Pin and Sleeve Connector Safety Insulator Plug

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Solution Overview

Problem

Existing pin and sleeve electrical connectors pose safety risks when removable electric modules expose live high voltage connections, as existing isolation methods are bulky, unreliable, or ineffective in dirty environments.

Innovation Solution

A female sleeve connector coated with a nonconductive material and equipped with a pressure-loaded insulator plug that compresses to make electrical contact and then pushes against the exterior surface when the pin is removed, ensuring safety without bulky moving parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional isolation methods (doors, shutters, curtains) are used to protect against exposed live high voltage connections, then safety is improved, but the device becomes bulky and large

Engineering Contradiction:

ImprovesafetyVSAvoidsize of isolation mechanism

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The insulator plug is nested within the female sleeve connector, fitting inside the existing structure. This eliminates the need for external isolation components while maintaining safety, as the insulator plug integrates the protective function within the connector's own volume.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The harmful conductive portion is isolated by extracting the insulating function into a separate insulator plug component. This plug can be inserted to block access to the live electrical connections, removing the hazard without requiring bulky external shielding structures.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If traditional isolation methods (doors, shutters, curtains) are used to protect against exposed live high voltage connections, then safety is improved, but the system becomes unreliable over time and in dirty environments

Engineering Contradiction:

ImprovesafetyVSAvoidlongevity of isolation mechanism

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The insulator plug incorporates a pressure mechanism that automatically maintains its position and sealing function without external intervention. The mechanism self-adjusts to ensure continuous insulation, eliminating the need for maintenance or replacement even in harsh dirty environments.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The insulator plug uses flexible insulating material that can conform to the connector interior and maintain effective isolation. This flexible design is more resilient to environmental degradation compared to rigid traditional isolation components, ensuring long-term reliability in dirty conditions.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If an insulator plug with pressure mechanism is added inside the female sleeve, then safety is improved, but the device complexity increases

Engineering Contradiction:

ImprovesafetyVSAvoidcomplexity of connector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulator plug combines multiple functions into a single integrated component: electrical insulation, mechanical blocking of access, and pressure-actuated operation. This merging reduces the number of separate parts needed compared to traditional isolation systems with multiple moving components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulator plug acts as an intermediary element between the male pin and the conductive portion of the female sleeve. It provides a simple intermediate barrier that eliminates the need for complex multi-stage isolation mechanisms, achieving safety through a single mediating component.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 high level of safety for pin and sleeve electrical connections in high voltage applications, particularly in dirty environments, without adding large or troublesome components, ensuring reliable isolation even when used in mining and manufacturing.

Implementation Method 1

A pressure mechanism is provided inside the female connector

Methodology Applied

Scientific EffectPressure mechanism: Mechanical Force

Implementation Method 2

the female (sleeve) connector exterior surface is coated or made from one or more nonconductive insulating material

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentUS10950966B2Safety stab technology

Publication Date: 2021.03.16 AMERICAN MINE RES

AI summary

A stab (pin and sleeve) electrical connector with improved safety is described. The female (sleeve) connector exterior surface is coated or made from with a nonconductive insulating material. A pressure loaded insulator plug is disposed inside the female sleeve. An electrical connection is made when the male (pin) connector is inserted into the female sleeve. The male pin contacts the insulator plug inside the female sleeve, causing compression, and makes electrical contact with the uninsulated inside of the sleeve. As the male pin is removed, the pressure mechanism of the insulator plug pushes the plug out flush with the external insulated surface making the female sleeve touch safe. Therefore, embodiments provide a high level of safety for the pin and sleeve electrical connection method without adding large or troublesome moving parts.