Contact Element Front Protection Strap Sealing
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Solution Overview
Problem
Existing electric contact arrangements face challenges in effectively sealing the front section against mechanical damage and corrosive media penetration, particularly when using aluminum conductors, which can lead to corrosion and compromised electrical and mechanical properties.
Innovation Solution
Incorporating a front protection strap that covers the electric conductor transversely and overlaps with an additional protection strap in the longitudinal direction, providing a stable and effective seal without relying on the crimping strap for sealing, and potentially being formed integrally with the contact element or extending from its base.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the crimping strap is used to seal the front section, then the sealing function is integrated into the contact element, but the sealing reliability is insufficient and mechanical damage can occur
Solution Approach 1:
The sealing function is separated from the crimping strap and assigned to a dedicated front protection strap. This segmentation allows the front protection strap to specialize in sealing and mechanical protection, while the crimping strap focuses on electrical connection and mechanical clamping, thereby improving overall sealing reliability without increasing overall structural complexity
Solution Approach 2:
The front protection strap acts as an intermediary element between the crimping strap and the conductor front section. It provides an additional layer of protection and sealing that mediates between the mechanical clamping force and the environmental exposure, enhancing sealing reliability
2Ease of operation
If the front section is left open for access, then installation is easier, but corrosive media and humidity can penetrate into the contact region
Solution Approach 1:
The front protection strap functions as a flexible protective barrier that seals the front section against corrosive media and humidity while maintaining the compact structure. It provides continuous coverage without requiring complex sealing mechanisms, thus protecting against harmful factors while preserving installation ease
Solution Approach 2:
The front protection strap is pre-formed and integrated into the contact element before crimping. This preliminary preparation ensures that the sealing function is already in place before the conductor is inserted and crimped, preventing corrosive media penetration from the outset while maintaining simple installation procedures
3Reliability
If material rolling is used to create the seal, then sealing can be achieved, but the process becomes more complex and time-consuming
Solution Approach 1:
The sealing function is extracted from the complex material rolling process and embodied in a simple front protection strap structure. This extraction eliminates the need for time-consuming rolling operations while maintaining effective sealing, thereby improving production efficiency without compromising sealing reliability
Solution Approach 2:
The front protection strap is designed as a simple, easily manufacturable component that can be produced through straightforward forming processes. This approach replaces complex rolling operations with a simpler, more efficient manufacturing method that maintains sealing effectiveness while improving productivity
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present invention relates to an electric contact element (1, 1') that has at least one crimping strap (31 a, 31 b) which is configured and arranged to reach around the outer circumference of an electric conductor (200), at least in sections, at least in a fully crimped state (C) of the contact element (1, 1'). Furthermore, the invention relates to an electric contact arrangement (100) that has at least one electric conductor (200) and at least one contact element (1, 1') that has at least one crimping strap (31 a, 31 b) which is crimped, at least in sections, around an outer circumference of the conductor (200). Finally, the invention relates to a method of producing an electric contact arrangement (100), at least one crimping strap (31 a, 31b) of a contact element (1, 1') being crimped, at least in sections, around an electric conductor (200). In order to seal an interior (80) of the contact arrangement (100) as simply and effectively as possible and with long-term stability against the penetration of corrosive media, provision is made according to the invention such that at least one front protection strap (11a, 11b) of the contact element (1, 1') is aligned running, at least in sections, transversely to the at least one crimping strap (31 a, 31 b) and rests against the latter, a front section (203) of the electric conductor (200) being covered, at least in sections, by the at least one front protection strap (11a, 11b).