Bulkhead-Locked Housing Assembly for High-Pressure Relay Sealing
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Solution Overview
Problem
Housing assemblies for electromagnetic components face durability issues due to high inside pressure and rapid temperature changes, which can deform and damage the housing.
Innovation Solution
A housing assembly with a bulkhead wall and locking sub-assembly that extends horizontally, featuring a glue transport channel and interlocking protrusions to prevent expansion and enhance sealing and locking strength, along with rail guides for precise alignment and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing assembly is subjected to high inside pressure due to high ambient and/or operating temperatures, then the housing may deform or be damaged, but increasing the housing thickness or rigidity may increase manufacturing complexity and cost
Solution Approach 1:
The housing is divided into multiple parts (first housing part, second housing part, bulkhead wall) that can be assembled together. The bulkhead wall is inserted into the housing part and locked in place, creating a segmented structure that distributes stress and prevents deformation under high inside pressure without requiring a single complex thick-walled structure
Solution Approach 2:
The bulkhead wall extends horizontally across the housing, creating a structural element in the horizontal dimension that prevents expansion and deformation. This horizontal reinforcement works together with the vertical stacking of housing parts to provide comprehensive structural support without increasing wall thickness
2Reliability
If the housing assembly is subjected to fast temperature changes in combination with humidity, then the inside pressure increases and may damage the housing, but adding more structural reinforcement may increase manufacturing complexity
Solution Approach 1:
The housing assembly is segmented into multiple parts including the bulkhead wall that can move independently to accommodate thermal expansion and contraction. This segmentation allows each part to respond to temperature changes without causing stress concentration that would lead to damage
Solution Approach 2:
The locking sub-assembly is designed to lock the bulkhead wall in position before thermal stress occurs. The bulkhead wall is pre-positioned and locked horizontally across the housing, providing structural support that prevents deformation from subsequent temperature changes and pressure buildup
3Reliability
If a locking sub-assembly is added to lock the bulkhead wall in the horizontal direction, then the sealing properties and locking strength are improved, but the device complexity increases
Solution Approach 1:
The locking sub-assembly merges multiple functions into a single component: it locks the bulkhead wall horizontally, provides sealing surfaces, and guides the bulkhead wall during insertion. This integration of functions reduces the number of separate components needed while maintaining improved sealing properties
Solution Approach 2:
The locking sub-assembly serves multiple purposes: it provides horizontal locking of the bulkhead wall, creates sealing interfaces, guides insertion during assembly, and distributes mechanical loads. This multi-functionality improves sealing without requiring separate components for each function
Data Source
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AI summary
The invention relates to a housing assembly (1) for encasing an electrical component (38) such as a relay (40), comprising a housing part (6) and at least one bulkhead wall (4). The at least one bulkhead wall (4) is configured to be inserted into the housing part (6) in an insertion direction (S) and, in an inserted state (2), extends from one wall section (8) to an opposite wall section (8) along a horizontal direction (H). The housing assembly (1) comprises a locking sub-assembly (10), which is configured to lock the at least one bulkhead wall (4) to the housing part (6) at least in a direction parallel to the horizontal direction (H) preventing damage to the housing assembly (1) due to high inside pressure. The invention further relates to a method for assembling a housing (1).