Integrated Connector Insulator for High Voltage Arcing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High voltage power supply modules in high altitude environments face issues with arcing across contacts due to increased conductivity of air, requiring enhanced creepage and clearance without increasing contact distance, as existing discrete spacers interfere with the module chassis and do not adequately address conductive surface effects.
Innovation Solution
An integrated insulator with fin features that extend through connector slots to increase creepage and clearance between contacts, replacing chassis components and eliminating the need for additional insulation materials, allowing for effective operation at high altitudes without increasing contact distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discrete spacers are placed between adjacent contacts to increase creepage and clearance, then electrical isolation between contacts is improved, but the spacers interfere with the existing module chassis and do not adequately address conductive surface effects
Solution Approach 1:
The insulator body is integrated with the connector housing to form a unified structure, eliminating the need for separate discrete spacers and resolving the interference issue with the module chassis. The integrated design combines the functions of electrical isolation and structural support into a single component.
Solution Approach 2:
The insulator body extends the creepage path by utilizing the vertical dimension and surface area of the connector housing, rather than relying solely on horizontal spacing between contacts. This dimensional approach increases effective creepage without requiring additional horizontal space that would interfere with the chassis.
2Reliability
If contacts are placed farther apart to increase creepage and clearance for high voltage operation, then arcing is reduced, but the predetermined spacings dictated by industry standards cannot be exceeded
Solution Approach 1:
The insulator body utilizes the vertical dimension and surface area of the connector housing to extend the creepage path, allowing increased electrical isolation without increasing the horizontal distance between contacts. This enables compliance with industry standard spacings while achieving the required arc resistance for high voltage operation.
Solution Approach 2:
The insulator body provides localized electrical isolation properties at critical areas where arcing is most likely to occur, such as between adjacent high voltage contacts. This targeted approach increases creepage and clearance where needed without requiring uniform increases in all contact spacings, maintaining compliance with industry standards.
3Reliability
If additional insulation components or materials are added to increase creepage, then electrical isolation is improved, but the design becomes more complex and requires further insulation components
Solution Approach 1:
The insulator body is integrated with the connector housing to form a unified structure, eliminating the need for separate discrete spacers and additional insulation components. This integration reduces the total number of parts while maintaining or improving electrical isolation performance.
Solution Approach 2:
The insulator body serves multiple functions simultaneously: it provides electrical isolation between contacts, maintains structural integrity of the connector housing, and extends the creepage path. This multi-functionality eliminates the need for separate dedicated insulation components, simplifying the overall design.
Data Source
AI summary
An integrated insulator having a body adapted for placement in proximity to a module connector, and at least one fin extending from the body so as to extend through a connector slot on the module connector and reside in a gap between a pair of contacts when the integrated insulator is engaged with the module connector.