Rotary Connector PTC Device Thermal Isolation
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Solution Overview
Problem
Conventional rotary connectors for automobiles, which use a PTC device to prevent overheating of flat cables, face issues where heat generated by the PTC device can cause deterioration and damage to the cable's base material and exterior, potentially leading to cable breakage due to direct heat transfer.
Innovation Solution
The rotary connector design includes a PTC device placed on one side of the base, with flat cables on the opposite side, and a cable retaining part that separates the PTC device from the cables, allowing heat to be dissipated away from the cables, reducing damage and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a PTC device is placed in the vicinity of a flat cable to prevent overheating, then circuit short protection is improved, but heat transfer to the flat cable causes deterioration and damage
Solution Approach 1:
The connector is divided into distinct regions: a first region housing the PTC device and connection terminals, and a second region housing the cable retaining part with flat cables. The base structurally separates these regions, preventing heat transfer from the PTC device to the flat cables while maintaining electrical protection functionality.
Solution Approach 2:
The base acts as an intermediary structure between the PTC device and the flat cables. It provides thermal isolation while maintaining electrical connectivity, allowing the PTC device to protect against short circuits without directly contacting or heating the flat cables.
2Device complexity
If the PTC device is placed close to the flat cable for compact design, then device complexity is reduced, but the flat cable may be locally bent or broken due to heat
Solution Approach 1:
The solution transitions from a one-dimensional arrangement (PTC device directly adjacent to cable) to a two-dimensional spatial separation using the base structure. The PTC device and cable retaining part are positioned on opposite sides of the base, creating thermal isolation while maintaining compact overall dimensions.
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 effectively prevents heat transfer from the PTC device to the flat cables, enhancing the reliability of the rotary connector by minimizing damage and maintaining cable integrity.
Implementation Method 1
If an overcurrent flows and the PTC device thereby generates heat, the heat is transferred to the flat cable
Implementation Method 2
a positive temperature coefficient (PTC) device 910
Data Source
AI summary
A rotary connector has a fixed housing, a movable housing that is rotatably linked to the fixed housing, flat cables wound in an annular space formed between the outer tube of the fixed housing and the inner tube of the movable housing, and a first connector connected to ends of the flat cables in their longitudinal directions. The first connector has connection terminals, a base, and, a cable retaining part. Each connection terminal has a cable attaching part at one end and an outer conductor at the other end, and also has one or more connecting parts. The base has a first plane and a second plane, which face each other. A PTC device is placed on the same side as the first plane. The cable retaining part is placed on the same side as the second plane.