Wind Protection Cover for Plug Connectors with Air Gap Insulation
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Solution Overview
Problem
Existing wind protection solutions for plug connections in cable harnesses, particularly in automobile manufacturing, face challenges such as noise generation, thermal bridging, uncontrolled assembly, and incompatibility with multiple line connectors, especially hydraulic connectors, which are prone to freezing and viscous fluid issues at low temperatures.
Innovation Solution
A plug connection device featuring a plastic shell with two sub-shells that enclose a receiving space, creating an air gap to hold line connectors at a distance, providing thermal insulation and noise reduction, with a swivel joint for easy handling and tool-free assembly, and optional sealing and heating elements for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If wind protection hoses are pushed over cable connectors, then wind protection is provided, but positioning accuracy deteriorates causing rattling noises
Solution Approach 1:
The wind protection cover is divided into a first sub-shell and a second sub-shell that can be opened and closed. This segmentation allows the cover to be opened during assembly to receive the cable connector, then closed to secure it in position, eliminating the positioning inaccuracies associated with pushing hoses over connectors.
Solution Approach 2:
The cable connector is received by the opened half-shells before closing. This preliminary action of opening the cover before insertion allows for precise positioning of the connector within the cover, preventing rattling noises while maintaining wind protection.
2Object-affected harmful factors
If wind protection hoses contact cable connectors, then coverage is achieved, but thermal bridging occurs causing fluid freezing
Solution Approach 1:
A holding means with receiving geometry is introduced as an intermediary between the wind protection cover and the cable connector. This holding means positions the connector at a defined distance from the sub-shells, creating a thermal buffer zone that prevents direct thermal contact while maintaining wind protection coverage.
Solution Approach 2:
The cable connector is extracted from direct contact with the wind protection cover by positioning it within the holding means at a defined distance. This separation removes the thermal bridging pathway while preserving the protective enclosure.
3Stability of the object's composition
If cable ties are tightened around hose ends, then assembly is secured, but assembly control deteriorates causing crushed conductors or loose connections
Solution Approach 1:
The holding means with receiving geometry provides self-aligning and self-positioning features that guide the cable connector into the correct position during assembly. This self-service mechanism eliminates the need for controlled cable tie tightening, preventing both crushed conductors and loose connections while maintaining assembly security.
4Object-affected harmful factors
If hose ends are turned inside out for assembly, then coverage is achieved, but operational complexity increases requiring manual skill
Solution Approach 1:
The wind protection cover is segmented into openable half-shells that can be separated for assembly. This eliminates the need to turn the hose ends inside out, as the connector can be simply inserted between the opened half-shells and then the cover is closed, significantly reducing operational complexity and manual skill requirements.
5Object-affected harmful factors
If membranes are used to cover connector openings, then protection is provided, but thermal bridging occurs from housing shell to connector
Solution Approach 1:
The holding means with receiving geometry serves as a thermal intermediary, positioning the cable connector at a defined distance from the sub-shells. This creates a thermal buffer zone that prevents direct thermal contact, unlike membranes that create thermal bridges from the housing shell directly to the connector.
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 prevents noise and thermal bridging, ensures precise and easy installation, and maintains the connectors in a defined position, while being cost-effective and suitable for both electrical and hydraulic connectors, addressing the issues of assembly complexity and thermal protection.
Implementation Method 1
designed such that a line connector received with the receiving geometry is held in the receiving space at a distance from the first sub-shell and the second sub-shell by an air gap
Implementation Method 2
The distance creates an air cushion around the connector contour, which provides thermal insulation. Rattling noises are also prevented because the cable connector is in a defined position
Data Source
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AI summary
The invention relates to a wind-protection casing (1) comprising: a plastic shell (10) having a first partial shell (11) and a second partial shell (12), wherein the first partial shell (11) and the second partial shell (12) surround an accommodating space (22) and form a first and second line opening (13, 14), which connect the accommodating space (22) with the surrounding region (U) outside the accommodating space (22); and a retaining means (20) with an accommodating geometry (21) for a line plug connector (110), which is arranged on the first partial shell (11) and is designed in such a way that a line plug connector (110) accommodated by the accommodating geometry (21) is retained in the accommodating space (22) at a distance from the first partial shell (11) and the second partial shell (12) via an air gap (23). The invention also relates to a plug-connector device (100) comprising a wind-protection casing (1) of this type, wherein a line plug connector (110) is accommodated in the accommodating geometry (21).