Dual Interface Separable Insulated Connector with Overmolded Faraday Cage
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Solution Overview
Problem
Conventional separable insulated connectors face challenges in bonding insulating material to metal bus bars, leading to air gaps, corona discharge, and potential disconnection of faraday cages, which are costly and environmentally problematic due to the use of adhesives and require labor-intensive smoothing of bus bar surfaces.
Innovation Solution
A dual interface separable insulated connector with a semi-conductive rubber faraday cage molded over a bus bar eliminates the need for adhesive bonding, ensuring a strong and consistent electric potential, reducing the risk of air gaps and disconnection, and simplifying the manufacturing process by avoiding the need to smooth the bus bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive material is used to bond insulating material to metal bus bars, then bonding strength is improved, but manufacturing cost increases and environmental harm occurs due to toxic adhesives
Solution Approach 1:
The patent removes the adhesive bonding step entirely from the manufacturing process. Instead of using adhesive material to bond insulating material to metal bus bars, the invention uses a semi-conductive rubber faraday cage molded directly over the bus bar, eliminating the need for toxic adhesives and their associated environmental harms while maintaining bonding strength through the molded rubber structure
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical/molding system. The semi-conductive rubber faraday cage is molded directly over the bus bar using rubber injection molding technology, creating a strong mechanical bond without requiring chemical adhesives. This substitution eliminates toxic emissions while maintaining or improving bonding strength
2Strength
If adhesive material is used to bond insulating material to metal bus bars, then bonding strength is improved, but manufacturing cost increases due to expensive adhesive materials and processes
Solution Approach 1:
The patent eliminates the adhesive application step and associated costs. By using direct rubber injection molding to create the semi-conductive faraday cage over the bus bar, the process removes the need for expensive adhesive materials and the labor-intensive application and curing processes, reducing overall manufacturing cost while maintaining bonding strength
Solution Approach 2:
The rubber injection molding process creates a self-bonding structure where the semi-conductive rubber faraday cage bonds to itself and to the bus bar through the molding process. The rubber material inherently bonds to metal surfaces during curing, eliminating the need for separate adhesive application steps and reducing manufacturing complexity and cost
3Manufacturing precision
If metal bus bar surfaces are smoothed before bonding, then bonding quality is improved, but manufacturing time increases due to labor-intensive smoothing operations
Solution Approach 1:
The patent changes the material parameter of the faraday cage from rigid metal to flexible semi-conductive rubber. This parameter change allows the rubber material to conform to the as-cast bus bar surface irregularities through elastic deformation during molding, eliminating the need for time-consuming surface smoothing operations while maintaining bonding quality and electrical performance
4Reliability
If conventional metal cups are used as faraday cages, then electrical shielding is achieved, but bonding to insulating material becomes difficult and air gaps form
Solution Approach 1:
The patent creates a composite structure where semi-conductive rubber material is molded directly over the metal bus bar, forming an integrated faraday cage. This composite of rubber and metal provides both the electrical shielding properties of the metal and the bonding capabilities of the rubber, eliminating air gaps and achieving strong bonding to insulating material while maintaining electrical shielding effectiveness
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 solution provides a strong, adhesive-free bond between the insulating material and the faraday cage, preventing corona discharge and ensuring a reliable connection while reducing manufacturing costs and environmental impact by eliminating the need for toxic adhesives and labor-intensive bus bar smoothing.
Implementation Method 1
A dual interface separable insulated connector with a semi-conductive rubber faraday cage molded over a bus bar eliminates the need for adhesive bonding
Implementation Method 2
The purpose of a faraday cage is to shield all gaps of air within the mating components of the separable insulated connector, as these air gaps can cause corona discharge within the connector
Data Source
AI summary
A dual interface separable insulated connector comprising a faraday cage molded over a bus bar for use in an electric power system and a method of manufacturing the same are provided. The faraday cage can be disposed within a semi-conductive shell. The configuration of the separable insulated connector can provide for easier bonding between the faraday cage and insulating material. Additionally, the configuration can eliminate or reduce the need to coat the bus bar with an adhesive agent and to smooth the metal bus bar to remove burrs, other irregularities, and sharp corners from the bar. Manufacturing the dual interface separable insulated connector can include molding a semi-conductive rubber faraday cage over a conductive bus bar, inserting the faraday cage into a shell, and injecting insulating material between the faraday cage and shell.