Sealed Electrical Connector Structure for High-Temperature Corrosion Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical connectors in exhaust aftertreatment systems are susceptible to corrosion, limited by a maximum operating temperature of 150 degrees Celsius, and generate excessive heat, which reduces efficiency and can lead to local damage and reduced thermal energy delivery.
Innovation Solution
The electrical connector design includes a male connector with a wire connection portion and a pin connection portion having male threads, surrounded by a collar and nut with seals to prevent moisture and corrosion, allowing for high electrical current transmission up to 250 amps at 200 degrees Celsius, while reducing heat generation and improving temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional electrical connectors are used in exhaust aftertreatment systems, then the system can operate, but the connectors are susceptible to corrosion from moisture and limited to maximum temperature of 150 degrees Celsius
Solution Approach 1:
The electrical connector employs a composite construction combining metal components (pin connection portion, collar, nut) with elastomeric seals. The metal parts provide structural integrity and electrical conductivity while the elastomeric seals provide corrosion protection and environmental sealing, creating a composite structure that withstands both high temperature and moisture exposure.
Solution Approach 2:
The elastomeric seals create a protected environment around the electrical connection components, isolating them from the corrosive external atmosphere containing moisture and exhaust gases. This sealing effect maintains a more inert local environment that prevents corrosion of the metal components.
2Loss of energy
If conventional electrical connectors are used, then the connection can be made, but they generate excessive heat that reduces system efficiency and can cause local damage
Solution Approach 1:
The connector design modifies critical parameters including the contact surface area between mating components, the compression force applied by the nut, and the material properties of the elastomeric seals. These parameter changes optimize electrical conductivity and reduce contact resistance, thereby minimizing heat generation while maintaining operational temperature within safe limits.
3Device complexity
If the pin connection portion has the same outer diameter as the wire connection portion, then the structure is simpler, but the collar and nut cannot properly seal and protect the connection
Solution Approach 1:
The connector deliberately employs asymmetric dimensions where the pin connection portion has a different outer diameter than the wire connection portion. This asymmetry enables the collar and nut to properly engage and seal around the pin connection, creating an effective barrier against moisture and contaminants while maintaining a relatively simple overall structure.
Data Source
AI summary
An electrical connector includes: a male connector comprising a wire connection portion configured to be connected to a wire, and a pin connection portion configured to contact a conductor pin in an electrically conductive manner; a collar comprising a collar cylindrical body portion and a collar outer flange having a first surface and a second surface; a nut comprising a nut cylindrical body portion and a nut inner flange having a first surface that faces the second surface of the collar outer flange; a first seal that surrounds the collar cylindrical body portion and is positioned between the second surface of the collar outer flange and the first surface of the nut inner flange; and a second seal that surrounds the pin connection portion of the male connector and is positioned between an end surface of the nut cylindrical body portion and a first surface of the wire connection portion.