Insulated High-Voltage Connector Assembly for Safe, Simple Mounting
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Solution Overview
Problem
Existing high voltage connections for devices that separate materials from gas flows are complex to manufacture and connect safely, lacking a simple and cost-effective solution.
Innovation Solution
A modular high voltage connection design featuring a housing with a circuit board, banana jack connector, and insulating material, allowing for easy assembly and safe connection to a high voltage source, with options for positive or negative voltage, and a method for manufacturing this connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high voltage connection is designed with traditional complex assembly, then electrical connectivity is achieved, but manufacturing complexity increases and safety decreases
Solution Approach 1:
The patent combines multiple components (housing, circuit board, connector, insulating material, and wiring) into a single pre-assembled high voltage connection unit. This merging of components into a modular assembly reduces manufacturing complexity while maintaining safety through integrated design features such as embedded insulating material and pre-configured creepage distances.
Solution Approach 2:
The high voltage connection is designed as a separate modular unit that can be independently manufactured and then integrated into the final device. This segmentation allows for specialized safety features to be built into the connection unit itself, improving reliability while simplifying overall device assembly.
2Ease of operation
If traditional high voltage connections are used, then electrical connectivity is provided, but connection safety and ease of use decrease
Solution Approach 1:
The patent introduces a banana jack connector as an intermediary component that provides a safe and user-friendly interface for high voltage connections. This standardized connector type with its external contact design allows for easy plugging and unplugging while maintaining safety through proper insulation and creepage distance design in the surrounding housing.
Solution Approach 2:
The insulating material is embedded in the housing beforehand to create pre-established safety barriers. The housing design incorporates adequate creepage distances and insulation layers before the user makes any connection, cushioning against potential safety hazards before they can occur.
3Ease of manufacture
If simple manufacturing methods are used, then cost efficiency improves, but manufacturing precision and safety may worsen
Solution Approach 1:
The insulating material is embedded in the housing during the manufacturing process, creating pre-formed safety barriers with precise creepage distances. This preliminary action ensures that safety-critical dimensions are built-in during manufacturing rather than requiring complex post-assembly adjustments, achieving both precision and cost efficiency.
Data Source
Figure 1~2
AI summary
According to an example aspect of the present invention, there is provided a high voltage connection (1) comprising a housing (2) comprising a base (3) and a perimeter wall (4) protruding from the base (3), thus providing a cavity (13) and an opening (14) into the cavity (13), a circuit board (5) placed within the cavity (13), a connector (6) comprising a tube (7), a banana jack connector (8) and an electric wire (9), wherein the banana jack connector (8) is coupled to a first end (10) of the tube (7), wherein the banana jack connector (8) and the circuit board (5) are electrically connected by the electric wire (9), further electric wiring (11) electrically connected to the circuit board (5), and an insulating material layer (12) within the cavity (13), wherein the circuit board (5), a part of the tube (7) comprising the first end (10), the banana jack connector (8), the electric wire (9) and a first part of the further electric wiring (11) are embedded in the insulation material layer (12), wherein a second part of the further electric wiring (11) and a second end (16) of the tube (7) are located outside of the housing (2).