Plug Electrical Connection Sealing Heat Dissipation
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Solution Overview
Problem
Existing electrical connections between a plug and a circuit carrier face challenges in sealing and heat transfer due to the plug being directly mounted on the circuit carrier, leading to increased housing size and cost, especially with high-quality ceramic carriers.
Innovation Solution
An electrical connection where the plug's end face completely covers a smaller opening in the housing wall, allowing for improved sealing and increased heat transfer, using a press-fit connection and optional radial or axial seals, with the circuit carrier partially covering the opening and connected via screws or rivets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the plug is arranged directly on the circuit carrier, then the tolerance chains are minimized, but the opening in the housing wall must be larger than the plug, leading to sealing difficulties
Solution Approach 1:
The plug is segmented into two functional parts: the contact area that interfaces with the circuit carrier (maintaining short tolerance chains) and the end face that interfaces with the housing wall (enabling sealing). This segmentation allows the opening to be smaller than the overall plug size while maintaining both manufacturing precision and sealing reliability.
2Power
If the plug is arranged directly on the circuit carrier, then the electrical connection is established, but the contact surface between the circuit carrier and housing wall is reduced, limiting heat transfer
Solution Approach 1:
The solution transitions from a two-dimensional planar arrangement to a three-dimensional configuration where the circuit carrier extends laterally beyond the opening. This dimensional change creates an annular contact surface between the circuit carrier and housing wall, significantly increasing the heat transfer area while maintaining the electrical connection function.
3Reliability
If the connector contacts the circuit carrier with its entire cross-sectional area, then the electrical connection is secure, but the circuit carrier area increases, increasing costs for high-quality ceramic carriers
Solution Approach 1:
The circuit carrier is designed with non-uniform geometry: it has a smaller cross-sectional area at the plug contact region (reducing overall area and cost) while maintaining adequate contact with the housing wall (ensuring reliable electrical connection and heat transfer). This local quality variation optimizes both cost and performance.
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 configuration enhances sealing efficiency, reduces the size and cost of the circuit carrier, and improves heat dissipation from the circuit carrier to the housing, while allowing for multiple insertions of press-fit connections without soldering stress.
Implementation Method 1
a seal designed as a sealing ring can be provided in particular in a groove surrounding the end face, which seals the plug against the housing wall in the axial direction
Implementation Method 2
The contact surface between the circuit carrier and the inner wall of the housing serves on the one hand as a stop for easy positioning of the circuit carrier on the inner wall of the housing when making the connection according to the invention, and on the other hand to dissipate heat from the circuit carrier to the housing
Implementation Method 3
the connection of a terminal contact to the corresponding receptacle in the circuit carrier is designed as a so-called press-fit contact
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Electrical connection of a plug (1) outside of a housing and a circuit carrier (4) inside the housing, wherein the plug comprises at least one plug contact (2) and comprises a front face (8) in the direction of the housing wall (3), the circuit carrier (4) comprises a recess (7) for a plug contact (2), wherein the plug contact (2) protrudes through an opening (6) in the housing wall (3) in order to establish the electrical connection, and wherein the cross-sectional surface of the opening (6) is smaller than the front face (8) of the plug (1), the front face (8) completely covers the opening (6), and the circuit carrier (4) at least partially covers the opening (6).