Connector With Annular Magnetic Core and Partitioned Potting
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Solution Overview
Problem
Conventional connectors configured to also function as surge reduction devices face productivity issues due to the time required for curing liquid insulating potting agents used to protect magnetic cores from external inputs like vibration.
Innovation Solution
A connector design that includes a housing chamber partitioned into separate spaces, with a solidified liquid insulating potting agent used only in the vicinity of the core assembling portion to cover the magnetic core, reducing the amount of potting agent needed and shortening curing time, while guiding conductors and providing structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid insulating potting agent is filled in the entire housing chamber to protect the magnetic core from external inputs, then protection against vibration is improved, but curing time increases and productivity decreases
Solution Approach 1:
The housing chamber is divided into a first space and a second space by a partition wall. The liquid insulating potting agent is filled only in the first space where the magnetic core is located, rather than the entire housing chamber. This segmentation reduces the volume of potting agent required and shortens the curing time while still providing adequate protection against vibration for the magnetic core.
Solution Approach 2:
The potting agent is applied locally only where needed - in the first space surrounding the magnetic core - rather than uniformly throughout the entire housing chamber. This local application provides sufficient protection against external inputs while reducing the overall amount of material and curing time required.
2Reliability
If liquid insulating potting agent is filled in the entire housing chamber, then comprehensive protection is improved, but the amount of material used increases
Solution Approach 1:
The housing chamber is segmented into two spaces, with the potting agent confined to the first space. This eliminates unnecessary material usage in the second space while maintaining comprehensive protection for the magnetic core and conductors in the first space.
Solution Approach 2:
The unnecessary portion of the potting agent that would fill the second space is extracted from the design. The partition wall removes the need for material in the second space, reducing the quantity of substance required while preserving the protective function where it is actually needed.
3Device complexity
If the housing chamber is not partitioned, then structural simplicity is improved, but protection effectiveness and material efficiency decrease
Solution Approach 1:
A partition wall is introduced to divide the housing chamber into two functional spaces. This segmentation improves protection effectiveness by concentrating the potting agent where it is needed and reduces material usage by eliminating unnecessary material in the second space, while adding only minimal structural complexity.
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 design enhances productivity by reducing the amount of potting agent used, shortening curing time, and improving protection against external inputs, maintaining electrical connections, and enhancing heat dissipation and liquid-proof performance.
Implementation Method 1
protect a magnetic core from such an external input... rattling between a magnetic core and a housing is suppressed by filling a liquid insulating potting agent
Implementation Method 2
liquid insulating potting agent filled in the vicinity of the core assembling portion
Data Source
AI summary
A connector includes: a plurality of conductors; a magnetic core; a housing; and an insulator that locates a core assembling portion therein, the core assembling portion being composed of the respective intermediate portions of the plurality of conductors and the magnetic core, the housing chamber is at least partitioned into a first space in which the core assembling portion is housed and a second space in which the first electrical connection portion and the first counterpart conductor side are housed and are physically and electrically connected to each other, and the insulator is a solidified material of a liquid insulating potting agent filled in the vicinity of the core assembling portion in the first space in order to cover the core assembling portion.