides structural integrity and electrical conductivity, while the elastomeric material provides compliance and sealing, resulting in a connection that is both reliable and simple to implement
2Volume of stationary object
If flat compressible interfaces are used to reduce bulk, then volume is reduced, but adaptability to different connector types decreases
Solution Approach 1:
The elastomeric connection interface serves multiple functions simultaneously: it provides electrical insulation, mechanical compliance, sealing, and electrical contact. This multi-functionality allows the same flat compressible interface design to work with various connector types (cables, busbars, terminals) without requiring design modifications, thereby achieving both volume reduction and universal adaptability
Solution Approach 2:
The patent uses a homogeneous elastomeric material throughout the connection interface, which provides consistent electrical and mechanical properties regardless of the specific connector type being connected. This homogeneity enables the same connection design to be universally applied across different connector configurations while maintaining compact dimensions
3Reliability
If elastomeric material is molded onto conductive core, then connection reliability is improved, but manufacturing complexity increases due to air entrapment
Solution Approach 1:
The patent employs a frustoconical (truncated cone) shape for the conductive core and elastomeric material arrangement. This conical geometry facilitates the molding process by providing a natural escape path for air bubbles during elastomer injection, preventing air entrapment while ensuring complete filling and reliable electrical contact between the elastomer and conductor
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 connector system provides a reliable, compact, and maintainable connection solution that addresses the challenges of high voltage and maintenance complexity, enabling efficient alignment and secure attachment of electrical equipment within medium voltage distribution stations.
Implementation Method 1
The height of the insert between its two connection surfaces is less than the distance between the two connection surfaces when the insulating material of the support is at rest, and greater than or equal to said distance when the material is entirely deformed by compression between its connecting surfaces
Implementation Method 2
a flexible, elastomeric material, in particular EPDM molded onto the conductive core of the connector
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
The connector (250) has a portion including an outer shell (252) made of rigid material around deformable material. An interface arranged between the deformable material and the shell is sealed. Thickness of the deformable material is increased according to a constant slope (alpha) between two ends of the portion while excluding a connection zone (260) that is adjacent to a connection part (212) of another portion. Thickness of an elastomeric material of the latter portion is increased according to a slope, which is four times that of the constant slope.