Connector Interface Dielectric Posts for High-Voltage Isolation

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Solution Overview

Problem

Electrical connector pairs face issues with high voltage causing current leakage or voltage breakdown due to the close proximity of contacts.

Innovation Solution

The use of rectangular dielectric posts surrounding the contacts, with corresponding rectangular openings in the plug housing, forms isolation paths that prevent current leakage and voltage breakdowns when high voltage is present between contacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If contacts are arranged in close array to increase connector density, then productivity and space utilization are improved, but high voltage between contacts causes current leakage and voltage breakdown

Engineering Contradiction:

Improveconnector densityVSAvoidelectrical isolation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Dielectric posts are introduced as intermediary elements between adjacent electrical contacts. These posts act as physical barriers and electrical insulators, preventing direct current leakage paths while allowing the contacts to maintain close spacing for high density connectivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The connector interior space is segmented into isolated compartments by dielectric posts. Each contact pair is separated by these posts, creating distinct electrical zones that prevent voltage breakdown between adjacent contacts while maintaining compact overall structure.

Inventive Principle:

Principle #1Segmentation

2Reliability

If dielectric posts are added to prevent current leakage, then electrical isolation is improved, but device complexity increases

Engineering Contradiction:

Improveelectrical isolationVSAvoidconnector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The dielectric posts are merged with the connector housing as a single integrated component. The posts are molded directly into the housing structure, eliminating the need for separate assembly steps and reducing the number of discrete parts while maintaining electrical isolation functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The dielectric posts serve multiple functions simultaneously: they provide electrical insulation between contacts, maintain precise spacing between contact pairs, and act as structural support elements within the connector housing. This multi-functionality reduces the need for additional specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This configuration effectively isolates adjacent contacts, preventing current leakage and voltage breakdowns, ensuring reliable electrical connections even under high voltage conditions.

Implementation Method 1

both plug and receptacle connectors have rectangular dielectric posts surrounding the contacts and extending outwardly from a root

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentEP2705577B1High-voltage resistance of a connector interface

Publication Date: 2017.04.26 CARDIOINSIGHT TECHNOLOGIES INC

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Figure 5~6

AI summary

An electrical connector has dielectric posts surrounding the contacts and extending outwardly from the root along the contact axis a finite amount. The mating connector (or plug) has a housing that surrounds the posts. A device that includes both the electrical connector and the mating connector provides good electrical isolation between adjacent contacts.