This application claims priority to foreign European patent application No. EP 22305238.2, filed on Mar. 2, 2022, the disclosure of which is incorporated by reference in its entirety.
The present invention relates to the field of high-voltage electrical connectors and more particularly to the field of high-voltage electrical connectors for the space sector.
In the space sector, high-voltage electrical connectors are known to those skilled in the art. “High-voltage electrical connectors” are understood here and in the remainder of the application to mean connectors that can operate at a voltage greater than 5 kV. It is known practice to produce a high-voltage connector by way of direct wired interconnects that include soldering of the wires in the high-voltage modules and overmoulding of this module in order to produce the electrical insulation.
This technique of interconnection by means of a solid insulator allows the electrical connection to be made robust to the entire range of service pressures from atmospheric pressure to deep vacuum during the mission in orbit.
In spite of this excellent functionality, this technique has several disadvantages:
New markets call for the compactness of the satellite to be increased, and this interconnection technique is therefore impossible or very difficult to imagine if the number of TWTs connected to a single EPC needs to be increased.
This is because the fact that the electronic part can be shared in order to supply power to more than two TWTs means that the present solution is inherently limited and poses numerous problems in terms of logistics and in terms of production means. Supplying power to more than two TWTs is particularly critical for producing satellites comprising an active antenna, which advantageously have a very large number of TWTs, thus creating a high level of complexity for the high-voltage interconnect.
In the aeronautical sector, high-voltage electrical connectors are known to those skilled in the art. These connectors are designed to operate over a certain range of altitudes (from sea level to often 33 000 feet or 10 000 m), that is to say for a predetermined pressure range. Typically, aeronautical connectors are made airtight, for example by means of seals around the electrical contact, in order to keep the air trapped between the electrical contacts at atmospheric pressure.
However, this type of connector is not necessarily designed to operate over a very long life (15 years or more) as required in the space sector. This is because, in aeronautics, they will be subject to a maintenance plan that entails maintaining or replacing them. The use of a gasket raises many questions about the behavior of the connector when it is inevitably degassed over a very long period of use. This is because the airtightness is not perfect and necessarily has a micro-leak that will change the internal pressure of the connector.
The invention aims to overcome certain problems of the prior art. To this end, a subject of the invention is a high-voltage electrical connector for the space sector, comprising a male portion and a female portion that are intended to produce an electrical contact. The connector of the invention is ventilated and has the advantage of allowing the male portion and the female portion to be easily separated. “Ventilated” is understood here and in the remainder of the description to mean that the connector is capable of being pumped so as to achieve a high vacuum (pressure less than 10-6 mbar) or less, particularly in its electrical contact region.
To this end, a subject of the invention is a high-voltage electrical connector for the space sector, comprising a male portion and a female portion, which are intended to produce an electrical contact between the portions, said male portion comprising:
According to one embodiment of the device of the invention, the leakage duct is the only means for the air included between the female structured region and the male structured region to flow to the outside of said connector.
According to one embodiment of the device of the invention, a portion of the leakage duct in which the electrical contact is arranged extends in the direction x, so that said portion is substantially perpendicular to field lines associated with said electrical contact. Preferably, a thickness of the leakage duct is small enough for there to be no electric breakdown in the air at a pressure of 1 Pa within the leakage duct.
According to one embodiment of the device of the invention, the male structured region is adapted so that what is called a male leakage line between the electrical contact and the male external shell, passing through a surface of the leakage duct that is included in the male dielectric block, has a length greater than a predetermined dielectric breakdown distance associated with said predetermined voltage, at atmospheric pressure, and the female structured region is adapted so that what is called a female leakage line between the electrical contact and the female external shell, passing through a surface of the leakage duct that is included in the female dielectric block, has a length greater than said predetermined dielectric breakdown distance. Preferably, the male leakage line has a length greater than 1.2 cm and the female leakage line has a length greater than 1.2 cm, for a predetermined voltage of 7 kV.
According to one embodiment of the device of the invention, the number of openings and the dimensions of the openings are adapted according to a volume of the leakage duct, so that it is possible to obtain a high vacuum in the leakage duct in a predetermined time.
