Underwater Electrical Connector with Stepped Pin for High Voltage
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Solution Overview
Problem
Existing underwater electrical connectors face challenges with high voltage applications, including electrical stress, material degradation, and heating issues due to high electric field gradients, which affect efficiency and reliability.
Innovation Solution
The design incorporates a contact pin with an axially extending conductive core and annular insulation portion, featuring a larger rear end diameter for increased stiffness and a conductive sleeve with a split collar for improved heat dissipation and electrical stress management, along with an earth guide member to control electric stress and prevent water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the conductive core has a constant diameter, then the manufacturing is simpler, but the rear end portion cannot have increased stiffness
Solution Approach 1:
The conductive core is designed with different diameters at different locations: a larger diameter at the rear end portion for increased stiffness and strength, and a smaller intermediate diameter to accommodate the insulating sleeve. This local variation in geometry optimizes both mechanical properties and assembly characteristics without requiring complex manufacturing processes.
2Reliability
If the annular insulation portion has sufficient thickness, then electrical stress is reduced, but the overall diameter of the contact pin increases
Solution Approach 1:
The insulating sleeve is positioned specifically at the intermediate portion of the conductive core where the diameter is smaller, rather than uniformly distributing insulation thickness. This localized insulation approach provides adequate electrical stress protection at critical interfaces while minimizing the overall diameter increase of the contact pin.
Solution Approach 2:
The earth shield extends radially outward from the insulating sleeve to provide additional electrical stress management in the radial dimension, allowing the axial insulation thickness to be optimized independently. This multi-dimensional approach to electrical isolation enables sufficient protection without excessive overall diameter.
3Strength
If the contact pin has a larger rear end diameter, then stiffness is improved, but the insulating sleeve cannot be easily inserted
Solution Approach 1:
The conductive core features a stepped diameter profile with a smaller intermediate portion that serves as an insertion path for the insulating sleeve, while the rear end portion maintains a larger diameter for structural stiffness. This local geometric variation simplifies assembly by providing a clear path for sleeve installation without compromising the mechanical strength of the rear end.
4Reliability
If the earth shield is provided, then electrical stress shielding is improved, but the device complexity increases
Solution Approach 1:
The earth shield is integrated with the insulating sleeve to form a combined electrical stress management component. This merged structure provides both insulation and earth shielding functions through a single assembly unit, reducing the number of separate components and simplifying the overall device complexity while maintaining effective electrical stress protection.
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
This configuration enhances the reliability and efficiency of underwater electrical connections by reducing material degradation, managing electrical stress, and maintaining performance under high voltage conditions while preventing water exposure.
Implementation Method 1
the rear end portion of the conductive core of the pin having a diameter larger than the diameter of the intermediate portion thereof
Implementation Method 2
the annular insulation portion comprising an inner insulating layer around the intermediate portion of the conductive core and an insulating sleeve around the inner insulating layer
Implementation Method 3
A certain minimum thickness is required for the annular insulation portion between the conductive core and the earth shield, to avoid excessively high electrical stresses in the insulation material
Implementation Method 4
The use of high voltages creates issues concerning the electric field around the live components, and the electric stress created in insulating components in the case of high electric field gradients. Insulating materials can suffer from breakdown of the materials above a critical level of electric field gradient. The drawing of high currents through the connector raises issues about heating and it is desirable to avoid hot spots
Data Source
AI summary
An underwater electrical connection assembly may include a contact pin including an axially extending conductive core and an axially extending annular insulation portion around said conductive core, a front end portion of the conductive core having an electrical contact surface, a rear end portion of the conductive core having an electrical contact surface, and an intermediate portion of the conductive core extending axially at an intermediate location between the front and rear end portions, wherein the rear end portion of the conductive core of the pin has a diameter larger than the diameter of the intermediate portion thereof, and wherein the annular insulation portion includes an inner insulating layer around the intermediate portion of the conductive core and an insulating sleeve around the inner insulating layer.