Potted Insert Feedthrough for Fluid-Tight Power Transmission
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Solution Overview
Problem
Existing cable feedthroughs in housings, particularly in motor vehicle engine compartments, face challenges in maintaining fluid-tightness due to high temperature differences and exposure to liquids, leading to potential leaks.
Innovation Solution
An electrical device design featuring an insert with aligned through-openings and chambers filled with potting compound, encasing power transmission components to create a fluid-tight seal, eliminating the need for injection molds and ensuring complete encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable feedthroughs are used in housings, then power transmission can be achieved, but fluid-tightness is compromised due to high temperature differences and liquid exposure
Solution Approach 1:
The insert is pre-formed with through-openings and chambers during manufacturing, creating a ready-to-encapsulate structure before the actual sealing process. This preliminary preparation ensures that when potting compound is introduced, the power transmission component is already positioned within a pre-configured sealing environment, preventing leaks under thermal and liquid stress
Solution Approach 2:
The insert acts as an intermediary component between the housing and the power transmission component. It provides a structured interface that guides the potting compound around the power transmission component, creating a reliable seal that protects against harmful factors while maintaining electrical power transmission
2Manufacturing precision
If injection molds are used to cast power transmission components, then complete encapsulation can be achieved, but manufacturing complexity and tooling requirements increase
Solution Approach 1:
The invention extracts the sealing and encapsulation function from the power transmission component itself and places it into a separate insert structure. This allows the power transmission component to be manufactured independently without requiring complex injection molding tools, while the insert provides the encapsulation environment using simpler manufacturing processes
Solution Approach 2:
The system is segmented into distinct functional parts: the housing, the insert with through-openings and chambers, and the power transmission component. This segmentation allows each part to be manufactured separately using appropriate processes, with the insert serving as a modular sealing unit that simplifies overall manufacturing complexity
3Ease of manufacture
If power transmission components are not fully encapsulated, then manufacturing is simpler, but fluid-tight sealing and protection from corrosive media are compromised
Solution Approach 1:
The potting compound forms a flexible sealing matrix around the power transmission component within the insert's chambers. This compound-filled chamber structure provides complete encapsulation and protection from corrosive media while maintaining ease of manufacture through a straightforward pouring and curing process
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 design provides a robust, fluid-tight seal that protects internal components from corrosive media, simplifies manufacturing by eliminating the need for additional tools, and ensures effective sealing without complex assembly processes.
Implementation Method 1
The first chamber and the housing chamber are filled with a potting compound, wherein the current transmission component extends through at least the first and second through-opening and is embedded in the potting compound between the first wall and the second wall
Implementation Method 2
The first wall is designed to bear against the first through-opening and the second wall is designed to bear against the second through-opening on a power transmission component of the electrical device
Data Source
Figure 1~4
Figure 5~8
Figure 9~13
AI summary
The invention relates to an insert (50, 95, 105, 115), an electrical device (10), and a method for manufacturing the electrical device (10), wherein the electrical device comprises the insert (50, 95, 105, 115), a current transmission component (60, 100, 110, 120), and a housing (25) with a housing wall (55) having an inner wall (225) and an outer wall (230) spaced apart from the inner wall (225) with respect to an axis (x), wherein the outer wall (230) has a third through-opening (245) and the inner wall (225) has a fourth through-opening (250) into which the insert (50, 95, 105, 115) engages, wherein the inner wall (225) and the outer wall (230) define a housing chamber (235), wherein the housing chamber (235) and the first chamber (205) merge into one another, wherein the first chamber (205) and the housing chamber (235) are filled with a potting compound (280), wherein the power transmission component (60, 100, 110,120) extends through at least the first and second through-opening (150, 215) and is embedded in the casting compound (280) between the first wall (130) and the second wall (200).