Electrical Device Plug Segmentation for Corrosion Resistance
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Solution Overview
Problem
Existing electrical devices, such as pumping devices, face corrosion issues when exposed to fuels containing water, leading to electrical contact interruptions and device failure, particularly at electrical connections and flexible cables, due to inadequate protection against electrolytic processes.
Innovation Solution
The electrical device separates electrical connections into distinct chambers within a hollow chamber, using partitions and seals to prevent corrosion, and the plug connections are designed with a tong-like shape for strong, corrosion-resistant contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrical connections are exposed to fuel-containing environments for simplicity, then ease of manufacture is improved, but corrosion resistance deteriorates
Solution Approach 1:
The hollow chamber is divided into multiple separate chambers using partitions, with each electrical connection housed in its own isolated chamber. This segmentation prevents direct exposure of electrical connections to the corrosive fuel environment while maintaining a simple overall structure that is easy to manufacture.
2Reliability
If extrusion coating with plastic is applied to protect electrical components, then corrosion resistance is improved, but manufacturing cost increases
Solution Approach 1:
Instead of applying expensive extrusion coating to all electrical components, the invention uses simple partition walls to create separate chambers. This provides effective corrosion protection through structural isolation rather than material coating, significantly reducing manufacturing costs while maintaining reliability.
3Ease of operation
If flexible cables are exposed to fuel environment, then ease of operation is improved, but corrosion resistance deteriorates
Solution Approach 1:
Flexible cables are routed through sealed openings in the partition walls rather than being exposed to the fuel environment. This allows the cables to remain accessible for connection and operation while their critical portions are protected within the sealed chambers, maintaining both ease of operation and corrosion resistance.
4Reliability
If electrical connections are isolated in separate chambers, then corrosion resistance is improved, but device complexity increases
Solution Approach 1:
The invention divides the hollow chamber into separate compartments using simple partition walls formed as integral parts of the connection cap or lid. This provides effective isolation of electrical connections from the corrosive environment while avoiding complex sealing mechanisms or additional components, thus improving corrosion resistance without significantly increasing device complexity.
Data Source
AI summary
Known pumping devices have a connection lid, a connection cap slipped over the connection lid, a hollow chamber formed between the connection lid and the connection cap, and electrical connections that extend through the connection cap into the hollow chamber. It is disadvantageous that when fuels containing water are being pumped, such as ethanol, corrosion can occur at the electrical connections and at the uninsulated cable segments that are exposed to fuel near the electrical connections, for instance at the electrical coils or flexible cables of the carbon brushes, and in the final analysis this leads to an interruption in the electrical contact and thus to failure of the pumping device. In the electrical device of the invention, corrosion of the electrical connections and of the electrical components adjoining them upstream and downstream is avoided entirely or at least greatly diminished. According to the invention, the electrical connections are each provided in separate chambers of the hollow chamber.