Hydraulic Electrical Connector Venting for Air Void Elimination
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Solution Overview
Problem
High voltage electrical connector assemblies using dielectric oil are prone to arcing and failure due to air voids, which can expand and cause erosion, leading to increased arcing probabilities.
Innovation Solution
A connector assembly with a sealable fluid chamber filled with dielectric oil and a sealable vent that allows manipulation to reduce or eliminate air voids, using a mechanical stop and spring to maintain hydraulic pressure and accommodate fluid expansion and contraction, thereby increasing the reliability and voltage rating of the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dielectric oil is used as insulating medium, then insulation performance is improved, but air voids cause arcing and reliability deteriorates
Solution Approach 1:
The patent applies preliminary action by providing a vent that allows air voids to be removed from the dielectric oil before the connector assembly is fully assembled and sealed. The vent is positioned to enable air escape during the filling process, preventing air pockets from remaining trapped in the oil, which would otherwise cause arcing and reduce reliability.
Solution Approach 2:
The patent applies the extraction principle by providing a dedicated vent pathway that extracts air voids from the dielectric oil. The vent allows trapped air to be removed from the sealed chamber during assembly, separating the harmful air pockets from the insulating oil to prevent arcing and improve reliability.
2Reliability
If connector housing is made sealed, then protection against contaminants is improved, but air voids trapped inside cause erosion and increase arcing probability
Solution Approach 1:
The patent applies preliminary action by incorporating a vent that enables air voids to be removed from the sealed chamber during the assembly process, before final sealing occurs. This preliminary air removal prevents trapped air pockets from expanding and causing erosion of internal components while maintaining the sealed protection against contaminants.
Solution Approach 2:
The patent applies extraction by providing a vent pathway that extracts air voids from the sealed chamber during assembly. The vent allows trapped air to be removed before sealing is complete, eliminating the source of erosion while preserving the sealed environment's protection against external contaminants.
3Reliability
If dielectric oil volume is increased, then insulation capability is improved, but fluid expansion requires larger housing or bellows
Solution Approach 1:
The patent applies dynamics by providing a compressible spring that can be compressed to accommodate the expansion of dielectric oil when temperature increases. The spring dynamically adjusts its compression state to absorb volume changes, allowing the connector housing to maintain a compact size while handling thermal expansion of the oil without requiring expansion bellows or a larger housing.
Solution Approach 2:
The patent applies pneumatics and hydraulics by using a compressible spring mechanism that responds to hydraulic pressure from expanding dielectric oil. The spring compresses under the pressure of expanding oil, providing a compact solution for accommodating volume changes without requiring additional space or bellows structures.
4Reliability
If mechanical stop and spring are added, then hydraulic pressure control is improved, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality by designing a spring that serves multiple purposes: it maintains hydraulic pressure on the dielectric oil to eliminate air voids, accommodates thermal expansion of the oil, and provides a mechanical stopping point. This single component performs multiple functions that would otherwise require separate mechanisms, reducing overall device complexity while improving reliability.
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 effectively reduces air voids, increases the reliability and lifetime of the connector assembly, and allows for higher voltage ratings without the need for expansion bellows, improving the connector's performance and reducing the risk of arcing.
Implementation Method 1
High voltage electrical connector assemblies using dielectric oil are prone to arcing and failure
Implementation Method 2
using a mechanical stop and spring to maintain hydraulic pressure and accommodate fluid expansion and contraction
Data Source
AI summary
Some embodiments include an assembly, comprising: a first connector housing including an opening and a first electrical contact a second connector housing including a portion insertable into the opening and a second electrical contact electrically interfaceable with the first electrical contact a seal configured to form a sealable fluid chamber with the first connector housing and the second connector housing when the portion of the second connector housing is inserted into the opening of the first connector housing and a sealable vent coupled to the sealable fluid chamber when the portion of the second connector housing is inserted into the opening of the first connector housing wherein, when the sealable fluid chamber is formed: the portion of the second connector housing is movable within the opening; and the volume of the sealable fluid chamber changes as the portion of the second connector housing moves within the opening.