Injection-Molded HV Header Sleeve for Touch Protection and Shielding

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Solution Overview

Problem

The production of high voltage (HV) connectors, particularly HV headers, is often expensive and not cost-efficient, while ensuring safe operation during plugging and unplugging, which is a challenge in existing technologies.

Innovation Solution

A touch protection sleeve made from injection moldable material with an attachment section for the HV header, providing a modular and cost-effective solution with optional shielding properties, including the use of conductive materials for enhanced shielding and a separate touch protection cap to prevent contact with high voltage carrying parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a touch protection sleeve is made from sheet metal by stamping and bending, then the structural strength and shielding effect are improved, but the production complexity and cost increase

Engineering Contradiction:

Improvestructural strengthVSAvoidproduction complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from sheet metal to injection moldable material, and changes the manufacturing process parameter from stamping and bending to injection molding. This resolves the contradiction by providing adequate structural strength through the molding process while dramatically simplifying production and reducing costs.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical stamping and bending process with an injection molding process. This substitution eliminates complex mechanical forming operations while achieving the required structural integrity and touch protection function through the molding process itself.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-affected harmful factors

If a full metal shield is used for HV header, then the shielding effect against electric and magnetic fields is improved, but the cost and weight increase

Engineering Contradiction:

Improveshielding effectVSAvoidweight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent applies local quality by providing touch protection only where needed (at the pin location) rather than using a complete metal shield. The injection molded sleeve provides localized protection and spacing, eliminating the need for full metal shielding and reducing overall weight while maintaining adequate protection for DC applications.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent replaces expensive metal shielding material with cheaper injection molded material (plastic or composite). This substitution significantly reduces cost and weight while providing sufficient protection for the intended application, particularly for DC power supply where electromagnetic shielding is less critical.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If a touch protection sleeve is made from injection moldable material, then the production ease and cost efficiency are improved, but the shielding effect is reduced

Engineering Contradiction:

Improveproduction easeVSAvoidshielding effect

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent uses composite materials that combine injection moldable plastic with conductive elements (such as conductive fillers, metal inserts, or conductive coatings). This composite approach maintains the production ease and cost benefits of injection molding while restoring adequate shielding effect for applications where electromagnetic protection is required.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent segments the protection function into two parts: the injection molded sleeve provides touch protection and spacing, while a separate conductive shield can be added if shielding is needed. This segmentation allows selective application of shielding based on specific application requirements, maintaining production efficiency while providing optional shielding capability.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If the touch protection sleeve is designed as a separate part, then the adaptability and modularity are improved, but the device complexity increases

Engineering Contradiction:

ImprovemodularityVSAvoidnumber of parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent designs the injection molded touch protection sleeve with universal features including an attachment section for mounting to the base plate, a receptacle for receiving the pin, and optional shielding capabilities. This multi-functional design allows the same basic component to serve different protection needs across various applications, improving adaptability without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20240413567A1Touch Protection Sleeve for an HV Header

Publication Date: 2024.12.12 TE CONNECTIVITY CZECH SRO

AI summary

The invention relates to a touch protection sleeve for an HV header with at least one pin that protrudes along a plugging direction away from a base plate and has a touch protection cap at its distal end, wherein the touch protection sleeve is made from an injection moldable material and comprises at least one attachment section for attaching the touch protection sleeve to the header, wherein the touch protection sleeve forms a receptacle adapted to surround the pin in a spaced and HV touch protection manner.