Power Connector Mating Assembly with Insulative Housing
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Solution Overview
Problem
Power connectors in systems with bi-directional power flow pose safety risks due to live accessible energy, leading to potential severe injuries from inadvertent contact with electrically 'hot' pins.
Innovation Solution
A power connector design featuring a mating assembly that moves between positions to protect operators from electrical hazards, with a contact assembly that redirects switching energy away from the connection between pins and sleeves, using insulative housings and operating mechanisms like manual levers or electromagnetic apparatuses to control power flow and prevent direct arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the pins are made accessible for electrical connection, then the ease of operation is improved, but the safety risk increases due to potential inadvertent contact with live pins
Solution Approach 1:
The patent introduces an insulative housing as an intermediary barrier between the operator and the electrical pins. The housing encloses the pins during storage and transport, and only allows access when properly connected to the mating receptacle, thus mediating between the need for accessibility and the need for safety protection.
Solution Approach 2:
The patent implements preliminary protective action by pre-enclosing the pins in an insulative housing before any electrical connection is made. The housing remains in place during insertion and only opens or becomes accessible after the connector is properly mated, ensuring safety is established before operational access is needed.
2Productivity
If the switching energy is allowed to arc between pins and sleeves, then the electrical connection is established, but the wear and heat dissipation increase reducing component lifespan
Solution Approach 1:
The patent introduces a contact assembly with contacts as an intermediary element between the pins and sleeves. These contacts are designed to make initial connection and carry the switching energy, preventing direct arcing between the main pins and sleeves, thus protecting them from wear and heat damage while still enabling rapid electrical connection.
Solution Approach 2:
The patent segments the electrical connection function into multiple stages: the contact assembly handles the high-stress switching operation, while the pins and sleeves handle the steady-state current carrying. This segmentation allows each component to be optimized for its specific function, extending overall system lifespan.
3Object-affected harmful factors
If the mating assembly is kept enclosed for safety, then the operator protection is improved, but the accessibility for connection deteriorates
Solution Approach 1:
The patent implements a dynamic enclosure system where the insulative housing transitions from a closed protective state to an open accessible state based on the connection status. The housing is designed to be rigid during storage for protection, but allows controlled opening or retraction when the connector is properly mated, providing both safety and accessibility as needed.
Data Source
AI summary
An electrical connection element is for a power connector. The power connector has an electrical component including a first insulative housing and a first mating assembly having a number of first electrical mating members structured to be substantially enclosed by the first insulative housing. The electrical connection element includes a second insulative housing; and a second mating assembly comprising a number of second electrical mating members structured to be electrically connected to the number of first electrical mating members. The second mating assembly is structured to move between a first position corresponding to the number of second electrical mating members being substantially enclosed by the second insulative housing, and a second position corresponding to the number of second electrical mating members being partially disposed external the second insulative housing.