Flat Interface Sensor with Compressible Insulating Support
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Solution Overview
Problem
Existing electrical connection measurement technologies face challenges in simplifying the connection process while ensuring dielectric strength, especially in high and medium voltage applications, and require improved insulation and shielding to manage electric fields effectively.
Innovation Solution
A sensor with flat, compressible connection interfaces and an insulating support made of deformable material, such as EPDM, integrated with a conductive insert and a conductive coating, which allows for efficient measurement of voltage and current by optimizing dielectric strength and reducing the risk of flashovers through orthogonal compression and clamping mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid bars with bicone connectors are used for electrical connection, then dielectric strength is ensured, but connection complexity and installation difficulty increase
Solution Approach 1:
The invention changes the geometric parameters of the connection interface from bicone to flat surfaces, and modifies the material parameters by using compressible insulating material instead of rigid structures. This allows simple flat surface contact while maintaining dielectric strength through the compressible material's ability to deform and fill gaps.
Solution Approach 2:
The invention uses composite construction combining conductive inserts (for electrical connection) with compressible insulating material (for dielectric strength and mechanical compliance). This composite structure achieves both electrical functionality and mechanical simplicity without requiring complex rigid connector assemblies.
2Ease of operation
If flat interface connections are used to simplify connection process, then connection ease is improved, but dielectric strength and insulation performance may deteriorate
Solution Approach 1:
The invention changes the material parameters of the flat interface connection by introducing compressible insulating material that can deform under compression. This material deformation allows the simple flat interface to achieve adequate contact pressure and dielectric strength, resolving the contradiction between simplicity and reliability.
Solution Approach 2:
The invention introduces dynamic compliance through the compressible insulating material that can deform and adapt to manufacturing tolerances and assembly variations. This dynamic adjustment capability allows the simple flat interface to maintain reliable dielectric performance without requiring precision alignment or complex rigid structures.
3Ease of operation
If insulating material is made deformable to enable compression connection, then ease of connection is improved, but structural stability may worsen
Solution Approach 1:
The invention uses composite construction where the deformable insulating material is combined with rigid conductive inserts and supported by a stable housing structure. The composite system allows the insulating material to deform for easy connection while the overall structure maintains stability through the rigid components and proper mechanical design.
Solution Approach 2:
The invention segments the connection structure into distinct functional parts: the deformable insulating material for compression and sealing, the rigid conductive inserts for electrical connection, and the stable housing for structural support. This segmentation allows each part to optimize its specific function without compromising overall structural stability.
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 simplifies electrical connection measurements by ensuring reliable dielectric strength, reducing the risk of flashovers, and maintaining tight contact, while allowing for compact and efficient electrical connections in high and medium voltage applications.
Implementation Method 1
the conductive coating and the insulating support are made by overmolding the same elastomer, whether or not charged with conductive particles
Implementation Method 2
when the material is entirely deformed by compression between its connecting surfaces
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The sensor (100) has an insulating support (114) defined by a primary set of connection surfaces. A conductive connection insert (124) is integrated in the support and opened on the connection surfaces at level of a secondary set of connection surfaces. A conductive coating part (172) is provided on a part of an outer face of the support. An acquisition unit acquires electrical quantities representing short-circuit in which the insert is associated to the coating part. Plain interfaces between the support, the insert and the coating part are sealed. Independent claims are also included for the following: (1) a current measuring device comprising a processing circuit for determining current (2) a voltage measuring device comprising a determination unit for determining voltage.