Power Feeder Connector Structure for Arc Isolation and Vibration Loads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical power feeder systems are inadequate for high amperage and high vibration environments, particularly in aerospace applications, as they lack sufficient electrical conduction and support, and do not effectively prevent arcing and contamination.
Innovation Solution
A power feeder device with a base and cover configuration that includes connector structures with barrier walls and lateral walls to block line of sight and increase creepage path length, along with a base plate pocket for terminal mounting and an insulating seal to prevent arcing and contamination, suitable for high voltage applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single threaded fastener is used for electrical power connection, then the device complexity is low, but the electrical conduction and mechanical support are insufficient for high amperage and high vibration environments
Solution Approach 1:
The connector is divided into multiple connector structures (e.g., three connector structures for three-phase systems), each handling individual terminal connections. This segmentation allows each connector to be optimized for high amperage and vibration resistance while maintaining manageable complexity through modular design.
Solution Approach 2:
The connector structure merges electrical conduction function with mechanical support function in a unified design. The connector structures provide both electrical pathways for high amperage and mechanical anchoring for vibration resistance, eliminating the need for separate fastening mechanisms.
2Object-affected harmful factors
If connector structures are spaced closely together, then the device compactness is improved, but the line of sight between adjacent terminals is not blocked, allowing arcing and contamination
Solution Approach 1:
The barrier walls extend in the axial dimension between connector structures, blocking line of sight between adjacent terminals. This dimensional approach to arc prevention allows compact lateral spacing while maintaining electrical isolation through vertical barrier elements.
Solution Approach 2:
The barrier walls act as intermediary elements between adjacent connector structures, physically blocking the path for arcs and preventing contamination while allowing the connectors to remain closely spaced for compactness.
3Object-affected harmful factors
If the creepage path between terminals is kept short, then the device compactness is improved, but the resistance to arcing and electrical breakdown is reduced
Solution Approach 1:
The cover provides localized creepage path extension specifically in the critical regions between terminals. The insert walls and side walls create tortuous creepage paths at strategic locations where arc risk is highest, rather than uniformly increasing the entire device dimensions.
Solution Approach 2:
The cover structure extends the creepage path by utilizing the vertical dimension and lateral dimensions through insert and side walls, creating a three-dimensional creepage route that increases arc resistance without significantly increasing the device's primary length.
4Object-affected harmful factors
If the connector structures are fully enclosed, then the protection from contamination is improved, but the terminal access for connection is reduced
Solution Approach 1:
The terminal openings are pre-configured in the base and cover structures to allow necessary terminal access before enclosure is finalized. The design anticipates connection needs by providing adequate opening dimensions and positions during the design phase, eliminating the need for post-assembly modifications.
Solution Approach 2:
The cover acts as a flexible enclosure that can be removed or opened for terminal access during installation and maintenance, then closed to provide contamination protection during operation. This flexible enclosure approach balances protection needs with operational access requirements.
Data Source
AI summary
A power feeder device can include a base having a mounting portion and a plurality of connector structures extending from the mounting portion and spaced apart relative to each other to form a respective gap therebetween. Each connector structure can be configured to receive a respective pair of terminals to electrically connect the respective pair of terminals within connector structures and to block a line of sight between an adjacent pair of terminals. The device can also include a cover configured to mate with the base to enclose each of the plurality of connector structures and to increase a length of a creepage path between each pair of terminals by at least partially inserting into each gap between the connector structures. The base and the cover can be configured to form a terminal opening on each lateral side when assembled to allow pass-through of a conductor and/or portion of each terminal.