High-Temperature Patch Plug with Irreversible Locking
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Solution Overview
Problem
Conventional high-temperature patch plugs for connecting electric supply and signal lines to heating elements and thermocouples are not compact and require significant manufacturing effort, with limited material resistance to thermal loads above 120°C, leading to high space requirements and complex assembly processes.
Innovation Solution
A compact high-temperature patch plug design featuring a one-piece insulating housing with irreversible deformation for locking contact elements, using high-temperature-resistant materials like PEEK or FEP, and incorporating partitions and sealing elements to ensure electrical isolation and thermal stability, along with steel contact elements for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high-temperature patch plugs are designed with individual pole connections surrounded by PEEK housing or heat-shrinkable sleeves, then thermal and electrical insulation is achieved, but the manufacturing effort and space requirements increase significantly
Solution Approach 1:
The patent combines multiple individual insulation functions into a single integrated one-piece housing structure. Instead of surrounding each pole connection with separate PEEK housing or heat-shrinkable sleeves, the invention uses one insulating housing that encloses all contact elements and conductors simultaneously, achieving thermal and electrical insulation while reducing manufacturing steps and space requirements
Solution Approach 2:
The one-piece housing serves multiple functions simultaneously: it provides thermal insulation, electrical insulation, mechanical protection, and structural support for all poles. This multi-functional design eliminates the need for separate insulation components for each pole connection, reducing both device complexity and manufacturing effort
2Ease of manufacture
If the housing is made from conventional plastic materials suitable for injection molding, then manufacturing ease is improved, but resistance to thermal loads of 120°C and higher is insufficient
Solution Approach 1:
The patent changes the material parameter by using high-temperature-resistant plastics that can withstand thermal loads of 120°C and higher. These specialized materials maintain their mechanical properties and dimensional stability at elevated temperatures while still being suitable for injection molding processes, thus achieving both thermal resistance and manufacturing ease
3Volume of moving object
If the patch plug design becomes more compact to reduce space requirements, then the space efficiency improves, but the manufacturing complexity and material selection constraints increase
Solution Approach 1:
The patent achieves compactness by merging all functional elements (contact elements, conductors, insulation, and housing) into a single integrated structure. The one-piece housing encloses all components in a compact arrangement, eliminating the need for separate insulation sleeves around each pole and reducing the overall volume of the plug while maintaining all necessary functions
Data Source
AI summary
A high-temperature patch plug (50) for one or more connection lines (60), especially for connecting electric supply and/or signal lines to heating elements and/or thermocouples or temperature sensors. The patch plug (50) has one or more poles each with a contact element (64) connected to an inner conductor (61) of a connection line (60), and with a one-piece, insulating housing (51), which surrounds an interior (59), in which at least the at least one contact element (64) is accommodated at least partially. The housing (51) has at least one insertion opening (63) on the side facing away from the plugging side and a passage opening (57), which is connected to the insertion opening via the interior (59) of housing (51) for each pole on the side facing the plugging side. The contact element (64) is locked in the housing (51) for each pole at a locking step (53) arranged in the interior of the housing such that a motion of the contact element (64) against the plugging direction is limited by the locking, wherein said locking step (53) is formed by an irreversible deformation of housing.