Plug Connector Overmolding for Moisture and Heat Management
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Solution Overview
Problem
Existing plug bridges face issues with moisture ingress and overheating due to gaps between metal surfaces and inadequate encapsulation, which can lead to short circuits and thermal issues during operation.
Innovation Solution
The plug bridge design incorporates a base plate and cover made of electrically insulating material, with the electrical safety device partially integrated into the cover, and a cooling device on the electrical conductors to enhance insulation and heat dissipation, preventing moisture ingress and overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stamped metal sheets are used as electrical conductors with cutouts in the base plate, then assembly is enabled, but gaps between metal surfaces allow moisture penetration causing short circuits
Solution Approach 1:
The patent applies overmolding with an insulating plastic material that completely encapsulates the metal conductor surfaces and fills the gaps between them. This creates a flexible, continuous insulating layer that seals against moisture while maintaining the electrical connection functionality, resolving the contradiction between assembly ease and moisture protection.
Solution Approach 2:
The patent combines metal conductor sheets with insulating plastic material through overmolding, creating a composite structure. The metal provides electrical conductivity and the plastic provides moisture protection and insulation, achieving both assembly ease and reliability simultaneously.
2Reliability
If the plug bridge is completely encapsulated with insulating material, then moisture protection is improved, but parts of the connector bridge become inaccessible from the outside
Solution Approach 1:
The patent segments the insulating material into two parts: an insulating base body that encapsulates the connector bridge for moisture protection, and a separate handle body that remains accessible. This segmentation allows the plug bridge to be protected from moisture while still enabling user access for insertion and removal operations.
Solution Approach 2:
The insulating base body acts as an intermediary that protects the electrical components from moisture while the handle body serves as the user interface. The handle body is designed to be accessible and provides the mechanical interface for plugging and unplugging, resolving the contradiction between protection and accessibility.
3Reliability
If the handle body is produced by overmolding the connector bridge, then insulation is improved, but heat dissipation becomes insufficient
Solution Approach 1:
The patent applies different material properties to different parts of the handle body: the insulating base body portion provides electrical insulation and moisture protection, while the handle body portion is made of thermally conductive material to dissipate heat. This local differentiation of material properties resolves the contradiction between insulation and heat dissipation.
Solution Approach 2:
The patent changes the thermal conductivity parameter of the handle body material while maintaining the insulating properties of the base body. By selecting materials with appropriate thermal conductivity for different regions, the patent achieves both adequate insulation and sufficient heat dissipation.
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 design improves electrical safety by preventing moisture ingress and effectively dissipating heat, ensuring reliable operation even under unfavorable conditions.
Implementation Method 1
at least one electrical conductor (8a, 8b, 8c, 8d) for contacting at least one plug pin (9a, 9b, 9c) is provided with a cooling device (13)
Implementation Method 2
the cooling device (13) is designed as a surface structure that increases the surface area
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The present invention relates, inter alia, to a plug connector, in particular for a safety plug according to BS 1363, having a base plate, which has a recess for an electrical fuse device and a cover, which covers the recess and is at least partially built into the electrical fuse device, and to a method for producing such a plug connector.