Plug Bridge Encapsulation Layout to Block Moisture Corrosion
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Solution Overview
Problem
Existing plug bridges, particularly those used in the Commonwealth, face issues with moisture penetration leading to corrosion of connection contacts due to capillary areas remaining unencapsulated during the manufacturing process, which is safety-critical as it can result in loss of grounding contact.
Innovation Solution
A plug bridge blank design featuring a positioning device that maintains a distance between connection contacts and the base housing, allowing for complete encapsulation with liquefied thermoplastic material, which solidifies to prevent moisture ingress, using a covering device with breakthroughs for injection and venting to ensure thorough encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If connection contacts are positioned close to the base housing to reduce overall plug bridge size, then compactness is improved, but capillary areas remain beneath the connection contacts allowing moisture penetration causing corrosion
Solution Approach 1:
The patent introduces a new spatial dimension by positioning connection contacts at a distance from the base housing, creating a gap space that can be filled with sealing material. This dimensional separation allows the sealing compound to access and encapsulate areas that would otherwise be inaccessible capillary spaces, thereby preventing moisture penetration while maintaining compact overall dimensions through optimized spatial arrangement.
Solution Approach 2:
The patent employs a sealing compound as an intermediary substance that fills the gap between the connection contacts and base housing. This intermediary material serves dual functions: it provides mechanical support and acts as a moisture barrier, preventing capillary action that would otherwise lead to corrosion. The sealing compound mediates between the electrical components and the external environment, isolating sensitive areas from harmful moisture.
2Reliability
If connection contacts are positioned at a distance from the base housing to enable complete encapsulation with sealing material, then moisture protection is improved, but the overall plug bridge size increases
Solution Approach 1:
The patent applies partial encapsulation rather than complete enclosure of the connection contacts. By positioning contacts at an optimized distance, only the critical capillary areas beneath the contacts require sealing material access, rather than enclosing the entire contact assembly. This partial action approach provides sufficient moisture protection while minimizing the volume increase that would result from complete encapsulation.
3Ease of manufacture
If conventional manufacturing process is used without positioning device, then manufacturing simplicity is maintained, but capillary areas remain unencapsulated leading to corrosion
Solution Approach 1:
The patent implements preliminary positioning of connection contacts relative to the base housing before the encapsulation process. The positioning device pre-establishes the correct spatial relationship and gap dimensions, ensuring that sealing material can properly access and fill capillary areas during subsequent manufacturing steps. This preliminary action prevents the need for complex post-assembly adjustments or rework, maintaining manufacturing simplicity while achieving reliable corrosion protection.
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
The solution effectively prevents corrosion by ensuring complete encapsulation of connection contacts, particularly the ground contact, thereby enhancing the safety and reliability of the plug bridges by eliminating capillary areas that could allow moisture penetration.
Implementation Method 1
liquefied thermoplastic material, which solidifies to prevent moisture ingress
Data Source
Figure 1a~1c
Figure 2~4
AI summary
The invention relates to a connector bridge blank for manufacturing a connector bridge with a base housing and a contact element, wherein the contact element has three connection contacts and three wire receptacles, wherein the three connection contacts are for electrically contacting three plug contacts, a fuse receptacle and three wires of a connecting cable, the three plug contacts are for electrically contacting a mains connection and the fuse receptacle is for receiving an electrical fuse and the electrical fuse received in the fuse receptacle achieves a limiting of a maximum current flow of at least one of the plug contacts, wherein a positioning device is arranged between the base housing and the contact element, wherein the positioning device positions at least one of the connection contacts at a distance from the base housing,that the resulting distance between the base housing and the respective connection contact enables the respective connection contact to be overmolded with liquefied thermoplastic material. Furthermore, the invention relates to a connector bridge and a method for manufacturing a connector bridge.