Integrated Touch Protection Structure for Electrical Connectors
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Solution Overview
Problem
Current electrical connectors with touch protection require a high manufacturing and assembly effort, which is inefficient and not fully aligned with the need for reliable occupational safety in high-voltage applications like electric vehicle batteries.
Innovation Solution
The design incorporates a conductor element, fastening element, contact ring, annular collar, and protective sleeve, where the annular collar and protective sleeve form a touch protection mechanism to prevent unintentional contact, with the protective sleeve being fixed to the contact ring to simplify assembly and ensure safety compliance with IPxxB standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current electrical connectors with touch protection are used, then reliable occupational safety is ensured, but manufacturing and assembly effort is high
Solution Approach 1:
The patent combines multiple protective functions (touch protection and insulation) into a single integrated protective sleeve structure. The protective sleeve simultaneously provides IPxxB touch protection and electrical insulation, eliminating the need for separate protective components and reducing manufacturing complexity while maintaining safety standards
Solution Approach 2:
The protective sleeve is designed to perform multiple functions: it provides touch protection according to IPxxB standards, ensures electrical insulation between conductive parts, and serves as a structural element of the connector. This multi-functionality reduces the total number of components and simplifies the manufacturing process
2Reliability
If complex touch protection structures are implemented, then reliable protection against unintentional contact is provided, but device complexity increases
Solution Approach 1:
The annular collar and protective sleeve are designed as integrated components that work together to provide touch protection. The annular collar surrounds the contact ring while the protective sleeve covers the fastening element, creating a unified protective structure that prevents finger insertion without requiring multiple separate protective components
Solution Approach 2:
The protective structure uses a nested arrangement where the annular collar surrounds the contact ring, and the protective sleeve is positioned within or alongside the annular collar structure. This nested design provides comprehensive protection while maintaining a compact and simple overall structure
Data Source
AI summary
Electrical connectors with integrated touch protection are described. An example electrical connector has a conductor element, a fastening element that contacts the conductor element, a contact ring, an annular collar, and a protective sleeve. The protective sleeve fixed to the contact ring and partially covering the fastening element. The annular collar surrounding the contact ring. The annular collar and the protective sleeve form a touch protection that prevents unintentional contact of the contact ring and the fastening element.