Shield Housing Air Volume Reduction for Electrical Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical distribution housings face pressure fluctuations due to temperature changes, leading to wear on sealing elements and moisture degradation, which existing venting membranes and pressure equalization elements cannot effectively address without increasing costs and pollution degree, and are difficult to implement in serial processing.
Innovation Solution
An electrical distribution system with an isolator and shield housing configuration that reduces air volume by using a crimping process to encase the isolator and cables, eliminating the need for venting membranes and maintaining a lower pollution degree, comprising a one-way and two-way body part with crimping elements to minimize air space and support minimal airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If venting membranes and pressure equalization elements are used to address pressure fluctuations, then pressure changes are mitigated, but manufacturing costs increase and pollution degree increases to three
Solution Approach 1:
The patent removes the pressure equalization element and venting membrane from the housing, extracting the problematic component that caused pollution degree increase. Instead, the housing is designed with reduced internal volume to minimize pressure fluctuations without requiring these complex sealing elements.
Solution Approach 2:
The patent changes the physical parameter of the housing by reducing its internal volume. This parameter change allows the housing to withstand pressure fluctuations better while maintaining lower pollution degree, eliminating the need for complex pressure equalization mechanisms.
2Reliability
If overmolding or potting is performed to reduce air volume, then pressure fluctuations are reduced, but additional manufacturing steps are required increasing costs
Solution Approach 1:
The patent incorporates air volume reduction features directly into the housing design from the beginning, rather than adding post-processing steps like overmolding or potting. The housing geometry is preliminarily configured to minimize internal air space, eliminating the need for additional manufacturing operations.
Solution Approach 2:
The patent combines the pressure fluctuation mitigation function directly into the housing structure itself, rather than requiring separate overmolding or potting processes. The housing design integrates volume reduction features that accomplish both structural support and pressure management in a single manufacturing step.
3Reliability
If the housing volume is reduced to minimize air space, then pressure fluctuations are reduced, but the housing may become too compact for cable routing
Solution Approach 1:
The patent segments the housing into functional zones that optimize both volume reduction and cable routing. Different sections of the housing provide different characteristics - some areas are compacted to reduce air volume while other areas maintain sufficient space for cable entry and routing operations.
Solution Approach 2:
The patent utilizes three-dimensional spatial optimization to reduce internal volume while maintaining external dimensions necessary for cable routing. By strategically positioning internal features and utilizing vertical space, the housing achieves compact air volume without compromising cable accessibility.
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 solution effectively reduces pressure fluctuations and maintains a lower pollution degree, ensuring the integrity of seals and compliance with safety standards by minimizing air and moisture within the housing, thus reducing the need for additional manufacturing steps and costly components.
Implementation Method 1
air that is trapped within the housing will expand and contract in response to these temperature changes
Data Source
AI summary
A method for reducing a volume of air within an electrical distribution system. The method includes providing at least one cable, surrounding the at least one cable with an isolating unit, placing a first shielding body on a top surface of the isolating unit, placing a second shielding body on a bottom surface of the isolating unit, wherein placing the first shielding body and the second shielding body creates a gap X1 between the first shielding body or the second shielding body and the isolating unit, and crimping the first shielding body to the second shielding body to create a shield housing, so that a gap X2 is created between the first shielding body or the second shielding body and the isolating unit, wherein X2 is less than X1. The at least a portion of the first shielding body may overlap with the second shielding body, and the first shielding body or the second shielding body may include at least one flared portion. The overlap may occur at a location corresponding to the flared portion, with the flared portion having a length N, wherein N may be equal to about 2(X1−X2). Gaps X1 and X2 may be air gaps.