Integrated AC Connection Housing With Molded Brass Inserts

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Solution Overview

Problem

Existing rotating rectifier assemblies for generators require complex multi-piece AC housing connections with threaded inserts, preformed packings, and Beryllium Copper components, leading to inefficiencies and safety concerns.

Innovation Solution

A simplified AC housing connection block system using brass inserts with continuous cylindrical interfaces and a polymer housing, eliminating the need for seal rings and Beryllium Copper, with alignment features for proper assembly and cooling, and a method for machining and molding these components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If conventional multi-piece AC housing connections with threaded inserts and preformed packings are used, then electrical connection functionality is achieved, but assembly complexity and manufacturing cost increase

Engineering Contradiction:

Improveassembly complexityVSAvoidconnection reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent combines multiple separate components (housing, inserts, and packings) into a single integrated AC housing connection block. The polymer housing incorporates molded-in threaded inserts and integrated sealing features, eliminating the need for separate preformed packings and reducing assembly complexity while maintaining connection reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The AC housing connection block serves multiple functions simultaneously: it provides structural housing, electrical connection interfaces through integrated inserts, and sealing functionality through molded-in features. This multi-functional design eliminates the need for separate specialized components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If Beryllium Copper components are used in the AC housing, then electrical conductivity and mechanical strength are improved, but manufacturing safety and compliance requirements worsen

Engineering Contradiction:

Improvemechanical strengthVSAvoidmanufacturing safety

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces expensive and hazardous Beryllium Copper components with standard brass inserts that are molded into the polymer housing. This substitution eliminates the safety hazards and compliance requirements associated with Beryllium Copper while maintaining adequate electrical and mechanical properties for the application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent uses a composite construction combining polymer material for the housing with brass inserts for electrical connections. This composite approach provides the necessary mechanical strength and electrical conductivity without requiring hazardous metals like Beryllium Copper, thereby improving manufacturing safety.

Inventive Principle:

Principle #40Composite materials

3Reliability

If preformed packings (o-rings) are used for sealing, then sealing effectiveness is achieved, but assembly steps and manufacturing cost increase

Engineering Contradiction:

Improvesealing effectivenessVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent integrates sealing features directly into the polymer housing structure through molded-in designs. The housing incorporates built-in sealing surfaces and features that work with the integrated inserts, eliminating the need for separate preformed o-ring packings and reducing assembly steps while maintaining sealing effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11894729B2Alternating current connection housing with integrated inserts

Publication Date: 2024.02.06 HAMILTON SUNDSTRAND CORP

AI summary

An assembly comprises an AC (alternating current) housing connection block and a plurality of inserts seated in the AC housing connection block, wherein for each of the inserts, an interface between the insert and the housing is continuous. A method includes inserting a plurality of inserts into a mold; and molding an AC (alternating current) housing connection block.