Stepped Electrical Connector for Structural Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In complex systems like gas turbine engines, where space is limited and mechanical components are subjected to strong forces, it is challenging to locate electrical connectors without compromising structural strength or causing arcing due to the proximity of connector pins.
Innovation Solution
A compact electrical connector assembly featuring a male and female connector with kidney-shaped surfaces and stepped mating surfaces, which allows for reduced hole size in mechanical components, minimizing strength reduction while maintaining adequate insulation to prevent arcing through strategically positioned pins and sockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a standard electrical connector is used with a large hole drilled through the mechanical component, then adequate space is provided for cable routing and connector installation, but the structural strength of the mechanical component is reduced below a suitable threshold
Solution Approach 1:
The patent transitions from a conventional single-plane connector layout to a three-dimensional stepped configuration where pins are arranged at multiple elevation levels. This vertical dimensionality allows the connector to fit through a smaller hole while maintaining adequate pin spacing, thus preserving mechanical component strength while enabling cable routing and installation space.
Solution Approach 2:
The connector design nests pins within a compact insulating body structure that features stepped mating surfaces. The pins are positioned at different levels within the insulating body, creating a nested arrangement that maximizes space utilization and reduces the overall footprint of the connector, allowing installation through smaller holes in mechanical components.
2Strength
If a smaller electrical connector is used to preserve mechanical component strength, then the hole size is reduced and structural strength is maintained, but the pins or contact elements get too close together causing arcing
Solution Approach 1:
By utilizing the vertical dimension with stepped mating surfaces at different elevations, the patent achieves adequate pin spacing without increasing the horizontal footprint of the connector. This allows the connector to be smaller (preserving mechanical strength) while maintaining sufficient dielectric distance between pins to prevent arcing.
Solution Approach 2:
The insulating body with its stepped mating surfaces acts as an intermediary structure that physically separates pins at different levels while providing mechanical support. This intermediary structure maintains reliable electrical isolation between contact elements even in a compact configuration, preventing arcing while enabling smaller connector dimensions.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electrical connector (24;26) includes an electrically insulating body (72;76) having a base mating surface (100;120) and a stepped mating surface (104;124) offset from the base mating surface (100;120). The electrical connector (24;26) either has first and second electrically conducting pins (88A,88B) extending from the base (100) and stepped mating surfaces (104), respectively, or has first and second electrically conducting sockets (90A,90B) extending from an interior portion of the electrically insulating body (76) to the base (120) and stepped mating surfaces (124), respectively.