High-Voltage Connector Sealing to Prevent High-Frequency AC Arcing
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Solution Overview
Problem
High-voltage electrical connectors in aircraft power networks face a significant risk of electrical arcing due to the lower dielectric strength of ambient air, particularly in high-frequency alternating current systems, leading to power loss and potential damage.
Innovation Solution
The connector design incorporates an elastic seal made of silicone or similar material that replaces air as an insulator, ensuring electrical continuity through distinct layers of conductive material on insulating inserts, minimizing potential differences and preventing arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of solid dielectrics is increased to withstand high voltage levels, then the voltage withstand capability is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent introduces an elastic seal as an intermediary component that fills the internal space of the connector, replacing air as the dielectric medium. This elastic seal acts as a mediator between the conductive elements, providing high dielectric strength without requiring increased thickness of solid dielectric layers, thus resolving the contradiction between voltage withstand capability and device complexity
Solution Approach 2:
The patent changes the dielectric parameter by replacing air (low dielectric strength) with an elastic seal material (high dielectric strength). This parameter change allows the connector to withstand high voltage levels without increasing the physical dimensions or complexity of solid dielectric components
2Device complexity
If ambient air is used as electrical insulator, then the device complexity is reduced, but the risk of electrical arcing increases due to lower dielectric strength
Solution Approach 1:
The elastic seal serves as an intermediary dielectric medium that replaces ambient air within the connector's internal space. This intermediary material provides superior dielectric strength, preventing electrical arcing between conductive elements while maintaining a simple connector structure without complex additional components
Solution Approach 2:
The patent creates an inert dielectric environment by filling the connector's internal space with an elastic seal material that has high dielectric strength. This inert environment prevents electrical arcing and ionization that would occur with ambient air, thereby improving reliability without increasing device complexity
3Productivity
If high-frequency AC voltage is applied to minimize mass and electrical losses in actuation systems, then the productivity and efficiency are improved, but the risk of electrical arcing increases due to voltage variations
Solution Approach 1:
The elastic seal acts as an intermediary dielectric barrier that withstands high-frequency AC voltage variations without breaking down. This intermediary material prevents electrical arcing caused by voltage fluctuations while allowing the actuation system to operate efficiently at high frequencies, resolving the contradiction between productivity and reliability
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 effectively eliminates the risk of electrical arcs by enhancing dielectric strength, reducing power loss, and protecting the connector from damage.
Implementation Method 1
ambient air also contributes to electrical insulation between the different equipotential bonding points... the dielectric strength (20 to 50 times) than that of solid dielectrics (1 to 3kV/mm for air and 20kV/mm to 150kV/mm for solid dielectrics)... said elastic seal being disposed in a space where an internal air volume of the electrical connector is likely to be subjected to a difference in electrical potentials
Implementation Method 2
an insulating insert intended to electrically insulate the electrical terminal from the body of said electrical connector, the insulating insert having a first zone of electrical continuity covered with a layer of electrically conductive material ensuring electrical continuity with the body, and a second zone of electrical continuity covered with a layer of electrically conductive material ensuring electrical continuity with the electrical terminal
Data Source
Figure 1~2
Figure 3~4a
Figure 4b~5
AI summary
The present invention relates to an electrical connector (10, 11) having: - a body (12, 21) made from an electrically conductive material, - at least one electrical conductor (13, 23) covered with a layer of electrically insulating material (15, 25), - at least one electrical terminal (16, 26) connected electrically to one end of the electrical conductor (13, 23), and - an insulating insert (18, 28) intended to electrically insulate the electrical terminal (16, 26) relative to the body (12, 21) of the electrical connector (10, 11), - the insulating insert (18, 28) having a first region of electrical continuity (31.1) covered with a layer of electrically conductive material (32, 34) to provide electrical continuity with the body (12, 21), and - a second region of electrical continuity (31.2) covered with a layer of electrically conductive material (33, 35) to provide electrical continuity with the electrical terminal (16, 26), - an elastic seal (40) being arranged in a space (41) in which a volume of air inside the electrical connector (10, 11) is liable to be subjected to a difference in electrical potentials between an electrical potential of the body (12, 21) and an electrical potential of the electrical terminal (16, 26), - the elastic seal (40) being in contact with the first region of electrical continuity (31.1) and with the second region of electrical continuity (31.2).