Electrical Plug Connector Isolator Structure for Creepage Distance
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Solution Overview
Problem
Existing electrical plug connectors face challenges in maintaining a sufficient creepage distance between live contact elements, leading to potential electrical shorting due to the need for slitting the isolator element to form elastic latching mechanisms, which reduces insulation effectiveness.
Innovation Solution
An electrical plug connector design featuring a dimensionally elastic isolator element with a variable cross-sectional profile that maintains an unchanged internal circumference, allowing for axial blocking and unblocking of contact elements without slitting, thereby enhancing creepage distance and insulation between live contact elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an elastic latching element is formed in the isolator element, then the contact element can be axially fixed, but the creepage distance is shortened and electrical shorting may occur
Solution Approach 1:
The isolator element is divided into a rigid portion and an elastic portion, with the elastic portion further segmented into multiple elastic arms. This segmentation allows the latching function to be distributed across multiple isolated elastic arms, maintaining creepage distance while providing reliable axial fixing through collective engagement.
Solution Approach 2:
Different portions of the isolator element are assigned different mechanical properties: the rigid portion provides structural support and electrical insulation, while the elastic portion provides the latching function. This local differentiation allows the elastic arms to deform for locking while maintaining adequate creepage distance to adjacent contact elements.
2Ease of operation
If the isolator element is slitted to form an elastic latching mechanism, then axial locking is achieved, but the insulation effectiveness is reduced
Solution Approach 1:
Instead of a single continuous slit, the design uses multiple discrete elastic arms that are locally flexible. These segmented elastic elements provide the necessary compliance for locking while maintaining electrical insulation between arms and adjacent conductors.
Solution Approach 2:
The elastic arms are nested within the isolator element structure, with each elastic arm contained within its own defined space. This nesting allows the elastic elements to deform for locking functionality while remaining electrically isolated from adjacent contact elements by the rigid isolator material.
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 design effectively increases the creepage distance and reduces the probability of electrical shorting by implementing elasticity through a deformable cross-sectional profile of the isolator element, ensuring reliable insulation and secure axial fixing of the inner conductor contact element.
Implementation Method 1
the isolator element, at least in an axial portion in which the counter-blocking means is formed, has a cross-sectional profile that is dimensionally elastic in such a manner that a spacing between two mutually opposite regions of the internal face is variable when transitioning between the blocked state and the unblocked state
Data Source
AI summary
An electrical plug connector has an inner conductor contact element and an isolator element which encases the inner conductor contact element at least in portions. A blocking structure is formed on an external face of the inner conductor contact element, and a counter-blocking structure is formed on an internal face of the isolator element. The blocking structure and the counter-blocking blocking in a blocked state impact axially on one another, and in an unblocked state are movable axially relative to one another. The isolator element, at least in an axial portion in which the counter-blocking structure is formed, has a cross-sectional profile that is dimensionally elastic in such a manner that a spacing between two mutually opposite regions of the internal face is variable when transitioning between the blocked state and the unblocked state. The elastic cross-sectional profile has an invariable internal circumference.