Electrical Connection Cover With Isolation Slots for High-Voltage Protection

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Solution Overview

Problem

Existing electrical connections lack adequate protection against small Foreign Object Debris (FOD) and voltage breakdown, particularly at high voltages, and do not provide sufficient safety for personnel from accidental contact.

Innovation Solution

An electrical assembly featuring a cover with isolation slots and a base that secures conductors, using a dielectric material to create long creepage distances and prevent line of sight between conductors, while allowing easy repair and service.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If dielectric covers with large openings are used for mechanical clearance and tolerance, then ease of assembly is improved, but protection against small FOD and voltage breakdown deteriorates

Engineering Contradiction:

Improveease of assemblyVSAvoidprotection against small FOD and voltage breakdown

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The cover is segmented into multiple isolation slots that separate different conductors and electrical components. Each slot acts as an independent isolation barrier, allowing the cover to provide comprehensive protection while maintaining assembly ease through modular design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cover transitions from generic uniform design to localized specialized slots. Each isolation slot is specifically designed for particular conductors or components, providing targeted protection against small FOD and voltage breakdown at critical locations while maintaining overall assembly simplicity

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If air gap spacing and surface creepage spacing are reduced to accommodate higher voltages, then device compactness is improved, but voltage breakdown protection deteriorates

Engineering Contradiction:

Improvedevice compactnessVSAvoidvoltage breakdown protection

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The design extends protection into the third dimension by creating vertical isolation slots that penetrate the cover. This dimensional approach allows adequate creepage distances to be maintained within a compact overall form factor, as the isolation occurs through the depth of the cover rather than just surface distance

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The cover utilizes dielectric material properties to provide electrical isolation. The combination of the dielectric material with the slot geometry creates a composite protection system that maintains voltage breakdown protection while enabling compact device design

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If generic cover designs are used for personnel protection, then manufacturing simplicity is improved, but protection against reaching around and touching electrical connections deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidprotection against reaching around

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The cover is divided into multiple isolation slots that physically segment access to different electrical connections. This segmentation prevents personnel from reaching around to touch connections that are isolated within individual slots, while the overall cover structure remains simple to manufacture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The isolation slots act as intermediary barriers between personnel and electrical connections. These slots provide the necessary physical isolation to prevent accidental contact while maintaining a simple cover design that is easy to manufacture

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enhances protection against FOD and voltage breakdown, providing improved safety for personnel and reliable operation in high voltage and altitude environments.

Implementation Method 1

using a dielectric material to create long creepage distances and prevent line of sight between conductors

Methodology Applied

Scientific EffectDielectric: Dielectric

Implementation Method 2

create long creepage distances

Methodology Applied

Scientific EffectCreepage distance:

Implementation Method 3

configured for receiving and electrically and mechanically isolating the first conductor and the second conductor from each other and from each fastener

Methodology Applied

Scientific EffectElectrical isolation:

Data Source

PatentEP3822998B1Electrical connection protection

Publication Date: 2026.03.04 HAMILTON SUNDSTRAND CORP

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AI summary

An electrical assembly (100) including a first conductor (102), at least a second conductor (104) parallel and electrically isolated from the first conductor (102), a component (106) connecting to the first conductor (102) and the second conductor (104), a cover (112) including fastener slots (116 a-c) each configured for receiving a fastener (114) therein configured for securing the cover (112) partially within the component (106), and including at least two isolation slots (118a/b) each configured for receiving and electrically and mechanically isolating the first conductor (102) and the second conductor (104) from each other and from each fastener (114), and a base (120) configured to secure and align the cover (112) and the component (106).