Electrical Connector Insulation Structure for Touch Protection
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Solution Overview
Problem
Existing electrical connectors pose a risk of user electrification due to direct or indirect contact with conductive components, and existing solutions like caps or insulators are complex to manufacture or do not fully prevent contact, especially when the connector is not yet fully connected.
Innovation Solution
An electrical connector design featuring a female contact with a protection system comprising an insulating envelope and a movable insulation member that translates between rest and depressed positions, combined with an insulating envelope on the male contact, to prevent axial and radial electrical contact with the user, while allowing efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If caps are placed on contacts to protect users, then user safety is improved, but device complexity and ease of operation deteriorate due to removal requirements
Solution Approach 1:
The patent applies preliminary action by pre-positioning an insulating member within the housing that automatically moves to cover conductive elements during insertion. This eliminates the need for separate protective caps that require manual removal, as the protection is already in place and activates automatically when needed.
Solution Approach 2:
The patent extracts the protective function from separate removable caps and integrates it into a permanent insulating member that is part of the housing structure. This separation of the protective function from the connector body allows the protection to be built-in while maintaining simplicity of use.
2Object-affected harmful factors
If permanent insulators are implemented to protect users, then user safety is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The insulating member serves multiple functions: it provides electrical insulation to protect users, acts as a structural component of the housing, and guides the insertion process. This multi-functionality reduces the need for separate protective components, simplifying manufacturing while maintaining safety.
Solution Approach 2:
The patent employs a thin insulating member that can be molded as a single piece and integrated into the housing. This thin-film approach reduces material usage and manufacturing complexity compared to bulky permanent insulators, while still providing effective electrical isolation.
3Object-affected harmful factors
If insulation is added to prevent direct contact, then user safety is improved, but indirect contact through conductive objects remains possible
Solution Approach 1:
The insulating member is nested within the housing structure, creating multiple layers of protection. The insulating member covers the conductive elements from multiple angles and positions, making it difficult for conductive objects to bypass the insulation and reach the electrical contacts.
Solution Approach 2:
The insulating member features an asymmetric design with varying thickness and coverage areas tailored to the specific geometry of the conductive elements. This asymmetric configuration provides enhanced protection in critical areas while maintaining overall simplicity, preventing both direct and indirect contact more effectively than symmetric designs.
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 user electrification while enabling efficient electrical connections and simplifying manufacturing, making it competitive in terms of cost and complexity.
Implementation Method 1
an insulation member (28) movable in axial translation relative to the body (12) between a rest position intended to be occupied in the non-inserted configuration, and a depressed position intended to be occupied in the inserted configuration
Implementation Method 2
The protection system (18) comprises an insulating envelope (26) surrounding the slats (16) around the insertion axis (D), and extending axially at least along the slats, the envelope being adapted to prevent electrical contact radially between a user and the slats
Implementation Method 3
The protection system (18) includes a return mechanism (30) adapted to return the insulating member (28) from the depressed position to the rest position
Data Source
Figure 1
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AI summary
Electrical connector (2) comprising a male contact (4) and a female contact (6) movable between an uninserted configuration, and an inserted configuration, in which the male contact is inserted along an insertion axis (D) into a housing (10) of the female contact, the female contact comprising: a body (12), a plurality of blades (16), and a protection system (18) comprising: - an insulating envelope (26) surrounding the blades, - an insulating element (28) movable in axial translation relative to the body between a rest position, in which the insulating element at least partially closes the housing and abuts axially against the female contact, and a pushed-in position, in which the insulating element is pushed towards the bottom of the housing by the male contact, - a return mechanism (30) of the insulating element towards the rest position.