Live Portion Protection Structure for High-Voltage Connectors
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Solution Overview
Problem
Existing protection structures for high-voltage electric wires fail to secure safety when disconnection occurs, leading to exposure of live portions and potential short-circuits or human contact.
Innovation Solution
A live portion protection structure is implemented, featuring an insulating extra-length portion on the wire cover and a regulation member within the housing, which covers disconnection parts when they protrude, preventing exposure and ensuring safety through misalignment prevention and elastic pressing forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connector structure is used, then the connector can be assembled and connected, but safety cannot be secured when disconnection occurs due to exposure of live portions
Solution Approach 1:
The patent applies preliminary action by pre-positioning the regulation member within the housing before connection occurs. The regulation member is preliminarily arranged to control the reception path, so that when disconnection happens, the extra-length portion can immediately be guided to cover the exposed conductor without requiring additional active intervention or complex detection systems.
Solution Approach 2:
The regulation member serves as an intermediary element between the housing and the extra-length portion. It mediates the interaction by actively guiding and controlling the movement of the extra-length portion during disconnection, ensuring that the insulating cover properly covers the exposed conductor without requiring direct complex mechanical coupling or additional safety systems.
2Reliability
If the extra-length portion is made longer to ensure coverage, then safety is improved, but misalignment may occur during assembly
Solution Approach 1:
The regulation member acts as an intermediary that actively guides the extra-length portion during assembly and operation. It provides physical constraints and directional control that prevent misalignment even when the extra-length portion extends beyond the normal length required for coverage, ensuring proper positioning without compromising manufacturing precision.
Solution Approach 2:
The regulation member enables the extra-length portion to self-align and self-position correctly during assembly. By providing guiding surfaces and constraints within the reception path, the system allows the extra-length portion to automatically find its correct position without requiring external alignment tools or complex precision manufacturing tolerances.
3Reliability
If additional protection components are added, then safety is improved, but the number of components and assembly complexity increases
Solution Approach 1:
The regulation member is designed as a multi-functional component that simultaneously performs several functions: it guides the extra-length portion during assembly, controls the reception path for proper positioning, and actively participates in covering the exposed conductor during disconnection. This consolidates multiple safety-related functions into a single component, avoiding the need for separate protection devices, sensors, or actuating mechanisms.
Solution Approach 2:
The patent merges the regulation function and the protection function into a unified structure. The regulation member is integrated within the housing and works in conjunction with the extra-length portion of the insulating cover, combining what could be separate protection components into a cohesive system that achieves safety without increasing component count.
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 covers disconnection parts, preventing exposure and ensuring safety by using an insulating extra-length portion and regulation member, enhancing assemblability and reducing component count while maintaining waterproof integrity.
Implementation Method 1
the regulation member is formed by an elastic body that generates a pressing force toward an inside of the electric wire
Data Source
AI summary
A live portion protection structure includes a high-voltage electric wire that has a conductor and an insulating cover covering the conductor, a conductive terminal fitting that is connected to the conductor exposed from the high-voltage electric wire, an insulating housing that receives a connection part between the terminal fitting and the conductor, a regulation member that is disposed in a reception path for receiving the connection part into the housing, and an insulating extra-length portion that is provided in the cover. When a part or all of the connection part on a side of the conductor drops out from the housing, the extra-length portion abuts against the regulation member so as to be moved to an outside of the part or all of the connection part to thereby cover the part or all of the connection part.