High-Voltage Isolation Cover With Extended Creep Path
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Solution Overview
Problem
High voltage systems experience arcing between contacts due to excessive voltage exceeding the breakdown voltage of the air or material between contacts, leading to physically large connectors and manufacturing challenges.
Innovation Solution
The solution involves designing electrical connectors with a dielectric barrier that creates a creep path at least four times longer than the direct distance between contacts, using materials like polymers with higher breakdown voltages and convoluted structures to prevent arcing, and securing the components with covers to limit movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the voltage applied to the connector exceeds the breakdown voltage of the air or material between contacts, then high voltage transmission is achieved, but arcing occurs between contacts
Solution Approach 1:
The patent transforms the simple linear distance between contacts into a multi-dimensional convoluted creep path by introducing dielectric barriers with protrusions and recesses. This increases the effective insulation path length without proportionally increasing the connector's external dimensions, allowing high voltage transmission while preventing arcing through the extended creep path geometry.
Solution Approach 2:
The dielectric barrier acts as an intermediary element between adjacent contacts, providing physical and electrical isolation. The barrier with its convoluted surface structure mediates the electrical field distribution, forcing any potential arc to follow the extended creep path rather than taking a direct route between contacts, thereby preventing arcing while maintaining high voltage capability.
2Reliability
If the distance between contacts is increased to prevent arcing, then arcing is reduced, but the connector size increases
Solution Approach 1:
Instead of increasing the linear distance between contacts, the patent utilizes the third dimension by creating a convoluted creep path through dielectric barriers with protrusions and recesses. This allows the electrical insulation path to be extended significantly while keeping the connector's external footprint compact, effectively decoupling the insulation path length from the connector volume.
Solution Approach 2:
The dielectric barriers with their convoluted structures are nested within the connector body, with protrusions and recesses creating internal pathways. This nesting approach allows the creep path to be folded within the available space, maximizing the insulation path length without proportionally increasing the connector's external dimensions.
3Reliability
If complex manufacturing methods are used to create precise contact spacing, then arcing is prevented, but manufacturing precision requirements increase
Solution Approach 1:
The dielectric barriers are pre-formed with integrated protrusions and recesses that automatically create the convoluted creep path geometry. This preliminary structuring of the dielectric material eliminates the need for precise post-assembly adjustments of contact spacing, as the creep path is built-in during dielectric barrier fabrication rather than requiring precise contact positioning during assembly.
Solution Approach 2:
The patent changes the geometric parameters of the dielectric barrier by introducing protrusions and recesses, transforming a simple flat barrier into a convoluted structure. This parameter change in the dielectric barrier geometry creates the extended creep path without requiring precise control of contact spacing, shifting the manufacturing precision requirements from contact positioning to dielectric barrier formation where the convoluted structure can be more easily manufactured.
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
This design effectively prevents arcing and simplifies assembly while maintaining high voltage transmission, reducing connector size and manufacturing complexity.
Implementation Method 1
High voltage systems with a plurality of contacts can experience arcing between the contacts if the voltage applied to the connector exceeds the breakdown voltage of the air or other material between the contacts
Data Source
AI summary
A device may include a front body. A device may include a rear body. A device may include a first forward contact supported by the front body. A device may include a second forward contact supported by the front body a direct distance from the first forward contact. A device may include a dielectric barrier between the first forward contact and second forward contact that defines a creep path that is no less than 2 times greater than the direct distance.