Electrical Machine Housing Plug Contact Seal Design
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Solution Overview
Problem
Housings for electrical machines exposed to splash water face moisture penetration issues due to gaps between the housing wall and plug contacts, compromising the integrity of both contacts and internal components.
Innovation Solution
The design incorporates a securing element and elastic seal to route and lock the plug contact through an aperture in the cover, using a flat seal and contact-pressure plate to seal off the gap, minimizing force on the contact and preventing moisture ingress, while allowing easy assembly and secure locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical plug contact is routed through an aperture in the housing wall to enable external electrical connection, then electrical connectivity is achieved, but a gap forms between the plug contact and housing wall that allows moisture penetration into the housing interior
Solution Approach 1:
A seal element is introduced as an intermediary component between the plug contact and the housing wall aperture. This seal element fills the gap formed by the aperture routing, preventing moisture penetration while allowing the plug contact to pass through and maintain electrical connectivity. The seal element acts as a mediator that resolves the conflict between needing an open aperture for electrical connection and needing a closed structure for moisture protection.
2Object-affected harmful factors
If a traditional sealing method is used around the plug contact aperture, then moisture protection is improved, but the assembly process becomes complex and requires multiple separate components
Solution Approach 1:
The sealing function is merged with the plug contact component itself. Instead of using a separate seal ring or gasket that would require additional assembly steps, the plug contact is designed with an integrated sealing structure that combines the electrical conductor with the sealing function. This integration reduces the number of components and simplifies the assembly process while maintaining effective moisture protection.
3Stability of the object's composition
If the plug contact is firmly secured in the aperture to prevent movement, then mechanical stability is improved, but high insertion forces are required that may damage the printed circuit board or contact
Solution Approach 1:
The securing mechanism uses a deformable seal element that changes its physical state during insertion. During the insertion phase, the seal element is in a more compliant state that allows easy insertion with low force. Once inserted, the seal element deforms elastically to create a friction fit that provides firm mechanical stability. This dynamic behavior allows the system to accommodate both low insertion force and high mechanical stability requirements.
4Ease of manufacture
If the aperture is made larger to facilitate easier insertion of the plug contact, then ease of assembly is improved, but the gap between the plug contact and housing wall increases, worsening moisture protection
Solution Approach 1:
A flexible seal element, typically made of elastomeric material, is used to bridge the gap between the plug contact and the housing wall. This flexible membrane can be compressed or deformed during insertion to accommodate varying aperture sizes, then returns to its original shape to provide effective sealing. The flexibility of this thin film allows it to adapt to different aperture dimensions while maintaining moisture protection, decoupling the aperture size from the sealing effectiveness.
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
This solution effectively seals the gap between the plug contact and housing wall, protecting internal components from moisture while reducing the load on the plug contact and printed circuit board during assembly, ensuring reliable electrical connections in wet environments.
Implementation Method 1
an elastic seal which extends in a flat manner, wherein the end section is routed between the cover wall and one end of the end section through an aperture in the seal. The securing element is preferably designed to press the seal against the cover and in this way to seal off the aperture.
Data Source
AI summary
A housing for an electrical machine includes a cover with an electrical plug connection. The plug connection includes at least one electrically conductive contact or a plurality of electrically conductive contacts configured to electrically connect the housing to a plug. The contact is routed through an aperture in the cover and forms an electrical plug contact via an end section that projects out of the cover. The plug connection has a securing element that extends in a flat manner. A lateral dimension of the aperture in the cover is formed such that the contact is routed through the aperture via the end section and engages behind a projection in an interlocking manner by virtue of moving transverse to the longitudinal extent in the aperture. The securing element has at least one aperture that is configured to fix the contact in the aperture transverse to a longitudinal extent of the contact.