High-Voltage Connector Seal Geometry for Partial Discharge Reduction
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Solution Overview
Problem
High-end equipment is prone to erratic signals due to low partial discharges caused by voltage gradients across entrapped air in traditional interconnects, which are challenging to minimize, especially in high-reliability applications like aerospace and deep space industries where system longevity is critical.
Innovation Solution
A low partial discharge high voltage connector design featuring a hybrid electrical seal with a convex geometry that compresses radially inward and outward, displacing air from partial discharge-sensitive regions to areas with reduced electrical flux, utilizing a multi-layer seal comprising semi-conductive and insulative materials to prevent electrical breakdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing regions are used in connectors, then sealing function is provided, but partial discharge occurs due to voltage gradient across entrapped air
Solution Approach 1:
The patent removes air from the sealing region by compressing the seal member to force air radially outward, eliminating the harmful factor (air) that causes partial discharge while maintaining the sealing function
Solution Approach 2:
The patent changes the physical state of air in the sealing region from entrapped to expelled by applying compressive force, altering the parameter of air presence from present to removed, thereby preventing partial discharge
2Reliability
If seal member is compressed to remove air from sealing region, then partial discharge is reduced, but high force is required
Solution Approach 1:
The patent employs a convex curved surface on the seal member that focuses compression force to a small initial contact region, creating radial force distribution that efficiently expels air with reduced overall compression force
Solution Approach 2:
The patent transforms the linear compression force into radial force distribution through the convex geometry, directing air expulsion in multiple radial directions simultaneously, reducing the magnitude of force needed
3Productivity
If convex seal geometry is used to force air radially outward, then air removal efficiency increases, but manufacturing complexity increases
Solution Approach 1:
The patent uses a flexible seal member made of elastomeric material that can be molded into the required convex geometry, allowing complex curved surfaces to be manufactured through standard rubber molding processes rather than rigid precision machining
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 significantly reduces the force required to remove air from high-stress regions, minimizing partial discharges and extending system longevity while maintaining effective sealing, even in high-voltage applications.
Implementation Method 1
compressing, in response to the mating, the seal member at an initial contact region between an innermost layer and an outermost layer of the seal member; and, in response to the compressing, forcing air radially inward toward the innermost layer of the seal member and radially outward toward the outermost layer of the seal member
Data Source
AI summary
Various techniques are provided for displacing air from partial discharge sensitive regions of a connector of a low partial discharge high voltage connector to other regions of the low partial discharge high voltage connector where electrical flux is reduced. A plug member is mated with a receptacle member to provide the connector, with a seal member disposed in a cavity provided by the plug member and/or the receptacle member. In response to the mating, the seal member is compressed at an initial contact region between an innermost layer and an outermost layer of the seal member. In response to the compressing, air is forced radially inward toward the innermost layer and radially outward toward the outermost layer away from the initial contact region to reduce partial discharge associated with the connector. Additional methods and systems are also provided.