Molded Electrical Sensor with Integrated Support Terminal
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Solution Overview
Problem
Existing electrical sensors in switchgear require multiple support points during molding, leading to holes that need separate filling and lack a unified terminal after molding.
Innovation Solution
A conductive insert is coupled to the voltage measurement screen to support it during molding, acting as both a gripping point and a terminal, remaining attached post-molding without creating additional holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple support points are used during molding, then the sensor is stable during molding, but holes are created that require separate filling and no unified terminal exists after molding
Solution Approach 1:
The patent combines multiple support functions into a single integrated conductive insert that serves as both the support structure during molding and the electrical terminal after molding. This eliminates the need for separate support points and post-molding hole filling operations, resolving the contradiction between stability during molding and device complexity.
Solution Approach 2:
The conductive insert performs multiple functions: it provides mechanical support during the molding process, maintains the screen's position, and serves as the electrical terminal after molding. This multi-functionality eliminates the need for separate components, reducing overall device complexity while maintaining stability during molding.
2Stability of the object's composition
If multiple support points are used during molding, then the sensor is stable during molding, but additional steps for hole filling are required after molding
Solution Approach 1:
By merging the support function and terminal function into a single conductive insert, the patent eliminates post-molding hole filling steps. The insert remains in place after molding and serves as the electrical terminal, allowing the molding cycle to complete without additional processing steps, thus improving productivity.
Solution Approach 2:
The conductive insert is pre-positioned and integrated into the molding process, providing support during molding and remaining as the terminal after molding. This preliminary integration eliminates the need for subsequent hole filling operations, reducing total manufacturing time and improving productivity.
3Device complexity
If a conductive insert is coupled to the voltage measurement screen, then a unified terminal is provided and hole filling is eliminated, but the insert must remain attached post-molding
Solution Approach 1:
The conductive insert is integrally formed with or permanently attached to the voltage measurement screen, creating a unified terminal structure. This integration ensures the insert remains reliably attached during and after molding, eliminating the risk of detachment while providing a simple, unified terminal that reduces device complexity.
Solution Approach 2:
The conductive insert is pre-attached to the voltage measurement screen before the molding process begins. This preliminary attachment ensures the insert remains securely connected throughout molding and subsequent handling, maintaining reliability while providing the structural simplicity needed for ease of connection.
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 insert supports the sensor during molding as a cantilever, eliminating the need for post-molding hole filling and providing a unified terminal, enhancing structural integrity and ease of electrical connection.
Implementation Method 1
a voltage measurement screen that surrounds an inner conductor and, together with the inner conductor, forms a capacitor. Such a voltage sensor is able to detect the voltage of the conductor without being in contact with the conductor
Data Source
AI summary
An electrical sensor includes a conductor and an electrical sensor surrounding the conductor to monitor the conductor. An insulating body is molded around the conductor and the electrical sensor. A conductive insert is coupled to the electrical sensor to support the screen around the conductor during molding of the insulating body. After molding, the conductive insert remains coupled to the electrical sensor as an electrical terminal.