High-Voltage Power Distributor Shield With Conductive Plastic Contacts
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Solution Overview
Problem
Conventional high-voltage power distributors with metal screens are expensive to manufacture and require a cost-effective solution for maintaining electromagnetic compatibility.
Innovation Solution
A high-voltage power distributor using a screen shield made from electrically conducting plastic material with integrated elastic spring contacts, which provides a resilient and efficient electrical connection between conductors, and an insulating housing for environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal screen shield is used in conventional power distributors, then electromagnetic compatibility is ensured, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter of the screen shield from metal to electrically conducting plastic, fundamentally altering the material composition while maintaining the shielding function. This substitution reduces manufacturing cost and complexity while preserving electromagnetic compatibility through the conductive properties of the plastic material.
Solution Approach 2:
The patent employs composite material construction by integrating elastic spring contacts made from conductive plastic with metallic reinforcement elements. This composite approach combines the cost advantages and electromagnetic shielding of conductive plastic with the superior electrical conductivity and mechanical stability of metal contacts, resolving the contradiction between cost and performance.
2Ease of manufacture
If conventional friction-locked contacts are used between metal screen shield and conducting plastic, then assembly is simple, but electrical conductivity is insufficient
Solution Approach 1:
The patent uses composite material construction by integrating elastic spring contacts made from conductive plastic with metallic reinforcement elements. This composite approach combines the cost advantages and electromagnetic shielding of conductive plastic with the superior electrical conductivity and mechanical stability of metal contacts, resolving the contradiction between cost and performance.
Solution Approach 2:
The patent changes the material parameter of the screen shield from metal to electrically conducting plastic, fundamentally altering the material composition while maintaining the shielding function. This substitution reduces manufacturing cost and complexity while preserving electromagnetic compatibility through the conductive properties of the plastic material.
3Reliability
If rigid screen shield contacts are used, then electrical connection is stable, but mechanical tolerance compensation is poor
Solution Approach 1:
The patent introduces dynamic elements by replacing rigid contacts with elastic spring contacts that can deform and adapt to mechanical variations. The spring mechanism provides continuous contact pressure while accommodating position deviations, thereby maintaining stable electrical connection despite manufacturing tolerances or assembly variations.
Solution Approach 2:
The patent incorporates elastic spring elements that beforehand cushion and compensate for mechanical tolerances before they can affect electrical connection quality. The spring deformation absorbs position deviations and maintains consistent contact force, preventing connection instability.
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 reduces manufacturing costs while maintaining effective electromagnetic compatibility and mechanical reliability, with improved electrical conductivity and resistance to vibrations.
Implementation Method 1
the elastic spring contacts comprise one or several spring tongues. Each spring tongue establishes a contact point which provides for a resilient electrical contact. This can be particularly advantageous to make the electrical contact resistant against vibrations.
Data Source
AI summary
A power distributor (200) with at least two incoming lines (101-103) and a method for manufacturing such a power distributor is suggested. Each incoming line has a conductor (106,107) and an individual screen (114). The conductors of the incoming lines are connected at a connection point (V1, V2), which is enclosed by a screen shield (201) that contacts each individual screen (114) of the incoming lines. The screen shield (201) is made from electrically conducting plastic material. Screen shields made from electrically conducting plastic material is easier to manufacture and less expensive than metal screen shields.