According to one embodiment of the device of the invention, the male and female recesses are in the form of hollow cylinders.
According to one embodiment of the device of the invention, the device comprises a plurality of basic connectors. Preferably, said basic connectors are arranged so as to form a row or a matrix. Even more preferably, the device comprises a first basic connector and a second basic connector, which are aligned along a direction y perpendicular to x, sharing one and the same leakage duct, and what is called a male intercontact leakage line, between the electrical contact of the first basic connector and the electrical contact of the second basic connector, passing through a surface of the leakage duct that is included in the male dielectric block, has a length greater than a predetermined dielectric breakdown distance, associated with the predetermined voltage, at atmospheric pressure, and what is called a female intercontact leakage line between the electrical contact of the first basic connector and the electrical contact of the second basic connector, passing through a surface of the leakage duct that is included in the female dielectric block, has a length greater than said predetermined breakdown distance
Other features, details and advantages of the invention will become apparent on reading the description provided with reference to the appended drawings provided by way of example, in which, respectively:
Unless indicated otherwise, the elements in the figures are not to scale.
The invention relates to a high-voltage electrical connector 1 for the space sector comprising a male portion M and a female portion F, which are intended to produce an electrical contact CE.
In the connector of the invention, the male portion M comprises a metal male external shell CM and the female portion F comprises a metal female external shell CF. These shells CM and CF are protective shells known to those skilled in the art.
The male portion M moreover comprises a male dielectric block DM encapsulated by the male shell CM. The block DM is made from polyether ether ketone (also called PEEK), for example, or else from any dielectric materials known to those skilled in the art. The block DM moreover has what is called a male structured region RSM comprising what is called a male recess RM.
Moreover, the male portion M comprises a male part PM of the electrical contact CE that is at least partially embedded in the dielectric block DM. The male part comprises what is called a male end EM, which is arranged in the male recess RM. This male part PM is known to those skilled in the art and is adapted to be connected to a high-voltage power supply (not shown in
The portion F itself also comprises a female dielectric block DF that is encapsulated by the female shell CF and has a female structured region RSF comprising a female recess RF. This block DF is itself also an electrical insulator that will be able to be used, by way of its cooperation with the block DM, to ensure proper electrical operation of the connector 1 at atmospheric pressure and under high vacuum.
Moreover, the portion F comprises a female part PF of the electrical contact CE that is at least partially embedded in the female dielectric block DF and extends in the direction x. In order to produce the electrical contact, what is called a female end EF of the female part is arranged in the female recess RF and the female end EF is adapted so that the male end EM is able to interlock with the female end EF in order to create the electrical contact CE. The electrical contact CE is defined as the contact zone between the male end EM and the female end EF. The principle of creating electrical contact from a male end EM and a female end EF that are capable of interlocking with one another is well known to those skilled in the art.
The term basic connector CNE is used to refer to an assembly formed by the male part PM, the female part PF, the male recess RM and the female recess RF.
Essentially, in the connector of the invention, the male external shell CM or female external shell CF has at least one opening O crossing the shell and opening onto the outside of the connector. These openings, which are also called “event holes”, can be used to place the connector 1 under high vacuum in order to produce its electrical insulation. By way of illustration, in
Finally, in the connector 1, the male structured region RSM has a shape that complements a shape of the female structured region RSF, so that the male structured region is capable of being inserted into the female structured region, or vice versa. Moreover, the two structured regions are configured so as, when inserted into one another, to allow the electrical contact CE and the creation of a leakage duct AC between the female structured region and the male structured region. This duct allows air included between the female structured region and the male structured region to flow to the opening. In the connector, the leakage duct AC is the only means for the air included between the female structured region and the male structured region to flow to the outside of the connector.
It is understood that the interlocking of the male end EM and the female end EF, and the creation of the leakage duct AC, are permitted both by way of the insertion of the regions RSM and RSF but also by way of the cooperation of the male shell CM and the female shell CF. That is to say that the male shell CM and the female shell CF each have a 3D structure that makes it possible to create the duct AC and prevents for example a portion that protrudes from the region RSM from being in contact with the region RSM, which would block the duct AC.
