Overmoulded Electrical Connector for Motor Vehicle Heating
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Solution Overview
Problem
The existing connection methods for electrical conductors in motor vehicle electrical heating devices are prone to disconnection under force, leading to unreliable power supply to the equipment.
Innovation Solution
A connection device featuring electrically insulating overmoulding that mechanically retains the connection between electrical conductors, enhancing their resistance to forces and ensuring a secure connection by enveloping the conductors with a rigid plastic material capable of withstanding high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If crimping or force fitting is used to connect electrical conductors, then the connection can be made simply, but the connection may disconnect when force is applied
Solution Approach 1:
The connection device combines a rigid support structure with an elastomeric material to create a composite connection system. The rigid portion provides structural stability while the elastomeric material provides flexible retention, creating a connection that is both simple to manufacture and reliable under force.
Solution Approach 2:
The elastomeric material forms a flexible retaining structure that envelops the electrical conductors. This flexible shell provides mechanical retention through elastic deformation, allowing the connection to withstand applied forces while maintaining electrical contact.
2Strength
If a rigid plastic overmolding is used to reinforce the connection, then the connection can withstand greater forces, but the material must be selected to withstand high operating temperatures
Solution Approach 1:
The invention changes the material parameters by selecting a rigid plastic material with appropriate thermal properties. The overmolding material is chosen to maintain its mechanical strength and retention properties at the high operating temperatures encountered in heating devices, thus achieving both connection strength and temperature compatibility.
Solution Approach 2:
The connection device uses a composite structure combining rigid plastic overmolding with elastomeric retention material. This composite approach allows the rigid portion to provide thermal stability and structural strength while the elastomeric portion provides flexible mechanical retention, together satisfying both strength and temperature adaptability requirements.
Data Source
Figure 1~3
Figure 4a~4b
AI summary
The invention relates to a connection device for powering electrical equipment, said connection device comprising: a first electrical conductor (3) configured such that it is electrically connected to an electrical power source, and a second electrical conductor (5) connected mechanically and electrically to the electrical equipment to be powered. According to the invention, said connection device comprises an electrically insulating overmoulding (7) held mechanically, covering the first (3) and second (5) electrical conductors at the connection thereof.