Rigid Conductor Connection Assembly for Weld Misalignment Sealing
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Solution Overview
Problem
The poor alignment between flat conductors and contact elements in battery-electric vehicles leads to premature wear of connections due to lateral seal compression, resulting from welding and misalignments, which compromises sealing performance.
Innovation Solution
A flexible connection arrangement is introduced, comprising a rigid conductor with a circumferential sealing section and a flexible connecting element that allows for angular and lateral movement to compensate for tolerances, using a combination of hard and soft components to ensure a durable and elastic seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid connection is created by joining or welding the flat conductor to the contact element, then electrical and mechanical connection strength is improved, but lateral seal compression occurs due to misalignment, worsening sealing performance
Solution Approach 1:
The patent applies a flexible sealing element (thin film/shell) between the rigid contact element and conductor to absorb misalignment and prevent lateral seal compression. This flexible component compensates for positioning tolerances while maintaining both mechanical strength and sealing reliability.
Solution Approach 2:
The solution combines rigid materials (for structural strength and electrical connection) with flexible materials (for sealing and tolerance compensation) in a composite assembly. This allows the system to simultaneously achieve strong mechanical/electrical connection and reliable sealing despite misalignment.
2Reliability
If welding is used to join the flat conductor to the contact element, then electrical conductivity and mechanical strength are improved, but component misalignments and distortions occur, worsening sealing performance
Solution Approach 1:
The flexible sealing element is pre-installed to compensate for expected welding distortions and misalignments before the actual welding process occurs. This beforehand cushioning prevents sealing failures that would result from anticipated manufacturing tolerances.
Solution Approach 2:
The patent changes the physical parameters of the sealing element by making it flexible and elastic, allowing it to adapt to dimensional changes and distortions caused by welding. This parameter change (from rigid to flexible) enables the system to accommodate manufacturing variations.
3Reliability
If a flexible connecting element is used to compensate for tolerances, then sealing performance is improved, but connection complexity increases
Solution Approach 1:
The patent merges the sealing function with the connection structure by integrating the flexible sealing element directly into the connection assembly between contact element and conductor. This combination eliminates the need for separate sealing components and simplifies the overall structure.
Solution Approach 2:
The flexible sealing element serves multiple functions simultaneously: it provides sealing, compensates for misalignment, absorbs welding distortions, and maintains electrical insulation. This multi-functionality reduces the need for additional specialized components.
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 flexible connection compensates for misalignments and distortions during welding, ensuring a robust, durable, and sealed connection that maintains sealing performance despite component misalignments.
Implementation Method 1
a flexible connecting element configured to mechanically and elastically connect the sealing section of the conductor to the housing seal, allowing for a range of movement in at least one spatial dimension
Implementation Method 2
a flexible connecting element configured to mechanically and elastically connect the sealing section of the conductor to the housing seal
Data Source
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AI summary
The disclosure relates to a connection arrangement (100) for mechanically and electrically connecting a rigid current-carrying conductor (110) to an electrically conductive contacting element (120), wherein the connection arrangement (100) comprises: a rigid current-carrying conductor (110) with a circumferential sealing section (112); a rigid current-carrying contacting element (120) that can be electrically and mechanically joined to the conductor (110), in particular welded; wherein the contacting element (120) has a housing (121) with a housing seal (122);and a flexible connecting element (200) configured to mechanically and elastically connect the sealing section (112) of the conductor (110) to the housing seal (122) while allowing a range of movement in at least one spatial dimension in order to compensate for tolerances between the sealing section (112) of the conductor (110) and the housing seal (122) resulting from the joining of the contacting element (120) with the conductor (110).