Flexible Multi-Channel High-Voltage Electrical Connectors: Design and Performance Optimization

Abstract

High-voltage electrical connectors are critical components in many industries, from power transmission to aerospace. Conventional rigid connectors have limitations in applications where flexibility and a compact design are required. This paper presents the design and optimization of flexible multi-channel high-voltage connectors aimed at overcoming the constraints of rigid connectors. The proposed connector design features a modular construction with individual high-voltage channels encased in a flexible polymer matrix. The polymer matrix provides electrical insulation while allowing for deformation and bending. Through finite element analysis (FEA) and design of experiments (DOE), key design parameters, including channel geometry, polymer composition, and connector layout, were optimized to maximize electrical performance and mechanical robustness. Prototypes were fabricated and tested, demonstrating a high dielectric breakdown strength exceeding 30 kV/mm, low leakage current, and the ability to withstand over 100,000 bend cycles at a bend radius of 5 cm without degradation. The optimized connectors exhibit superior performance compared to commercial alternatives, unlocking new possibilities for compact, high-density, and flexible high-voltage interconnects.