Electric Coupling Unit With Integrated Clamping Elements
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Solution Overview
Problem
Existing electrical coupling parts face challenges in maintaining moisture protection without increasing overall dimensions, as they often require separate protective bodies and complex locking mechanisms to secure contact points and conductors.
Innovation Solution
The solution involves integrating clamping elements within the contact carrier's dimensions, which are rotatably mounted and pivot to securely fix wires in place, eliminating the need for a separate injection-molded protective body and ensuring radial immobility without protruding beyond the carrier's profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate injection-molded protective body is used to seal the contact carrier, then moisture protection is improved, but the overall dimensions and device complexity increase
Solution Approach 1:
The sealing function is merged with the contact carrier itself by integrating sealing lips directly into the contact carrier structure. The sealing lips are formed as integral parts of the contact carrier, eliminating the need for a separate injection-molded protective body while maintaining moisture protection functionality.
Solution Approach 2:
The contact carrier is designed to perform multiple functions simultaneously: it provides structural support for contact parts, enables electrical connections, and provides moisture sealing through integrated sealing lips. This multi-functionality eliminates the need for separate protective components.
2Reliability
If locking flaps are added to secure conductors, then reliability is improved, but the lateral dimensions of the contact carrier increase
Solution Approach 1:
The conductor securing function is merged with the contact carrier structure by forming securing elements directly on the contact carrier. These securing elements are integrated into the carrier body, preventing the need for additional lateral-protruding locking flaps while maintaining reliable conductor fixation.
3Reliability
If clamping bodies are used to secure sealing elements on conductors, then reliability is improved, but the device complexity and number of components increase
Solution Approach 1:
The sealing elements are designed to secure themselves to the conductors without requiring separate clamping bodies. The sealing lips are configured to automatically grip and retain the conductors through their geometric design, eliminating the need for additional clamping components while maintaining reliable sealing.
Data Source
Figure 1~5
AI summary
An electrical coupling element with an attached electrical conductor is described, comprising a contact carrier made of mechanically stable insulating material and featuring at least two parallel, separate through-holes. Each through-hole contains an electrical contact element connected to an electrical conductor of the cable, which has at least two insulated cores. A sealing element with a clamping fit is mounted on each core within the contact carrier, ensuring a tight seal of the respective through-hole in the installed position. Pivotally mounted clamping elements are attached to an end face of the contact carrier from which the cores protrude, securing the cores radially and immovably in the installed position.