High Voltage Connector Assembly With Potting Compound
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Solution Overview
Problem
High-voltage electrical connectors used in Automatic Testing Equipment (ATE) are bulky and expensive, posing performance and cost limitations due to their bulkiness and potential for arcing or shorting.
Innovation Solution
A high voltage connector assembly featuring pogo pin assemblies with a pin alignment structure, encapsulated connector pads, and a potting compound to prevent arcing, allowing for reliable high-voltage signal transmission while minimizing bulkiness and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard electrical connectors with molded housing are used for high-voltage connections, then reliable electrical connection is achieved, but the connector becomes bulky and expensive
Solution Approach 1:
The connector is divided into separate functional components: a circuit board with connector pads, wire-based conductors, and a potting compound. This segmentation allows each component to be optimized independently, reducing overall volume while maintaining reliability through proper electrical isolation and connection.
Solution Approach 2:
A potting compound is used to create an inert, protective environment around the electrical connections. This encapsulation prevents arcing and shorting by isolating the electrical components from the external environment, enabling compact design without compromising high-voltage reliability.
2Reliability
If standard electrical connectors with molded housing are used for high-voltage connections, then reliable electrical connection is achieved, but the connector becomes expensive
Solution Approach 1:
By segmenting the connector into standard components (circuit board, wire conductors, potting compound), the design allows use of off-the-shelf parts and simplified manufacturing processes, reducing overall cost while maintaining reliability through proven technologies.
Solution Approach 2:
The design uses cost-effective materials and components, including standard wire-based conductors and readily available potting compounds, replacing expensive specialized high-voltage connector housings with simpler, more economical alternatives that achieve the same reliability.
3Volume of moving object
If compact connector design is implemented, then bulkiness is reduced, but the risk of arcing or shorting increases
Solution Approach 1:
The potting compound creates a protective environment that prevents arcing and shorting by isolating electrical components from moisture, contaminants, and air. This allows compact spacing between conductors without increasing electrical breakdown risk.
Solution Approach 2:
The potting compound acts as an intermediary protective layer between electrical conductors and the external environment. It provides electrical insulation and physical protection, enabling reduced spacing while maintaining safety margins against arcing and shorting.
Data Source
AI summary
A high voltage connector assembly includes a plurality of pin assemblies, each of the plurality of pin assemblies having a first end and a second end. The first end of each of the plurality of pin assemblies is configured to releasably electrically engage a load board. A plurality of pin pads, wherein the second end of each of the plurality of pin assemblies is configured to electrically engage a pin pad included within the plurality of pin pads. A plurality of connector pads are electrically coupled to the plurality of pin pads, wherein each of the plurality of connector pads is configured to be electrically coupled to a wire-based conductor included within a plurality of wire-based conductors. A potting compound is configured to encapsulate the plurality of connector pads.