High-Current Pass-Through Standoff With Anti-Rotation Sealing

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Solution Overview

Problem

Existing high-voltage electronic box connectors are expensive to manufacture, complicated to assemble, lack anti-rotation features, are not leak-tight, and have exposed threads, posing safety concerns during assembly.

Innovation Solution

A standoff connection structure with anti-rotation features and sealing elements to provide a leak-tight connection between a standoff connector and a high-voltage electronic box, incorporating hexagonal shapes and seals to prevent rotation and leakage, and a press-fit connection for assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing connector designs are used for high-voltage electronic boxes, then electrical connection between PCB and exterior is achieved, but manufacturing cost increases and assembly complexity increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidconnector assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connector is divided into three separate components: a standoff component with threaded aperture, a connector component with sealing features, and a housing with connector recess. This segmentation allows each component to be manufactured independently with optimized features, reducing overall assembly complexity while maintaining reliable electrical connection through the standardized interface between components

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The standoff component serves multiple functions: it provides mechanical support through the housing wall, creates the electrical connection pathway, and features anti-rotation geometry that also serves as a mounting interface. This multi-functionality reduces the number of separate components needed, simplifying assembly while ensuring reliable electrical connection

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If existing connector designs are used, then electrical pass-through connection is provided, but anti-rotation protection is absent causing potential connector damage

Engineering Contradiction:

Improveconnector connection stabilityVSAvoidconnector rotation damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The standoff component features asymmetric hexagonal outer geometry while the connector component has corresponding asymmetric hexagonal inner geometry. This asymmetric pairing prevents rotation by allowing only one orientation where the geometries mate properly, protecting the connector from rotational damage while maintaining stable electrical connection

Inventive Principle:

Principle #4Asymmetry

3Reliability

If existing connector designs are used, then electrical pass-through is achieved, but exposed threads create safety concerns during assembly

Engineering Contradiction:

Improveelectrical connection establishmentVSAvoidexposed thread safety hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The connector component with its sealing features and threaded aperture is nested within the housing's connector recess, with the standoff component's threads engaged by the connector component. This nested arrangement encloses the threaded interfaces within the housing structure, eliminating exposed threads and safety hazards while maintaining secure electrical connection establishment

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12401143B2High-current electrical pass through standoff connection for electronic box

Publication Date: 2025.08.26 VITESCO TECHNOLOGIES USA LLC

AI summary

A standoff connection structure which is suitable for connecting a standoff connector and a high-voltage electronic box. The standoff connection structure includes at least one anti-rotation feature, and also includes various sealing features to provide a leak-tight connection between a standoff connector and high voltage electronic box, even after exposure to thermal shock. The standoff connector also facilitates an electrical connection between a high voltage or high current component and the high voltage electronic box.