Plug Connector Holding Means for Fretting Corrosion
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Solution Overview
Problem
The existing electrical connectors in motor vehicle fuel tanks experience fretting corrosion due to dry friction as the fuel level decreases, leading to contact failures, and existing solutions involving additional coatings are costly.
Innovation Solution
A plug with a holding means that securely fixes electrical lines in receptacles with a smaller cross-section than the lines, preventing movement and relative displacement of contact elements, thus eliminating fretting corrosion without additional coatings, and featuring a latching connection for easy assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional coatings are applied to contact elements to prevent fretting corrosion, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The harmful relative movement between contact elements is extracted and eliminated by introducing a holding means with receptacles that firmly secure the electrical lines, preventing the lines from transmitting movement to the contact elements
Solution Approach 2:
The electrical lines are preliminarily fixed in the receptacles of the holding means before connection to the contact elements, so that when the plug is assembled, the lines are already positioned to prevent any relative movement between contact elements
2Ease of operation
If electrical lines are allowed to move freely in the fuel tank, then ease of installation is improved, but reliability deteriorates due to fretting corrosion
Solution Approach 1:
The fixation system is segmented into two independent stages: first fixation in the receptacles of the holding means, and second fixation in the housing of the connector, allowing flexible installation while ensuring reliability
Solution Approach 2:
The holding means with receptacles acts as an intermediary component between the electrical lines and the contact elements, decoupling the lines from the contact elements to prevent movement transmission
Data Source
Figure 1
Figure 2
AI summary
A plug connector for an electrical connection has at least two electrical lines, the ends of which are connected to contact elements, includes: a housing that encompasses the electrical lines and the contact elements at least in a region of connecting the electrical lines to respective contact elements; and a holder fixedly connected to the housing. The holder has receptacles configured to hold the electrical lines, the receptacles holding the lines such that the lines cannot move out of position.