Insulated Screw Plug Connector for High-Voltage Touch Protection
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Solution Overview
Problem
Existing plug-in connections for high-voltage and high-current applications require fasteners that ensure secure connection while preventing electrical contact, which is challenging due to the need for both mechanical stability and electrical insulation.
Innovation Solution
The fastener, such as a screw, is made entirely of electrically nonconductive material or has a metal core with an electrically nonconductive coating, and is insulated from voltage-carrying parts using additional insulating elements, ensuring both mechanical stability and electrical safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal fastener is used to achieve sufficient tightening forces and long-term stability, then mechanical strength is improved, but electrical conductivity increases creating touch protection risks
Solution Approach 1:
An insulating element made of electrically nonconductive material is introduced as an intermediary between the metal fastener and the voltage-carrying parts. This mediator allows the metal fastener to provide sufficient tightening forces while preventing electrical contact, thus resolving the contradiction between mechanical strength and electrical conductivity.
Solution Approach 2:
The fastening system combines metal material (for strength) and electrically nonconductive material (for insulation) into a composite structure. The metal fastener provides the required tightening forces while the insulating element prevents electrical conductivity, achieving both mechanical strength and electrical safety simultaneously.
2Object-affected harmful factors
If an insulating coating is applied to the fastener surface, then electrical insulation is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of coating the entire fastener, the insulating element is segmented as a separate component that only covers the portions of the fastener that contact voltage-carrying parts. This segmentation reduces manufacturing complexity compared to full-surface coating while still providing adequate electrical insulation where needed.
3Object-affected harmful factors
If a plastic fastener is used to achieve electrical insulation, then electrical safety is improved, but mechanical strength deteriorates
Solution Approach 1:
The solution merges two different materials into a single integrated fastening system: a metal fastener for providing sufficient tightening forces and an insulating element made of electrically nonconductive material for ensuring electrical safety. This combination allows both electrical insulation and mechanical strength to be achieved simultaneously.
Data Source
AI summary
A plug-in connection comprises a plug-in connector (1) and a mating plug-in connector that can be plugged together with the latter. The plug-in connector (1) has a housing (2) into which an electrical conductor (3) is inserted. The electrical conductor (3) is electrically contacted with a contact partner (4) likewise arranged in the housing (2) by means of their surfaces coming to rest on each other. The contact partner (4) is contacted via its circumferential end face (5) with a contact partner of the mating plug-in connector in such a way that the end faces come to rest on each other. The plugging-together is effected and supported by a screw (6). The screw includes insulation (e.g., insulating element (12) or a coating) such that the screw (6) does not touch voltage-carrying parts such as the electrical conductor (3) and/or the contact partner (4).