Compact High Voltage Connector Flame-Proof Encapsulation
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Solution Overview
Problem
Existing high voltage connectors are limited to 11 kV to prevent explosions in explosive atmospheres, restricting electrical system performance and requiring larger installations in compact designs, such as swivel stacks on offshore units.
Innovation Solution
A high voltage connector with an encapsulating casing that creates a closed, flame-proof, liquid-proof, and dust-proof space around the electric terminal and housing, allowing higher voltage applications while preventing electrical contact and explosion transmission, and featuring sealable openings for inspection and cable management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing high voltage connectors are used to prevent explosions in explosive atmospheres, then safety is improved, but voltage level is limited to maximum 11 kV
Solution Approach 1:
The patent applies nesting by placing the electric terminal and housing inside an encapsulating casing that creates a closed space. This nested structure allows the connector to maintain safety in explosive atmospheres while accommodating higher voltage levels by isolating the internal components from the external environment.
Solution Approach 2:
The encapsulating casing acts as an intermediary barrier between the high voltage components and the explosive atmosphere. The closed space with flame path provisions mediates between the need for higher voltage operation and the requirement for explosion prevention, allowing voltage levels above 11 kV while maintaining safety.
2Power
If standard junction boxes with cable glands are used instead of high voltage connectors, then higher voltage applications are enabled, but device size increases
Solution Approach 1:
The encapsulating casing is designed to closely surround the housing, creating a compact nested structure. This minimizes the additional volume required while enabling higher voltage applications, making the connector suitable for space-constrained environments like swivel stacks on FPSO/FSO units.
Solution Approach 2:
The encapsulating casing functions as a protective shell that encloses the housing with minimal additional space. This shell structure enables the connector to achieve higher voltage ratings without significantly increasing device size, unlike bulkier standard junction boxes.
3Reliability
If the encapsulating casing provides a closed space for flame proofing, then explosion transmission is prevented, but manufacturing complexity increases
Solution Approach 1:
The encapsulating casing is designed as a separable component that can be manufactured independently and then assembled with the housing. This segmentation allows for simpler manufacturing of individual parts while achieving the flame-proof closed space requirement through proper assembly and sealing.
Solution Approach 2:
The encapsulating casing serves multiple functions: it provides flame-proofing, UV protection, and structural support. By consolidating these functions into a single component, the design reduces the number of separate parts needed, thereby simplifying manufacturing despite the added protection requirements.
4Power
If the connector is designed for higher voltage applications, then electrical system performance is improved, but adaptability to existing standards is reduced
Solution Approach 1:
The connector design incorporates universal features that allow it to meet various standards (IECEx, ATEX, NEC, UL) while supporting higher voltage applications. The encapsulating casing with its closed space and flame path provisions provides a standardized approach that can be adapted to different regulatory requirements.
Solution Approach 2:
The connector maintains standard dimensions and external interface characteristics while changing internal parameters (encapsulation, closed space) to enable higher voltage operation. This allows the connector to adapt to existing installation standards and regulations while providing enhanced voltage capability.
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
Enables the use of standard high voltage connectors at higher voltage levels, enhancing safety and compactness in explosive environments, and allowing for easier maintenance without downtime.
Implementation Method 1
The casing is provided with at least one flame path of any type e.g. spigot, flat, threaded, etc., that acts to prevent transmission of the explosion from the inside to the outside of the casing
Implementation Method 2
The connector socket provides a radial insulating wall that prevents electrical contact and sparking of the connector in a radial direction
Implementation Method 3
Moreover, the encapsulating casing provides a protection of the high voltage connector from sunlight and thus suppresses solar and UV radiation ageing effects on the components of the high voltage connector
Data Source
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AI summary
A high voltage connector includes an electric terminal and a housing elongated in a first direction along a longitudinal axis of the connector. An end surface of the electric terminal is mounted on an proximal end surface of the elongated housing with the respective body axis directions of the housing and the connector in parallel, and is arranged with an outer electric connection area for connection to an external electric terminal. The elongated housing is arranged at a distal end to receive at least one power cable for internal electrical connection of the at least one power cable with an inner connecting area of the electric terminal. The high voltage connector includes an encapsulating casing that encloses the electric terminal and the elongated housing in the first direction, and the encapsulating casing provides a closed space between said casing and the housing.