Tulip Plug-In Connector With Ceramic Cladding for Hot Electrolyzer Stacks

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Solution Overview

Problem

Existing high-temperature plug-in connectors for electrolyzers face challenges such as slipping or electrical contact interruption due to changing clamping forces with temperature, and the need for replacing entire plug assemblies if one connector fails.

Innovation Solution

A plug-in connector design featuring a sheet-metal part with a tulip contact and a ceramic cladding that is dimensionally stable up to 1000°C, allowing for secure retention and easy release at high temperatures, and enabling flexible selection and replacement of individual connectors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the clamping forces of the tulip contact are increased to prevent slipping and contact interruption, then the reliability of electrical connection is improved, but the forces are lost with increasing time and temperature due to relaxation processes, and thicker material or stronger molding is required increasing device complexity

Engineering Contradiction:
Improveelectrical connection reliabilityVSAvoidplug-in connector structure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by utilizing the phase transition of the shape memory alloy from austenite to martensite. This phase change enables the material to automatically adjust its clamping force: in the austenite phase at operating temperature, the material maintains strong clamping force without relaxation, while in the martensite phase during assembly, it allows easy insertion. This resolves the contradiction by dynamically changing material properties rather than increasing structural complexity.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent directly applies phase transitions through the use of shape memory alloy that undergoes austenite-martensite transformation. The phase transition enables the connector to exhibit different mechanical properties at different temperatures: strong clamping force at operating temperature (austenite) and flexible insertion at assembly temperature (martensite). This eliminates the need for complex structural designs to maintain clamping force over time and temperature.

Inventive Principle:
Principle #36Phase transitions

2Ease of manufacture

If several plug-in connectors are enclosed in a common connector housing to simplify assembly, then the ease of manufacture is improved, but if one plug-in connector fails, the entire plug assembly must be replaced, worsening the ease of repair

Engineering Contradiction:
Improveassembly simplicityVSAvoidconnector replacement simplicity
Core Design Contradiction:
Ease of manufactureVSEase of repair

Solution Approach 1:

The patent applies segmentation by separating each plug-in connector into an independent module with its own housing. This allows individual connectors to be manufactured separately and then assembled onto the stacking plate, maintaining manufacturing simplicity while enabling independent replacement of failed connectors. The segmentation resolves the contradiction by eliminating the need for a common housing while preserving assembly efficiency through modular design.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies dynamics through the temperature-dependent phase transition of the shape memory alloy, which dynamically adjusts the clamping force based on operating conditions. This dynamic behavior ensures reliable electrical connection at high temperatures while allowing easy assembly at lower temperatures, resolving the contradiction between maintaining connection reliability and enabling easy maintenance.

Inventive Principle:
Principle #15Dynamics

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 ensures reliable electrical connection and easy maintenance by maintaining locking between the plug-in connector and stacking plate even when spring force drops at high temperatures, while allowing for flexible selection and replacement of connectors.

Implementation Method 1

The plug-in connector (2) comprises a sheet-metal part (2a) with a tulip contact (4) made of shape memory alloy, in particular of Fe-Mn-Si shape memory alloy

Methodology Applied
Scientific EffectShape memory effect:

Implementation Method 2

The tulip contact (4) is in the austenite state in the assembled state and in the martensite state in the de assembled state

Methodology Applied
Scientific EffectAustenite-martensite phase transition:

Implementation Method 3

a cladding (30) made of a material which is dimensionally stable up to over 1000° C.

Methodology Applied
Scientific EffectThermal stability:

Data Source

PatentUS20250062551A1Plug-in connector and arrangement comprising a plug-in connector and a stacking plate of an electrolyzer
Publication Date: 2025.02.20 WEIDMULLER INTERFACE GMBH & CO
  • US20250062551A1 patent drawing
  • US20250062551A1 patent drawing
  • US20250062551A1 patent drawing

AI summary

A plug-in connector for contact with a stacking plate of an electrolyzer includes a sheet-metal part having a tulip contact for contacting the stacking plate and a cladding made of a material which is dimensionally stable at 1000° C. A single cladding is allocated to each sheet-metal part, respectively, for contacting a single stacking plate.