Cooling-Fin Connection Pin for Exhaust Heater Feedthroughs
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Solution Overview
Problem
Existing connection pins in exhaust systems of internal combustion engines face excessive thermal loading, which can damage cables and potentially lead to ignition due to inadequate heat dissipation.
Innovation Solution
A connection pin design featuring a cooling surface formation with radially extending cooling fins and a ring-like cooling element body, providing an enlarged surface for heat dissipation, and optionally integrated groove-like depressions to enhance thermal interaction with ambient air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional connection pin without cooling features is used, then the structure is simple and manufacturing is easy, but excessive heat accumulates causing cable damage and potential ignition
Solution Approach 1:
The connection pin transitions from a simple cylindrical shape to a three-dimensional structure with radially extending cooling fins. This dimensional change adds heat dissipation surfaces perpendicular to the original axis, dramatically increasing the surface area available for thermal radiation and convection without significantly extending the pin's length along its primary axis.
Solution Approach 2:
The cooling fins are pre-formed as integral features of the connection pin during the manufacturing process. This preliminary action ensures that heat dissipation capabilities are built-in from the start, preventing heat accumulation before it can cause damage to cables or surrounding components, rather than adding corrective cooling measures after the problem arises.
2Loss of energy
If the surface area of the connection pin is increased to improve heat dissipation, then heat dissipation efficiency improves, but the device complexity increases
Solution Approach 1:
The connection pin surface is segmented into multiple discrete cooling fins rather than a single continuous surface. This segmentation creates multiple independent heat dissipation zones that can efficiently transfer heat to the surrounding air through convection and radiation. The segmented structure also allows for optimized fin spacing and dimensions to maximize thermal performance while controlling material usage and manufacturing complexity.
Solution Approach 2:
The cooling fins extend radially outward from the pin body, adding surface area in the radial dimension rather than extending the pin lengthwise. This dimensional approach increases the heat dissipation surface area without proportionally increasing the overall volume or mass of the connection pin, maintaining a favorable strength-to-weight ratio while improving thermal performance.
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
Prevents overheating of cables by efficiently releasing heat generated in the connection pin, thereby avoiding thermal damage and potential ignition.
Implementation Method 1
a cooling surface formation is provided in the cooling area... an enlarged surface is created on the terminal pin, through which heat absorbed or generated in the terminal pin can be dissipated to the environment
Implementation Method 2
heat absorbed or generated in the terminal pin can be dissipated to the environment
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A connecting pin, in particular for a connection unit for electrically contacting a heating conductor of an exhaust gas heater of an exhaust system of an internal combustion engine, comprises a pin body (38) elongated in the direction of a pin body longitudinal axis (L) with an outer connection area (44) for connecting a power supply line (26, 28) to the connecting pin (36), a cooling area (54), a feedthrough area (40) for electrically insulated passage of the pin body (38) through a pin carrier (30) of a connection unit (22, 24) and an inner connection area (42) for connecting the connecting pin (36) to a heating conductor (16) of an exhaust gas heater (14), wherein a cooling surface formation (56) in the form of ribs (62) or groove-like recesses, which increase the surface area for enhanced thermal cooling, is provided in the cooling area (54).