Elastic Electrical Lead-Through for Pressure-Resistant Electronics Housings
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Solution Overview
Problem
Existing electrical lead-throughs in electronics housings are difficult to produce efficiently, leading to increased production costs and time, particularly in environments with pressure-resistant casings to prevent flame or spark escape, and are challenging in the region of the electrical interface.
Innovation Solution
An electrical lead-through design comprising a first and second stop element with through-holes, an elastic element, and an electrical contact element, allowing for deformation and sealing under temperature fluctuations, with complementary fastening regions for easy installation in an electronics housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical lead-throughs are cast in a complicated manner to ensure pressure resistance, then sealing reliability is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The electrical lead-through is divided into separate components: a housing portion, a contact element, and a sealing element. This segmentation allows each component to be manufactured independently using simpler processes, then assembled together to achieve the required pressure-resistant sealing function, thereby reducing overall manufacturing complexity while maintaining reliability.
Solution Approach 2:
A sealing element is introduced as an intermediary component between the housing portion and the contact element. This sealing element specifically provides the pressure-resistant sealing function, allowing the housing and contact element to be manufactured separately without compromising sealing reliability.
2Reliability
If electrical lead-throughs are cast in a complicated manner to ensure pressure resistance, then sealing reliability is improved, but production time increases
Solution Approach 1:
By segmenting the electrical lead-through into separate components that can be manufactured independently, the production process is parallelized. The housing portion, contact element, and sealing element can be produced simultaneously in different manufacturing steps, significantly reducing total production time compared to a monolithic casting process.
Solution Approach 2:
The sealing element is pre-formed and prepared in advance as a separate component. This preliminary preparation allows the sealing function to be ensured without requiring time-consuming casting operations during final assembly, thereby reducing overall production time while maintaining sealing reliability.
3Reliability
If electrical lead-throughs are cast in a complicated manner to ensure pressure resistance, then sealing reliability is improved, but material costs increase
Solution Approach 1:
Segmenting the electrical lead-through allows for optimized material selection and usage in each component. The sealing element can be made from specialized sealing materials, while the housing and contact elements use standard materials, reducing overall material costs compared to using expensive pressure-resistant materials throughout the entire monolithic structure.
Solution Approach 2:
The sealing element is designed as a separate, replaceable component that can be manufactured from cost-effective materials. If wear or damage occurs, only the sealing element needs replacement rather than the entire electrical lead-through, reducing material costs and waste.
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 design provides reliable sealing and efficient installation, optimizing manufacturing costs and time while maintaining pressure resistance, even under high temperature conditions.
Implementation Method 1
The elastic element is suitable for deforming when the first stop element and the second stop element are moved relative to each other
Implementation Method 2
at least one electrical contact element with a first end and a second end lying opposite the first end. The first end is movably arranged in the first through-hole and/or the second end is movably arranged in the second through-hole
Data Source
AI summary
An electrical lead-through for an electronics housing, comprises a first stop element with at least one first through-hole, a second stop element with at least one second through-hole, an elastic element which extends between the first stop element and the second stop element along a first axis, and at least one electrical contact element with a first end and a second end lying opposite the first end. The first end of the contact element is movably arranged in the first through-hole and the second end is movably arranged in the second through-hole. The elastic element is suitable for deforming when the first stop element and the second stop element are moved relative to each other, and the first stop element and the second stop element are each suitable for being fixed to the electronics housing.