Basket-Shaped Housing Electrical Connection Sealing
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Solution Overview
Problem
Existing electrical devices face challenges in maintaining a permanent, airtight and stable electrical connection between internal components and external cables, especially under temperature fluctuations and mechanical stress, due to the weak sealing at the connection point and conflicting requirements for cable lugs.
Innovation Solution
The electrical device features a basket-shaped housing configuration with recesses and a metallic sealing ring and cap system that ensures airtight sealing, combined with a low-resistance conductor and bolt assembly for secure and conductive connections, allowing for high-torque stability and low-impedance current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cable lug is screwed onto the housing with large torque to prevent movements and ensure stable electrical connection, then the electrical connection stability is improved, but the sealing at the connection point deteriorates because the plastic injection molding detaches from the current conductor due to temperature fluctuations
Solution Approach 1:
The connection system is divided into separate functional components: a cable lug for mechanical connection and electrical contact, a current conductor for current transmission, and a sealing element for hermetic sealing. This segmentation allows each component to be optimized independently - the cable lug can be torqued for stability while the sealing element maintains the seal without being affected by the mechanical fastening forces
Solution Approach 2:
A sealing element is introduced as an intermediary component between the cable lug/current conductor assembly and the housing. This sealing element (such as an O-ring or gasket) specifically addresses the sealing function at the connection point, allowing the cable lug to be securely fastened with large torque while the sealing element compensates for any gaps and maintains the hermetic seal despite temperature fluctuations
2Object-affected harmful factors
If the housing is hermetically sealed to protect components from environmental influences, then the protection from dust and moisture is improved, but the electrical connection from inside to outside the housing becomes more difficult to maintain airtight
Solution Approach 1:
A sealing element acts as an intermediary that enables the electrical connection to penetrate the hermetically sealed housing while maintaining the seal. The sealing element is positioned at the connection point where the current conductor passes through the housing wall, allowing electrical current to conduct through while preventing dust and moisture ingress
Solution Approach 2:
The sealing solution is applied locally at the connection point rather than requiring the entire housing seal to be compromised. The sealing element (such as an O-ring or gasket) is specifically installed at the penetration point where the current conductor exits the housing, providing localized sealing that maintains the overall hermetic integrity of the housing while allowing the electrical connection to function
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 maintains a stable and airtight electrical connection capable of withstanding temperature fluctuations and mechanical stress, ensuring reliable current transmission and corrosion protection while supporting high current flow with minimal resistance.
Implementation Method 1
The sealing ring has an annular, closed, integral groove on the side wall, with an O-ring being coated in this groove. This O-ring seals the gap between the sealing ring and the first recess in an airtight manner.
Implementation Method 2
A metallic sealing ring and a sealing cap are preferably used as the sealing means, the sealing ring and the sealing cap being arranged at the two openings of the first recess and closing this recess from both sides or sealing it airtight.
Implementation Method 3
An electrical current conductor protrudes from the housing interior into the first recess through this second recess, this current conductor making electrical contact with the electrical or electronic component located in the housing interior
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to an electrical apparatus having an electrical or electronic component and a housing which encloses this component, wherein this apparatus has an air-tight stable electrical connection from the housing interior to the housing exterior. The electrical apparatus according to the invention has an electrical or electronic component and a housing, wherein the component is arranged in this housing, wherein the housing has a basket-like shaped portion on a side wall, wherein the shaped portion has a first cutout in the floor, and the side wall of the housing has a second cutout, which connects the first cutout to the housing interior, in the region which is adjacent to this first cutout, wherein an electrical current conductor projects from the housing interior into the first cutout through this second cutout, wherein the current conductor is in electrical contact-connection with the electrical or electronic component which is located in the housing interior, and is anchored in an anchoring means in the first cutout by way of the section which is located in the first cutout, wherein the first cutout is sealed off with the aid of at least one sealing means.