Spring-Loaded Plug-In Insulation to Minimize Air Gaps
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Solution Overview
Problem
High-voltage bushings face a risk of electrical breakdown due to air gaps between the plug-in device and the receiving device, which can lead to arcing, and existing solutions do not effectively manage temperature-induced expansions or contractions of insulating materials.
Innovation Solution
A plug-in device with a sliding element and a spring device that presses the insulating material into close contact with the receiving device, minimizing air gaps and accommodating temperature fluctuations by yielding or compressing the insulating material, and featuring a pusher section and bearing part to ensure secure contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating material is rigidly fixed between the insulating body and the receiving device, then the electrical insulation is maintained, but air gaps form during temperature fluctuations leading to electrical breakdown
Solution Approach 1:
The patent applies the dynamics principle by making the insulating material deformable rather than rigid, allowing it to dynamically adapt its shape and volume in response to temperature fluctuations. The insulating material can expand when hot and contract when cold, maintaining continuous contact with both the insulating body and the receiving device throughout temperature cycles, thereby preventing air gap formation and electrical breakdown.
Solution Approach 2:
The patent utilizes parameter changes by selecting an insulating material whose physical properties (specifically volume and shape) change in response to temperature variations. This thermally responsive behavior allows the material to automatically compensate for dimensional changes in the insulating body and receiving device, ensuring maintained contact and electrical insulation across varying temperature conditions.
2Adaptability or versatility
If the insulating material is made deformable to accommodate temperature changes, then adaptability improves, but the risk of material failure under electrical stress increases
Solution Approach 1:
The patent applies composite materials by combining the deformable insulating material with the rigid insulating body and receiving device. This composite structure leverages the advantages of both rigid and deformable materials: the rigid components provide structural support and electrical insulation, while the deformable insulating material provides thermal adaptation and maintains contact pressure, creating a synergistic system that satisfies both adaptability and strength requirements.
Solution Approach 2:
The patent implements local quality by applying the deformable insulating material specifically in the contact region between the insulating body and the receiving device, rather than throughout the entire structure. This localized application allows the system to maintain rigidity where structural support is needed while providing deformability only where thermal adaptation is required, optimizing both strength and adaptability.
3Reliability
If a spring device is added to press the insulating material into contact, then contact reliability improves, but device complexity increases
Solution Approach 1:
The patent applies self-service by utilizing the natural thermal expansion and contraction of the deformable insulating material to maintain contact pressure automatically. The material's own physical properties serve as the mechanism for ensuring reliable contact, eliminating the need for external spring devices or active control systems, thereby maintaining simplicity while achieving high contact reliability.
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 significantly reduces the risk of electrical arcing by maintaining contact and adapting to temperature changes, ensuring reliable operation and easy replacement of insulating materials.
Implementation Method 1
a spring device which, when the plug-in device is plugged into the receiving device, exerts an axially acting spring force on the sliding element in the direction of the receiving device
Implementation Method 2
the spring device can absorb expanding or shrinking of the insulating material mentioned in the event of temperature fluctuations
Data Source
AI summary
An electric plug-in device, which is suitable for plugging into an electric receiving device, has an inner conductor and an insulating body that encloses the inner conductor. The plug-in device includes a retaining element which can be firmly connected indirectly, in particular with the help of a housing wall, or directly to the receiving device; a sliding element which can be moved axially along a longitudinal axis of the inner conductor relative to the retaining element includes the internal conductor and the insulating body. When the plug-in device is plugged into the receiving device, the sliding element protrudes into a receiving portion of the receiving device. A spring device exerts an axially active spring force on the sliding element in the direction of the receiving device when the plug-in device is plugged into the receiving device.