Ribbed Insulative Wall Electrical Connector Safety
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Solution Overview
Problem
Existing electrical connection systems for high-voltage, high-current applications often require complex moving parts to prevent finger contact with electrical terminals, leading to increased manufacturing costs and potential reliability issues due to tight tolerances.
Innovation Solution
An electrical connection assembly featuring a first connector with a ribbed insulative wall and a second connector with slotted body towers, preventing human contact with electrical contacts until mating, eliminating the need for moving parts and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a complex moving part connection system with protective pieces is used to prevent finger contact with electrical terminals, then safety is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the complex moving protective piece mechanism entirely and extracts only the essential protective function by using a fixed insulative barrier structure that prevents finger contact without requiring mechanical movement or complex components
Solution Approach 2:
The patent replaces the mechanical moving protective piece system with a static insulative barrier structure, eliminating mechanical complexity while maintaining the safety function of preventing finger contact with electrical terminals
2Object-affected harmful factors
If tight tolerances are applied to allow protective piece movement between positions, then protective function is improved, but manufacturing precision requirements and cost increase
Solution Approach 1:
The insulative barrier is pre-positioned in a fixed location within the connector housing during manufacturing, eliminating the need for post-assembly adjustments or tight tolerances on moving protective pieces. The barrier is integrated into the housing structure itself, ensuring proper positioning without requiring precise mechanical tolerances
3Ease of manufacture
If a fixed insulative barrier structure is used instead of moving parts, then manufacturing cost is reduced, but electrical communication during mating may be affected
Solution Approach 1:
The connector is segmented into distinct functional zones: the insulative barrier occupies the outer periphery to provide safety, while the central region remains clear for electrical contact engagement. This segmentation ensures that the fixed barrier does not interfere with the mating process or electrical communication between connectors
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
An electrical connection assembly (200, 300) includes a first connector (202, 302) which includes a first electrical contact (250, 350) surrounded by a first connector wall (254, 354) defining a first connector cavity (256, 356). The first connector wall (254, 354) includes a plurality of ribs (262, 362) extending into the first connector cavity (256, 356). A second connector (204, 304) is matable with the first connector (202, 302) along a mating axis (A, B) and includes a second electrical contact (210, 310) in electrical communication with the first electrical contact (250, 350) when the first connector (202, 302) is mated with the second connector (204, 304). The second connector (204, 304) includes a second connector body (212, 312) surrounding the second electrical contact (210, 310).