Spring-Loaded Plug-In Insulation for Air Gap Prevention
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Solution Overview
Problem
High-voltage bushings face challenges in minimizing the risk of electrical breakdown at the contact region between the plug-in device and the receiving device due to potential air gaps caused by insulating material expansion or contraction with temperature fluctuations.
Innovation Solution
A plug-in device with a spring device that exerts an axial force on a pusher element, ensuring close contact between the insulating material and the receiving device, and accommodating thermal expansion or contraction by adjusting the volume of the insulating material, thus eliminating air gaps and reducing the risk of electrical arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating material is used between the insulating body and receiving device, then electrical insulation is improved, but air gaps may form due to thermal expansion/contraction increasing the risk of electrical arcing
Solution Approach 1:
The patent employs a spring device that dynamically adjusts the compression force applied to the insulating material based on temperature-induced volume changes. As temperature fluctuates and the insulating material expands or contracts, the spring device modifies the compressive force to maintain optimal contact pressure, preventing air gap formation and eliminating electrical arcing risks while preserving reliable electrical insulation
Solution Approach 2:
The spring device introduces a dynamic mechanism that automatically adapts to thermal expansion and contraction of the insulating material. Instead of a fixed rigid connection, the spring-loaded pusher element continuously adjusts the contact pressure between the insulating material and both the insulating body and receiving device, ensuring maintained electrical insulation reliability across varying temperature conditions without creating air gaps
2Stability of the object's composition
If the insulating material is rigidly fixed, then contact stability is improved, but thermal expansion and contraction cause air gaps and increase arcing risk
Solution Approach 1:
The spring device transforms the rigid fixed connection into a dynamic adaptive system. The spring-loaded pusher element continuously adjusts the contact pressure on the insulating material as it expands or contracts with temperature changes, maintaining stable contact between the insulating material and both the insulating body and receiving device throughout the thermal cycle, preventing air gap formation and eliminating electrical breakdown risks
Solution Approach 2:
The patent explicitly accounts for thermal expansion and contraction of the insulating material by incorporating a spring device that compensates for volume changes. The spring mechanism allows the insulating material to expand into the available space during heating while maintaining contact pressure, and prevents gap formation during cooling by pushing the material forward, thereby maintaining contact stability and preventing electrical breakdown across the thermal cycle
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 effectively minimizes the risk of electrical arcing by maintaining continuous contact and accommodating thermal changes, ensuring reliable operation of high-voltage bushings.
Implementation Method 1
a spring device which—after the plug-in device has been plugged into the receiving device—exerts an axially acting spring force on the pusher 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 which encloses the inner conductor. The plug-in device has: a main element, which can be fixed indirectly, in particular with the involvement of a housing wall, or directly to the receiving device and which encloses the inner conductor and insulating body; a pusher element, which can be displaced relative to the main element; and a spring device, which, after the plug-in device has been plugged into the receiving device, exerts an axial spring force on the pusher element in the direction towards the receiving device.