Power Feeder Terminal Structure With Extended Creepage Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical power feeder systems face challenges with high amperage connections, particularly in aerospace applications, where a single bolt joint is insufficient for mechanical and thermal support, and traditional dielectric covers fail to provide adequate protection against high voltages and Foreign Object Debris (FOD), especially at high altitudes.
Innovation Solution
A power feeder device with a base and cover configuration that includes multiple connector structures with creepage barriers and alignment systems to enhance electrical isolation, mechanical support, and thermal conductivity, while preventing line of sight between terminals and incorporating multiple fasteners for robustness and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single bolt joint is used for electrical connections, then the device complexity is reduced, but the mechanical strength and thermal conduction area are insufficient for high amperage applications
Solution Approach 1:
The single bolt joint is segmented into multiple fastener points (at least two fasteners per terminal connection). This segmentation distributes the mechanical load and thermal conduction requirements across multiple connection points, providing sufficient mechanical support and thermal management for high amperage applications while maintaining relatively simple device complexity
Solution Approach 2:
The terminal block is nested within a dielectric cover that contains multiple connector structures. Each connector structure houses terminal pairs with multiple fasteners, creating a nested arrangement where fasteners are integrated into the terminal block assembly, which is then enclosed by the protective cover
2Ease of manufacture
If traditional dielectric covers with large openings are used, then ease of manufacture is improved, but protection against high voltage breakdown and small FOD elements is insufficient
Solution Approach 1:
The dielectric cover extends in the vertical dimension with protruding portions that insert into gaps between adjacent connector structures. This dimensional extension creates additional creepage path length without complicating the horizontal manufacturing process, providing enhanced electrical isolation and protection against high voltage breakdown while maintaining ease of manufacture
Solution Approach 2:
The dielectric cover acts as an intermediary barrier between adjacent high voltage terminals. The protruding portions of the cover insert into the gaps between connector structures, creating a physical and electrical isolation barrier that prevents direct arcing and protects against small FOD elements while allowing the terminals to maintain their simple manufactured form
3Ease of operation
If connector structures are spaced apart to form gaps, then ease of operation for terminal access is improved, but electrical isolation and creepage path length are reduced
Solution Approach 1:
The dielectric cover is segmented into multiple protruding portions, with each portion inserting into the gap between adjacent connector structures. This segmentation allows the cover to maintain electrical isolation across the gaps while still permitting operational access to terminals through the lateral openings, resolving the contradiction between isolation and accessibility
Solution Approach 2:
The dielectric cover extends vertically into the gaps between connector structures, adding a third dimension to the electrical isolation strategy. This vertical extension creates sufficient creepage path length for high voltage isolation while leaving the horizontal lateral openings intact for terminal access, thereby maintaining both electrical isolation and ease of operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides improved mechanical strength, reduced thermal losses, and enhanced protection against voltage breakdown and contamination, ensuring reliable high-amperage connections in harsh environments with increased creepage paths and integrated dielectric protection.
Implementation Method 1
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
Implementation Method 2
Each of the plurality of connector structures includes first and second barrier walls extending from the mounting portion and axially spaced apart to block a line of sight to an adjacent connector structure
Implementation Method 3
These have a single bolt (threaded fastener) and are compatible with power levels of hundreds of amperes and large wire gauge feeders
Implementation Method 4
The electrical conduction area needs to have good mechanical loading distributed across the electrical interfaces for low resistance and to prevent mechanical movement due to vibration or thermal cycling
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 adjacent pairs 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.