High-Voltage Connector Sealing to Prevent High-Frequency AC Arcs
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Solution Overview
Problem
High-voltage electrical connectors used in aircraft power networks face a significant risk of electric arcs during high-frequency alternating operations due to the dielectric strength of ambient air being much lower than that of solid dielectrics.
Innovation Solution
The electrical connector design incorporates an elastic gasket made of silicone, which replaces ambient air as the electrical insulator by being in contact with first and second electrical continuity zones covered with conductive material, thereby minimizing potential differences and reducing the risk of electric arcs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ambient air is used as electrical insulator in high-voltage connectors, then device complexity is reduced, but dielectric strength is insufficient leading to electric arcs in high-frequency AC operation
Solution Approach 1:
The patent introduces an elastic gasket as an intermediary component between the male and female connector bodies. This gasket replaces ambient air as the electrical insulator in critical gaps, providing superior dielectric strength while maintaining connector functionality. The gasket acts as a mediator that eliminates the harmful effect of air ionization without requiring complete redesign of the connector architecture.
Solution Approach 2:
The patent changes the physical and electrical parameters of the insulation medium by replacing air (low dielectric strength) with an elastic gasket material (high dielectric strength). This parameter change directly addresses the electric arc problem in high-frequency AC operation while allowing the connector to maintain its overall structural simplicity.
2Reliability
If solid dielectric thickness is increased to support high voltage, then dielectric strength is improved, but device volume and mass increase
Solution Approach 1:
The patent applies local quality by placing the elastic gasket specifically in the gap regions where electrical insulation is most critical, rather than uniformly increasing solid dielectric thickness throughout the entire connector. This localized approach provides enhanced dielectric strength exactly where needed (at the interfaces between male and female connectors) without unnecessarily increasing overall connector volume.
Solution Approach 2:
The patent employs composite material strategy by combining the elastic gasket material with the existing connector structure. The gasket material possesses superior dielectric properties compared to conventional solid dielectrics, allowing for more compact design while maintaining high voltage withstanding capability.
3Reliability
If elastic gasket is added to replace air insulation, then dielectric strength is significantly increased, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The elastic gasket serves as a mediator component that simplifies the overall manufacturing process despite adding a part. By concentrating the insulation function in this single replaceable component, the patent avoids the need to redesign entire connector assemblies or use complex multi-layer solid dielectric structures, making the addition manufacturable and assembleable.
Solution Approach 2:
The patent changes the material parameter of the insulation medium to elastic gasket material, which offers not only superior dielectric strength but also manufacturing advantages such as flexibility for easy installation and tolerance compensation during assembly, thereby mitigating the complexity increase.
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
This design effectively eliminates the risk of electric arcs in high-voltage, high-frequency operations by significantly increasing the dielectric strength relative to air, ensuring reliable electrical connectivity and power transmission.
Implementation Method 1
the dielectric strength of ambient air being much lower than that of solid dielectrics
Implementation Method 2
an elastic gasket being arranged in a gap where an internal air volume of the electrical connector is likely to be subjected to a difference in electrical potentials
Data Source
AI summary
Disclosed is an electrical connector having:a body made from an electrically conductive material,at least one electrical conductor covered with a layer of electrically insulating material,at least one electrical terminal connected electrically to one end of the electrical conductor, andan insulating insert intended to electrically insulate the electrical terminal relative to the body of the electrical connector,the insulating insert having a first region of electrical continuity covered with a layer of electrically conductive material to provide electrical continuity with the body, anda second region of electrical continuity covered with a layer of electrically conductive material to provide electrical continuity with the electrical terminal,an elastic seal being arranged in a space in which a volume of air inside the electrical connector is liable to be subjected to a difference in electrical potentials between an electrical potential of the body and an electrical potential of the electrical terminal,the elastic seal being in contact with the first region of electrical continuity and with the second region of electrical continuity.