Plug Insulating Body With Circumferential Webs For Tracking Resistance
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Solution Overview
Problem
Existing electrical connectors face challenges in maintaining effective basic insulation, particularly due to erosion of brass contact pins and associated contamination, which can reduce protection against direct contact and increase the risk of electric shock.
Innovation Solution
A plug design featuring a rotationally symmetrical insulating body with circumferential webs and a conical outer contour, combined with a mushroom head and threaded connection, enhances tracking resistance and prevents impurity accumulation, using a polyamide insulating body that can be easily mounted on the contact pin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating caps are provided on contact pins to protect against direct contact, then basic insulation is improved, but erosion of brass contact pins and contamination can reduce the protective insulation over time
Solution Approach 1:
The patent transitions from a simple cap covering approach to a webbed structure that extends the insulation path in multiple dimensions. The circumferential webs create a three-dimensional barrier that increases the creepage distance across the insulating cap surface, making it more resistant to contamination and tracking effects.
Solution Approach 2:
The insulating cap is made from highly tracking-resistant plastic material that combines electrical insulation properties with resistance to contamination and tracking. This composite approach ensures long-term reliability even when exposed to moisture and conductive contaminants.
2Ease of manufacture
If a simple insulating cap is used on the contact pin, then basic protection is provided, but the tracking resistance under moisture and contamination is insufficient
Solution Approach 1:
The insulating cap is segmented into multiple functional zones: a base portion covering the contact pin, and multiple circumferential webs extending outward. This segmentation creates multiple insulation barriers that collectively provide high tracking resistance while remaining manufacturable as a single molded piece.
Solution Approach 2:
The circumferential webs add vertical and radial dimensions to the insulation structure, creating a three-dimensional barrier network that significantly increases the creepage path length without substantially increasing the overall size or complexity of the component.
Data Source
Figure 1~3
Figure 4~6
AI summary
The plug has a contact pin (3) arranged within a plug housing. The contact pin is provided with an electric shock protection unit that is formed by an isolation body (4) attached to the contact pin. The electric shock protection unit includes a base body, and a rotary rod is formed on a mantel surface of the base body. The base body is symmetric rotationally formed in a form of cylinder or cone part, and an outer contour of the mantel surface of the base body provided with the rod. The isolation body is formed of a plastic material selected from polyamide.