Component Sealing with Elastic Material and Overflow Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing components with electrical and electronic contact elements face challenges in sealing against environmental media, such as moisture, which can lead to erosion and reduce the service life of internal components.
Innovation Solution
A component design featuring a closed volume with a permanently elastic sealing material that surrounds the contact elements, including a cover element with a sealing edge and overflow channels, ensures a medium-tight configuration and allows for easy replacement of defective contact elements, while using temperature-resistant materials like silicone or epoxy resins for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-walled housing is used, then the device complexity is low, but the sealing reliability against environmental media is insufficient
Solution Approach 1:
The patent implements a nested structure where an inner wall and an outer wall are positioned concentrically, with sealing material introduced into the space between them. This nested configuration creates multiple sealing zones without significantly increasing overall device complexity, as the walls share common structural features and mounting points.
Solution Approach 2:
The patent employs composite sealing by combining rigid wall structures with flexible sealing material (such as elastomers or polymers) in the annular space between inner and outer walls. This composite approach leverages the advantages of both material types: structural integrity from the walls and sealing compliance from the flexible material, thereby improving sealing reliability.
2Duration of action of stationary object
If the component is sealed tightly to prevent environmental media penetration, then the service life of internal components is increased, but the risk of damage from thermal expansion of sealing material increases
Solution Approach 1:
The patent incorporates overflow channels that are pre-designed into the housing structure before the sealing material is introduced. These channels provide a predetermined escape path for excess sealing material that expands during curing or thermal cycles, preventing pressure buildup that could damage the housing or compromise the seal.
Solution Approach 2:
The overflow channels act as an intermediary mechanism between the sealed interior space and the exterior environment. They allow the sealing material to expand freely into the channels rather than against the rigid housing walls, mediating the thermal expansion effect and preventing structural damage while maintaining seal integrity.
3Reliability
If the sealing material is introduced into the closed volume to surround contact elements, then the medium-tight configuration is improved, but air inclusions may form reducing sealing effectiveness
Solution Approach 1:
The patent introduces guiding elements that create directional flow paths for the sealing material as it is injected into the closed volume. These elements channel the material along specific trajectories, guiding it to flow around contact elements in a controlled manner rather than allowing random turbulent flow, thereby minimizing air entrapment.
Solution Approach 2:
The patent replaces reliance on purely mechanical injection processes with flow-guiding structures that passively direct the sealing material. Instead of using complex injection mechanisms or vacuum systems to prevent air inclusions, the guiding elements use the material's own flow characteristics to achieve uniform distribution and eliminate air pockets.
4Reliability
If the cover element is fastened destructively to ensure sealing, then the sealing reliability is improved, but the ease of repair for defective contact elements deteriorates
Solution Approach 1:
The patent divides the housing into separable segments: a permanent base housing and a removable cover element. The cover element can be detached non-destructively (e.g., via snap-fit or threaded connection) while maintaining sealing through integrated sealing edges or gaskets. This segmentation allows the cover to be removed for contact element replacement and reattached to restore sealing, combining repairability with sealed protection.
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
The solution effectively reduces the risk of environmental media penetration, increases the service life of internal components, and allows for automated production with high temperature resistance, ensuring reliable performance across varying environmental conditions.
Implementation Method 1
a permanently elastic sealing material which completely surrounds the contact element at least in certain sections being introduced into said volume
Implementation Method 2
By means of the overflow channel, it is possible to compensate for an excess of the sealing material introduced into the volume, in particular on account of thermally induced expansion
Data Source
AI summary
A component has at least one opening through which an electric and/or electronic contact element is guided outwards in a sealed manner against the penetration of environmental media. A closed volume is formed at least in a wall of the component in the region of the contact element, and a permanently elastic sealing material which completely surrounds the at least one contact element in at least some sections is filled into said volume.