Adapter Plug Sealing for Lamp Module Cables
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Solution Overview
Problem
Existing electrical connection cables for lamp modules are difficult to install and maintain, as they are permanently connected, and previous sealing solutions complicate assembly and disassembly, often requiring manual handling.
Innovation Solution
An electrical connection cable with an adapter plug made of a small circuit board and connector housing, sealed with potting material, allows for easy automated installation and sealing, featuring latching means and a flange for secure mounting, and includes contact points for electrical connection, ensuring mechanical and electrical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connection cable is permanently connected to the lamp module, then the sealing is improved, but the ease of maintenance deteriorates
Solution Approach 1:
The connection cable system is divided into separate components: a connector part that remains in the lamp module and a cable part that can be removed. The adapter plug with circuit board and housing separates the sealing function (remaining in the module) from the cable connection function (removable), allowing maintenance without compromising sealing integrity.
Solution Approach 2:
The connection system transitions from a static permanent connection to a dynamic system where the cable can be connected and disconnected. The adapter plug design with recesses and latching mechanisms enables the cable to be securely connected during operation but easily removed for maintenance, providing both reliability and maintainability.
2Reliability
If a rubber seal is used to seal the grommet, then the sealing is improved, but the device complexity and ease of assembly deteriorate
Solution Approach 1:
The mechanical rubber seal system is replaced with an integrated adapter plug design where sealing is achieved through the housing structure itself, with seals positioned in grooves and covered by a cover. This eliminates the need for complex manual assembly of rubber seals and grommets, reducing assembly complexity while maintaining sealing reliability.
Solution Approach 2:
The sealing function is merged into the adapter plug housing structure rather than being a separate component. The housing includes integrated grooves for seals and a cover that together provide the sealing function, simplifying the overall assembly and reducing the number of separate sealing components that need to be manually installed.
3Reliability
If the circuit board is completely covered with potting material, then the sealing is improved, but the ease of repair and electrical connectivity deteriorate
Solution Approach 1:
The potting material application uses local quality by selectively covering only certain areas of the circuit board. The first contact points are enclosed in recesses and covered with potting material for sealing, while the second contact points remain exposed for electrical connection. This localized approach provides sealing where needed while maintaining electrical connectivity where required.
Data Source
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AI summary
The invention relates to an electrical connection cable for mounting in an opening of a lighting module, wherein the connection cable comprises: an electrical cable with an end close to the light source and an end farther from the light source; and an adapter plug at the end of the electrical cable close to the light source, wherein the adapter plug comprises a circuit board having at least one first contact point to which a conductor of the electrical cable is connected, and at least one second contact point which is electrically connected to the first contact point via the circuit board and to which an electrical cable can be connected inside the lighting module, as well as a plug housing which is connected to the circuit board by a potting material and which has the means for securing the adapter plug in the opening of the lighting module, wherein the potting material seals the circuit board and the at least one conductor with the plug housing.Furthermore, the invention relates to a lighting module with a corresponding connecting cable.