The leakage duct AC of the invention has several advantages:
The connector of the invention therefore has an ingenious structure that allows the male portion and the female portion to be easily separated and that is capable of being used at atmospheric pressure and under high vacuum over a very long life (greater than 15 years). It is therefore particularly suited to producing satellites comprising an active antenna having a very large number of TWTs.
To the right of and below the Paschen curve (portion R1 in
Thus, at atmospheric pressure, it is necessary to prevent a routing between the shell CM and the contact CE passing along the surface of the block DM. As such, according to one embodiment of the invention, the male structured region is adapted so that what is called a male leakage line LM between the electrical contact and the male external shell, passing through a surface of the leakage duct that is included in the male dielectric block, has a length greater than a predetermined dielectric breakdown distance associated with the predetermined operating voltage of the connector, at atmospheric pressure. This predetermined dielectric breakdown distance corresponds to the maximum distance between two electrodes, passing through the surface of an insulator, for which the routing takes place between the two electrodes, for a given voltage and a given pressure. This dielectric breakdown distance is determined by standard rules (see for example paragraph 5.1.10 of ECSS-E-HB-20-05A).
Likewise, in order to prevent a routing between the shell CF and the contact CE, passing along the surface of the block DF, the female structured region is adapted so that what is called a female leakage line LF between the electrical contact CE and the female external shell CF, passing through a surface of the leakage duct AC that is included in the female dielectric block DF, has a length greater than the predetermined dielectric breakdown distance.
Preferably, the male leakage line and the female leakage line have a length greater than 1.2 cm, for a predetermined voltage of 7 kV, in order to prevent the occurrence of the routing phenomenon.
It is noted that the condition relating to the length of the lines LM and LF necessarily allows prevention of the occurrence of breakdown in the air at this pressure between the electrical contact CE and the male external shell CM, on the one hand, and the female external shell CF, on the other hand. This is because the breakdown in the air takes place for a voltage greater than the routing (or a shorter distance between two electrodes), and therefore if the routing is prevented, the breakdown in the air is prevented.
When the air pressure decreases, the Paschen curve (portion R2 in
If the pressure continues to fall, we are then below and to the left of the Paschen curve (portion R3 in
In the invention, the male region RSM and the female region RSF can exhibit any shape without departing from the scope of the invention so long as the male region RSM is capable of being inserted into the female region RSF, or vice versa, so as to create the leakage duct AC. Thus, according to the embodiment illustrated in
Moreover, according to one embodiment of the invention, which is different from that illustrated in
Likewise, the specific shape of the recesses RF and RM is not relevant to the invention so long as the male region RSM is capable of being inserted into the female region RSF. By way of non-limiting example, the recesses RF and RM are in the shape of hollow cylinders having a square base, a circular base or a polygonal base.
In the invention, the male structured region RSM should not be in contact with the female structured region RSF without sealing the leakage duct AC. This could prevent the high vacuum from being achieved in the connector 1 and/or could disrupt the protection of the connector against electric breakdown.
Preferably, the number of openings and the dimensions of the openings are adapted according to the volume of the leakage duct, so that it is possible to obtain a high vacuum in the leakage duct (or a pressure equilibrium between the leakage duct and the outside of the connector) in a predetermined time. This predetermined time is defined by the specifications of the user and by standards related to the field of use.
Preferably, the region RSM and the region RSF have a structuring that can be used to limit the effects of projections related to their volume. Thus, preferably, the region RSM and the region RSF are such that the edges of the leakage duct are rounded.
According to a preferred embodiment of the invention, the portion of the leakage duct PAC extends in the direction x, as illustrated in
According to a preferred embodiment of the invention, denoted MP, the connector of the invention comprises a plurality of basic connectors CNE, for example arranged so as to form a row or a matrix. This allows the number of signals transmitted by the connector 1 to be maximized.
Number | Date | Country | Kind |
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22305238.2 | Mar 2022 | EP | regional |