Protective Cover Radiation Windows for High-Voltage Connectors
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Solution Overview
Problem
Conventional high-voltage electrical connectors have opaque conductive shields that prevent visual inspection of the contact status, making it difficult to achieve a safe disconnect without compromising electrical functionality or safety.
Innovation Solution
A protective cover with radiation windows formed by a plurality of adjacent openings in the electrically conductive layer, allowing optical radiation to penetrate while maintaining electrical screening effectiveness, fabricated using a transparent insulating main body and an overmolded opaque conductive layer with chamfered geometry to avoid sharp edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an opaque electrically conductive outer screen is used to cover the connector, then electrical functionality and safety are improved, but visual inspection of contact status becomes impossible
Solution Approach 1:
The radiation window is segmented into a plurality of adjacent openings within the electrically conductive layer. This segmentation allows optical radiation to penetrate through the gaps while the conductive material maintains electrical screening between the openings, thus enabling visual inspection while preserving electrical functionality and safety
Solution Approach 2:
The electrically conductive layer is designed with locally different properties: in the regions of the openings, it allows optical radiation passage, while in the adjacent conductive regions, it maintains electrical screening. This local differentiation enables simultaneous achievement of visual inspection and electrical safety
2Loss of information
If an opening is provided in the outer shield to enable visual check, then visual inspection capability is improved, but electrical conductivity and safety are compromised
Solution Approach 1:
Rather than providing a single large opening that would compromise electrical conductivity, the window is segmented into multiple smaller adjacent openings. The conductive material bridges these openings, maintaining electrical continuity and screening effect while still allowing sufficient light transmission for visual inspection
Solution Approach 2:
The protective cover combines transparent insulating material with opaque conductive material in a composite structure. The transparent main body allows light passage, while the overmolded conductive layer provides electrical screening with integrated openings, creating a composite material system that simultaneously achieves optical transparency and electrical conductivity
3Loss of information
If a transparent insulating main body with overmolded conductive layer is used, then visual inspection through radiation windows is enabled, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process merges multiple steps into an integrated overmolding operation. The transparent insulating main body is first formed, then the opaque conductive layer is overmolded directly onto it in a single continuous process, creating the final composite structure with integrated radiation windows. This combining of steps reduces overall manufacturing complexity despite the multi-material nature
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
Enables safe visual verification of the contact status without compromising electrical functionality or safety, allowing for a visible disconnect and enhanced monitoring capabilities through optical communication links.
Implementation Method 1
at least one radiation window is formed in the electrically conductive opaque layer by a plurality of radiation passages for allowing optical radiation to penetrate the protective cover
Data Source
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AI summary
The present invention relates to a protective cover for an electric component and to a method of fabricating such a protective cover. Furthermore, the present invention relates to an electrical connector assembly, in particular a high-voltage connector assembly, which uses a protective cover according to the present invention, and to a method of monitoring the connected status of such an electrical connector assembly A protective cover according to the present invention comprises an electrically insulating at least partly transparent or translucent main body (118), an electrically conductive opaque layer (120), wherein the electrically conductive layer (120) comprises at least one radiation window (128) formed by a plurality of radiation passages (130) for allowing optical radiation to penetrate the protective cover.