Multi-shell Housing for Flat Conductor Contact Sealing
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Solution Overview
Problem
Existing contact point solutions for flat conductors in automotive engineering lack a detachable and effectively sealed connection with reduced component count and increased production costs, while also requiring additional support components.
Innovation Solution
A multi-shell housing with gasket-equipped openings, made of fiberglass-reinforced polyamide, encases the contact element and flat conductor, providing a self-supporting structure with overlapping shells for a secure seal and integrated fuse protection, using a two-component injection molding process for enhanced sealing and moisture management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a housing supports the contact point, then structural stability is improved, but device complexity increases due to additional support components
Solution Approach 1:
The housing serves itself as the support structure by directly encasing the contact point assembly. The housing's own structural integrity provides the necessary support without requiring separate support components, thus achieving self-service functionality that reduces overall device complexity while maintaining stability.
Solution Approach 2:
The support function is merged with the housing structure itself. Instead of having a separate support component and a housing, the housing is designed to inherently provide both enclosure and support functions through its rigid structure and direct attachment to the contact point assembly.
2Ease of manufacture
If multiple separate components are used for connection, then ease of assembly is improved, but device complexity increases
Solution Approach 1:
Multiple separate components (housing, support structure, sealing elements) are merged into an integrated assembly where the housing directly encases and supports the contact point. This integration reduces the number of discrete parts while maintaining ease of assembly through modular design of the contact point unit itself.
Solution Approach 2:
The contact point is designed as a detachable module that can be assembled separately and then integrated into the housing. This segmentation allows for easy manufacturing and assembly of individual components while reducing overall device complexity through standardized interfaces and modular architecture.
3Reliability
If insulation is removed from conductor and contact element, then electrical connection quality is improved, but protection against harmful factors worsens due to exposed transitional areas
Solution Approach 1:
A sealing element (gasket) is introduced as an intermediary between the exposed metallic contact areas and the external environment. This gasket provides the necessary protection against moisture and contaminants while allowing the electrical connection to remain exposed for optimal conductivity, thus mediating between the conflicting requirements of electrical quality and environmental protection.
Solution Approach 2:
A flexible sealing element (gasket) is used to protect the exposed transitional areas between conductor and contact element. The gasket conformally seals around the connection area, providing effective protection against moisture and contaminants while maintaining the electrical connection's integrity and accessibility.
4Ease of manufacture
If uniform insulating material is used on all conductors, then ease of manufacture is improved, but sealing compatibility worsens due to lack of material selection flexibility
Solution Approach 1:
Instead of requiring uniform insulating materials across all conductors for sealing compatibility, the solution applies local quality by selecting specific sealing materials (such as silicone rubber or fluoropolymer) that are compatible with the particular conductor and contact element materials at each connection point. This allows optimization of sealing performance for each specific application while maintaining manufacturing simplicity through standardized sealing processes.
Data Source
AI summary
A contact point for establishing a connection to a conductor element according to the present disclosure comprises a flat conductor having first and second ends, and a contact element connected to the flat conductor in a terminal area of the flat conductor, wherein the contact element is also configured to connect to the conductor element. The contact point comprises a multi-shell housing attached to the flat conductor and configured to cover the contact element and the terminal area. The housing comprises at least three openings, wherein first and second openings enable passage of first and second ends of the flat conductor, and a third opening enables passage of the conductor element. A gasket is attached to at least one of the openings for sealing the housing.