Power Connector with Insulating Separation Member for Arc Prevention
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Solution Overview
Problem
Conventional power connectors fail to comply with electric safety standards in high-voltage DC power distribution and supply systems, leading to potential damage and electric arc generation when connecting or disconnecting.
Innovation Solution
A power connector assembly with non-parallel conductive terminals and insulating separation members, featuring complementary profiles for secure coupling and increased creepage distance, along with signal-detecting terminals to prevent electric arc generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional power connectors are used in high-voltage DC power distribution systems, then power transmission is achieved, but electric arc generation and component damage occur
Solution Approach 1:
The insulating separation member is pre-installed within the power connector body to establish creepage distance barriers before power connection occurs. This preliminary structural arrangement ensures that when high-voltage DC power is transmitted, the electric field is already constrained by the insulating barriers, preventing arc flash generation at the moment of connection or disconnection.
Solution Approach 2:
The insulating separation member acts as an intermediary element between conductive terminals, physically separating them to increase creepage distance. This intermediate insulating structure prevents direct electrical breakdown between terminals, thereby mediating the harmful electric arc effect while maintaining necessary electrical connections for power transmission.
2Ease of manufacture
If conductive terminals are arranged in parallel for simple manufacturing, then manufacturing ease is improved, but creepage distance is insufficient leading to safety issues
Solution Approach 1:
The conductive terminals are arranged in a non-parallel asymmetric configuration within the power connector body. This asymmetric arrangement, combined with the insulating separation member, creates varied creepage paths between terminals. The non-uniform spacing and angular relationships between terminals maximize the minimum creepage distance while maintaining manufacturability through standardized molding processes.
3Reliability
If insulating separation members are added to increase creepage distance, then electric safety is improved, but device complexity increases
Solution Approach 1:
The insulating separation member is merged with the power connector body as an integrated component. Rather than being a separate assembly step, the insulating separation structure is molded as part of the connector housing, combining multiple functions (structural support, electrical insulation, creepage distance provision) into a single manufactured part. This merging approach maintains electric safety while minimizing the increase in device complexity.
Solution Approach 2:
The insulating separation member serves multiple functions simultaneously: it provides structural support for conductive terminals, establishes electrical insulation barriers, defines creepage distance paths, and contributes to the overall mechanical integrity of the power connector. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in device complexity while achieving improved electric safety.
Data Source
AI summary
A power connector includes a main body, a first conductive terminal, a second conductive terminal, a third conductive terminal, and an insulating separation member. The first conductive terminal, the second conductive terminal and the third conductive terminal are disposed within the main body and arranged in a non-parallel manner. The insulating separation member is disposed within the main body, and arranged between the first conductive terminal, the second conductive terminal and the third conductive terminal for separating at least two of the first conductive terminal, the second conductive terminal and the third conductive terminal from each other.