Shielded HV Connector Adapter for Low-Resistance Shield Coupling
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Solution Overview
Problem
The adaptation of shielded high-voltage conductors to user-specific shield housings is complex and costly due to mismatched user-defined interface openings and manufacturer-defined shield header contacts, leading to insufficient shielding and increased manufacturing costs.
Innovation Solution
A connector kit comprising a multifunctional adapter with user-defined aggregate connection sections and manufacturer-defined shield header openings, allowing for easy adaptation of shielded high-voltage conductors to various shield housings without redesign, and ensuring a secure electrical connection through enlarged contact surfaces and structured adapter surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shielded high-voltage conductor is adapted to user-specific shield housings, then electrical shielding is achieved, but the adaptation becomes complex and costly due to mismatched interface openings and shield header contacts
Solution Approach 1:
The adapter serves multiple functions: it provides mechanical coupling between the shield header and shield housing, establishes electrical contact for shielding, and accommodates different interface geometries. This multi-functionality resolves the contradiction by enabling universal compatibility across different shield housing types without requiring complex custom adaptations for each case.
Solution Approach 2:
The adapter acts as an intermediary component between the manufacturer-defined shield header and the user-defined shield housing interface. By introducing this intermediate element, the patent decouples the fixed shield header design from the variable shield housing interfaces, thereby simplifying the overall adaptation process while maintaining effective shielding.
2Reliability
If shield header contacts are made to match user-defined interface openings, then shielding is improved, but manufacturing costs increase due to custom adaptations
Solution Approach 1:
The connection system is segmented into three independent components: the shield header (manufacturer-defined), the adapter (intermediate component), and the shield housing (user-defined). This segmentation allows each component to be manufactured independently using standard processes, avoiding the need for costly custom adaptations while maintaining effective shielding through the coordinated interface design.
Solution Approach 2:
The adapter is designed as a universal component that can interface with multiple shield housing types through its user-defined interface sections. This universality eliminates the need to manufacture custom shield headers for each user-specific application, thereby reducing manufacturing costs while maintaining effective shielding through standardized contact mechanisms.
3Reliability
If contact surfaces are enlarged to reduce contact resistance, then electrical connection is improved, but the adapter structure becomes more complex
Solution Approach 1:
The adapter provides enlarged contact surfaces by utilizing the lateral dimension rather than increasing contact length in the plugging direction. The user-defined interface sections extend perpendicular to the plugging direction, offering expanded contact areas that reduce contact resistance without adding complexity to the primary connection structure.
Data Source
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AI summary
The present invention relates to a connector kit (100) for connecting a shielded high-voltage conductor to an aggregate, the connector kit (100) comprising: a power connector (120) for contacting a cable core (144) of the shielded high-voltage conductor to a mating connector of the aggregate in the plugging direction (S), a shield header (110) with a manufacturer-defined shield header contact (112, 114), wherein the shield header (110) forms a shield path at least in part between a shield conductor (142) of the shielded high-voltage conductor and a shield housing (1200) of the aggregate, and wherein the shield housing (1200) comprises a user-defined interface opening (1210) so that the mating connector is contactable to the power connector, a multifunctional adapter (300) with a user-defined aggregate connection section (312) for the electromechanical coupling to the shield housing (1200) of the aggregate and a manufacturer-defined shield header opening (320) extending perpendicular to the plugging direction (S) so that the power connector is contactable to the mating connector, wherein the multifunctional adapter (300) and the shield header contact (112) can be coupled to form a unit so that an adapter section (310) between the user-defined aggregate connection section (312) and the manufacturer-defined shield header opening (320) electrically closes the shield path between the shield housing (1200) of the aggregate and the shield conductor (142).