Shielded Electrical Line Assembly with Sealed Housing
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Solution Overview
Problem
Existing arrangements for connecting multiple electrical lines with shields face challenges in maintaining a secure, moisture-tight seal, especially under high-voltage and mechanical stress conditions, due to complex production processes and material compatibility issues.
Innovation Solution
A mechanically stable housing with a seal carrier and line seals, where the seal carrier has a cone for a tight fit and a housing seal to prevent moisture ingress, along with a filling cushion to eliminate the need for injection molding, ensuring the seals are not compromised by mechanical forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an injection molding process is used to produce the insulation element, then the seal against moisture is achieved, but the production becomes complex and the suitability depends on the jacket material type
Solution Approach 1:
The arrangement is divided into separate functional components: a housing for structural protection, a seal carrier with integrated seals for moisture protection, and a filling material for space occupation. This segmentation eliminates the need for complex injection molding while maintaining sealing effectiveness through modular assembly of standardized parts.
2Adaptability or versatility
If many components are sealed in the arrangement, then the connection of multiple electrical lines is achieved, but the tightness is adversely affected by vibrations and bends
Solution Approach 1:
A filling material is introduced into the housing to occupy empty spaces and provide mechanical support. This cushioning effect protects the sealed components from vibrations and bends by distributing mechanical stresses uniformly, preventing seal degradation while maintaining the ability to connect multiple electrical lines.
3Ease of operation
If the seals are exposed to mechanical forces, then the connection of lines is achieved, but the sealing function is impaired
Solution Approach 1:
The seal carrier serves as an intermediary component between the housing and the electrical line connections. It carries the seals in a protected position and transmits mechanical forces to the housing structure rather than directly to the seals, thereby maintaining sealing effectiveness while enabling line connections.
4Manufacturing precision
If a cone is added to the seal carrier for a tight fit, then the play-free assembly is achieved, but the device complexity increases
Solution Approach 1:
A conical geometry is applied to the seal carrier to achieve a tight, play-free fit within the housing. The tapered shape provides self-centering and progressive engagement during assembly, ensuring precise positioning and eliminating gaps without requiring complex additional features or adjustment mechanisms.
Data Source
Figure 1~2B
Figure 3
Figure 4A~4B
AI summary
An arrangement for the electrically conductive connection of several electrical conductors, which are provided with an electrically conductive shield, is proposed. The conductors of the conductors are electrically connected to one another in the region of a connection point (V). The arrangement comprises a housing (302) made of insulating material that completely encloses the connection point (V). The arrangement has at least one seal (304A, 304B) in the region of the conductors (301A-301D), which enables improved sealing of the housing.