Plug-In Connector Screw Isolation for Safe High-Voltage Assembly
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Solution Overview
Problem
Existing electrical connectors for high-voltage and high-current applications, particularly in battery cell modules, face complexity in touch protection due to screw connections aligned with insertion direction, requiring additional components and increasing the risk of dangerous electrical contact during assembly.
Innovation Solution
An electrical connector design with an insulating housing and a screw mechanism where the screw shank is insulated from the contact element assembly, using an elastic element to maintain electrical isolation until tightened, ensuring safe assembly and secure mechanical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional contact sleeves and touch protection areas are provided, then touch protection is improved, but the complexity of the connector structure increases
Solution Approach 1:
The patent merges the touch protection function with existing structural components by integrating insulating elements into the contact sleeve and housing structures. This approach provides reliable touch protection without adding separate dedicated touch protection components, thereby maintaining structural simplicity while improving safety.
Solution Approach 2:
The patent introduces insulating elements as intermediary components that provide touch protection while maintaining electrical isolation. These insulating elements act as mediators between conductive parts and external environments, ensuring safety without requiring complex additional protection structures.
2Strength
If the screw is tightened in the insertion direction with contact sleeves, then mechanical connection is achieved, but the risk of dangerous electrical contact during assembly increases
Solution Approach 1:
The patent implements preliminary electrical isolation measures by pre-installing insulating elements on contact sleeves and around the screw pathway before the tightening operation. This preliminary action ensures that electrical isolation is already in place during the assembly process, preventing dangerous electrical contact risks before they can occur.
Solution Approach 2:
The patent uses insulating elements as intermediary barriers between the screw and conductive components during the tightening process. These intermediaries maintain electrical isolation throughout the mechanical connection process, allowing the screw to be tightened in the insertion direction without creating electrical contact hazards.
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
Provides simplified touch protection by maintaining electrical isolation during assembly, reducing the risk of lethal electrical contact and ensuring a stable, long-term mechanical connection.
Implementation Method 1
an elastic element is arranged between a screw head of the screw and the contact element arrangement, which in an un-screwed state of the screw and the nut distances a bearing surface of the screw head from the contact element arrangement and in a screwed state of the screw and the nut is compressed in such a way that the bearing surface is electrically and mechanically connected to the contact element arrangement
Data Source
Figure 1~2A
Figure 2B~2C
Figure 2D~3B
AI summary
The present invention relates to an electrical connector. The present invention further relates to an electrical plug connection. An electrical connector (4) for electrical and mechanical connection with a corresponding mating electrical connector (5) has an electrically insulating housing (9), a contact element assembly (15), and a screw (6) for screwing it to a nut (8) of the mating connector (5). A passage (16) is formed in the contact element assembly (15) through which a screw shank (17) of the screw (6) passes. The screw shank (17) is electrically insulated from an inner wall (18) of the passage (16).An elastic element (22) is arranged between a screw head (23) of the screw (6) and the contact element arrangement (15), which in an un-tightened state of the screw (6) and the screw nut (8) distances a bearing surface (26) of the screw head (23) from the contact element arrangement (15) and in a tightened state of the screw (6) and the screw nut (8) is compressed such that the bearing surface (26) is electrically and mechanically connected to the contact element arrangement (15).