Cylindrical Contact Element Sealing and Heat Dissipation
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Solution Overview
Problem
Existing cylindrical high-current contact socket systems face challenges in sealing against environmental factors like moisture and dirt while dissipating heat effectively, particularly in harsh climatic conditions such as those found in electric drives and hybrid vehicles, and require complex and costly solutions that also occupy significant installation space.
Innovation Solution
A cylindrical high-current contact socket design featuring a flat metallic contact cover that serves both as a seal and a heat dissipation mechanism, with an uninterrupted butt weld seam that replaces additional sealing elements and housing components, allowing for easy production and connection to electrical cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing solutions and housing components are used to protect against environmental factors, then sealing reliability is improved, but device complexity and production cost increase
Solution Approach 1:
The patent combines the sealing function and cable connection function into a single integrated contact cover component. The contact cover serves as both the sealing element and the cable connector, eliminating the need for separate housing components and reducing overall device complexity while maintaining sealing reliability.
Solution Approach 2:
The contact cover is designed to perform multiple functions simultaneously: it provides sealing against environmental factors, serves as a mounting structure for cable connections, and acts as a structural component of the connector. This multi-functionality reduces the number of parts needed and simplifies the overall housing structure.
2Reliability
If extensive sealing solutions are implemented to prevent moisture penetration, then sealing reliability is improved, but production cost increases
Solution Approach 1:
The sealing function is merged into the contact cover itself, which is a necessary component for cable connection anyway. By integrating sealing into an existing required component rather than adding separate sealing elements, the solution achieves watertight protection without significantly increasing production cost.
3Reliability
If complex housing solutions are used to fulfill sealing and touch protection functions, then reliability is improved, but installation space requirements increase
Solution Approach 1:
The contact cover performs multiple protective and functional roles within a compact structure. It provides sealing, cable connection, and structural support in a single integrated component, reducing the overall volume required compared to separate housing elements that would each need to be accommodated in the installation space.
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 provides a cost-effective, simple, and efficient sealing and heat dissipation system that is watertight and adaptable to various cable geometries, reducing production complexity and enhancing reliability in demanding environmental conditions.
Implementation Method 1
The metallic contact cover is advantageously fastened to one end of the cylindrical socket contact by means of a butt weld.
Data Source
Figure 1~2
AI summary
The invention relates to a bushing contact element (1) with a receiving chamber (10) for a counter contact, comprising a cylindrical metal contact sleeve (2) and a contact grid (3) arranged in the contact sleeve (2) in the receiving casing (10) for electrically contacting a counter contact, the cylindrical contact sleeve (2) at one of its ends being completely sealed with respect to the receiving chamber (10) by a metal contact cover (4).