Dielectric Component Isolates Connector Terminal Pins

Solution Overview

Problem

Electrical connector assemblies in modern vehicles face increased risks of electrical arching due to higher voltage and amperage demands, which can lead to detrimental effects on the electrical circuit, and existing solutions like conformal coatings may not adequately address these issues.

Innovation Solution

A dielectric component comprising a base panel member and isolation panel members, which form channels to isolate terminal pins and prevent electrical arching, is integrated into the electrical connector assembly, enhancing dielectric characteristics and preventing arching between juxtaposed terminal pins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conformal coating is applied to terminal pin portions to inhibit electrical arching, then dielectric characteristics are improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvedielectric characteristicsVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A dielectric component is introduced as an intermediary element between juxtaposed terminal pin portions. This component includes a body with a first surface and a second surface, and protrusions extending from the first surface that define isolation channels. The terminal pin portions are received in these isolation channels, physically separating them and preventing electrical arching without requiring conformal coating application.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If conformal coating is applied to terminal pin portions to inhibit electrical arching, then electrical arching is prevented, but manufacturing cost and process complexity increase

Engineering Contradiction:

Improveinhibition of electrical archingVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

A dielectric component is introduced as an intermediary element between juxtaposed terminal pin portions. This component includes a body with a first surface and a second surface, and protrusions extending from the first surface that define isolation channels. The terminal pin portions are received in these isolation channels, physically separating them and preventing electrical arching without requiring conformal coating application.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If terminal pin portions are exposed in open-air environment, then device simplicity is maintained, but electrical arching occurs causing detrimental effects

Engineering Contradiction:

Improvedevice simplicityVSAvoidelectrical arching

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

A dielectric component is introduced as an intermediary element between juxtaposed terminal pin portions. This component includes a body with a first surface and a second surface, and protrusions extending from the first surface that define isolation channels. The terminal pin portions are received in these isolation channels, physically separating them and preventing electrical arching without requiring conformal coating application.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The dielectric component is segmented into a body and multiple protrusions that extend from the first surface. These protrusions define separate isolation channels for different terminal pin portions. The segmentation creates physical barriers between conductive elements while maintaining an open-air environment, eliminating electrical arching risks without complex coatings.

Inventive Principle:

Principle #1Segmentation

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 dielectric component effectively isolates terminal pins, reducing the incidence of electrical arching and enhancing the dielectric characteristics of the electrical connector assembly, thereby ensuring reliable operation under higher voltage and amperage conditions.

Implementation Method 1

The base panel member is fabricated from a dielectric material... The plurality of isolation panel members is also fabricated from a dielectric material... enhance the dielectric characteristics of the electrical connector assembly... inhibit electrical arching

Methodology Applied

Scientific EffectDielectric: Dielectric

Data Source

PatentUS8210879B2Dielectric component and an electrical connector assembly incorporating the same

Publication Date: 2012.07.03 JST CORP

AI summary

A dielectric component is fabricated from a dielectric material and includes a base panel member and a plurality of isolation panel members. The base panel member has a first base panel member surface. The plurality of isolation panel members is connected to and projects perpendicularly from the first base panel member surface. The plurality of isolation panel members are disposed apart from and extend parallel to one another to form a plurality of isolation channels. An electrical connector assembly includes an electrical connector housing and the dielectric component. Consecutive ones of a plurality of terminal pin portions projecting from the electrical connector housing are isolated from one another by consecutive ones of the plurality of isolation panel members such that the terminal pin portions are disposed in the isolation channels and are therefore isolated from one another. The electrical connector assembly might also incorporate a printed circuit board.