Water-Tight Stud Assembly for High Current Applications
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Solution Overview
Problem
Autonomous vehicles' electrical components, which require high currents, are susceptible to water damage due to potential ingress points created by additional parts used for fastening, leading to reduced current delivery and increased heat generation, necessitating a water-tight sealed fastening assembly for high current applications.
Innovation Solution
A water-tight sealed stud assembly comprising a conductive sleeve and a non-conductive body, with a stud having a thickened portion and an annular groove for a sealing ring, forming a mechanical interference seal to prevent liquid ingress while allowing current transfer, and a cap to secure the power cable and reinforce the seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional parts are used for fastening electrical components, then the fastening reliability is improved, but water ingress points increase leading to reduced reliability
Solution Approach 1:
The patent combines multiple functions into a single integrated fastening assembly that includes the stud, sleeve, sealing ring, and cap as one unified structure. This merging eliminates gaps and potential water ingress points between separate components while maintaining secure fastening, thus resolving the contradiction between fastening reliability and water protection.
Solution Approach 2:
The fastening assembly uses composite material construction with a conductive sleeve for electrical connection, a non-conductive body for insulation and structural support, and a sealing ring for water protection. This composite approach allows each material to perform its optimal function while working together to prevent water ingress.
2Reliability
If multiple components are used in the fastening assembly, then the sealing capability is improved, but the device complexity increases
Solution Approach 1:
The patent integrates the stud, sleeve, sealing ring, and cap into a single pre-assembled unit that functions as one component during installation. This merging maintains the sealing capabilities provided by multiple elements while eliminating the complexity of assembling multiple separate parts, thus resolving the contradiction between sealing capability and device complexity.
3Power
If a conductive sleeve is used for current transfer, then the electrical conductivity is improved, but heat generation increases due to resistance
Solution Approach 1:
The patent uses a composite structure where the conductive sleeve is surrounded by a non-conductive body that provides thermal management. The non-conductive material acts as thermal insulation and heat dissipation pathway, allowing the conductive sleeve to efficiently transfer current while the composite structure manages the resulting heat, thus resolving the contradiction between electrical conductivity and heat generation.
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 seals against water ingress, maintains high current transfer efficiency, and reduces heat generation by minimizing additional resistance, thus protecting sensitive electrical components in autonomous vehicles.
Implementation Method 1
forming a mechanical interference seal to prevent liquid ingress while allowing current transfer
Implementation Method 2
A water-tight sealed stud assembly for high current applications comprises a stud, a sleeve disposed circumferentially around the stud, and a body disposed circumferentially around the sleeve. The sleeve may be comprised of a conductive material
Data Source
AI summary
The subject disclosure relates to a water-tight sealed stud assembly for high current applications. The water-tight sealed stud assembly can include a stud, a sealing ring, a sleeve, and a body. The stud may have a stud base and a thickened portion having an annular groove. The sealing ring may be disposed in the annular groove. The sleeve may be disposed circumferentially around the stud and made of a conductive material. The body may be disposed circumferentially around the sleeve and made of a non-conductive material. Systems and methods are also provided.