Electrical Connector Insulating Shutter for Shock Protection
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Solution Overview
Problem
Existing electrical connectors pose a risk of electric shock to users due to direct or indirect contact with conductive components, and existing protective measures are complex to manufacture or do not adequately prevent contact.
Innovation Solution
An electrical connector design featuring radially flexible blades with an insulating jacket and a movable insulating component, combined with a return mechanism, to prevent radial and axial electrical contact, and a snap-fitted insulating component to ensure safety without complicating manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent protection (insulator with cage and central finger) is implemented, then user safety is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent employs a movable insulating component that dynamically changes position between a first position (blocking access when male contact is absent) and a second position (allowing access when male contact is inserted). This dynamic mechanism replaces static complex structures like cages and central fingers, achieving safety through motion rather than permanent physical barriers.
Solution Approach 2:
The insulating component is designed to be automatically actuated by the insertion of the male contact itself. The male contact pushes the insulating component from the first position to the second position, eliminating the need for separate actuation mechanisms or complex control systems. The system serves itself using the operational element as the actuator.
2Ease of manufacture
If movable cap protection is used, then manufacturing simplicity is improved, but user safety deteriorates due to exposure during cap removal
Solution Approach 1:
The insulating component is positioned in advance (in the first position) to block access to the blades before the male contact is even inserted. This preliminary protective action occurs automatically as part of the connector's default state, eliminating the need for users to manually remove caps or take protective actions before connection.
Solution Approach 2:
The insulating component acts as an intermediary element between the user and the conductive blades. It provides automatic protection during the transition state when the connector is being operated, mediating the interaction between user actions and electrical components without requiring manual intervention.
3Reliability
If insulator with small space between finger and cage bars is used, then direct contact prevention is improved, but indirect contact through conductive objects is not prevented
Solution Approach 1:
Rather than relying on fixed small spaces that can be bridged by conductive objects, the patent uses a dynamic insulating component that completely blocks the entry to the housing when in the first position. This dynamic barrier prevents both direct contact and indirect contact through objects, as the insulation is positioned to seal the access path entirely.
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 design effectively reduces the risk of electric shock while maintaining a simple and cost-effective manufacturing process, allowing for safe and efficient electrical connections.
Implementation Method 1
the return mechanism comprises a spring compressed axially and situated axially between the insulating component and the bottom of the housing
Data Source
AI summary
An electrical connector is provided which has a male contact and a female contact movable between an uninserted configuration and an inserted configuration, wherein the male contact is inserted along an axis of insertion into a housing of the female contact. The female contact includes a body, a plurality of blades, and a protective system that has an insulating jacket surrounding the blades, an insulating component movable in axial translation with respect to the body between a rest position, wherein the insulating component at least partially closes the housing and abuts axially against the female contact, and a pushed-in position, wherein the insulating component is pushed towards the bottom of the housing by the male contact, and a mechanism for returning the insulating component to the rest position.