Power Connector Protection Structure for IPXXB and Low Heating
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Solution Overview
Problem
Existing connector assemblies face challenges in providing IPXXB protection while accommodating power terminals with large cross-sections to handle high-power currents, as they often fail to prevent accidental contact and limit heating simultaneously.
Innovation Solution
The connector assembly incorporates protection structures, such as ribs or pins, arranged within the cavity to prevent insertion of cylindrical objects larger than 12 mm, while allowing power terminals with diameters greater than 12 mm, ensuring compliance with IPXXB protection and reducing heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If power terminals have large cross-sections to carry high-power currents, then heating is limited, but IPXXB protection cannot be ensured when terminals are inserted through a cavity or passage of insulating housing
Solution Approach 1:
The protection structure is segmented into multiple protection elements (first protection element and second protection element) arranged at different levels in the cavity. This segmentation allows the structure to block fingers at multiple positions, providing redundant protection while accommodating large-diameter terminals that need to pass through the cavity.
Solution Approach 2:
The protection structures are arranged at different levels (different positions along the insertion direction) rather than at the same level. This dimensional arrangement creates a multi-level barrier system that prevents finger insertion while allowing terminal passage, resolving the contradiction between protection and terminal size accommodation.
2Ease of operation
If a cavity or passage of housing is opened on an energized electrical conductor, then access to the conductor is enabled, but IPXXB protection requires limiting the diameter of the cavity or passage to prevent finger contact
Solution Approach 1:
The cavity is equipped with multiple protection elements positioned at different levels, creating segmented barriers that block finger access to energized conductors while maintaining necessary access for terminal insertion and electrical connection operations.
Solution Approach 2:
The protection elements act as intermediary structures within the cavity that mediate between the need for conductor access and the requirement for finger protection. These elements block hazardous access while permitting legitimate operational access.
3Device complexity
If protection structures are arranged at the same level in the cavity, then结构简单 (structure is simple), but large-diameter terminals cannot be inserted while maintaining IPXXB protection
Solution Approach 1:
Protection elements are arranged at different levels along the insertion direction rather than at the same level, utilizing the longitudinal dimension of the cavity. This multi-level arrangement provides both finger protection and adequate clearance for large-diameter terminals to pass through.
Solution Approach 2:
The protection system is divided into multiple segments (protection elements) positioned at different levels, creating a distributed protection architecture that accommodates various terminal sizes while maintaining protection effectiveness.
Data Source
AI summary
A spacer for maintaining one or more wires during a molding process, the spacer having an external frame, and a plurality of spring curved leaves. Each spring curved leaf has a fixed end attached to an inner face of the external frame and a free end. The free ends of the plurality of spring curved leaves are arranged to flexibly wrap the one or more wires.