Adhesive Sealing of Plug Contacts in Servo Steering Connectors
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Solution Overview
Problem
Existing electrical connector plugs in electromechanical motor vehicle servo steering mechanisms face challenges in achieving reliable and rapid sealing of plug contacts against dust and water spray, especially when no mating connector is fitted, due to issues with molding compound curing and distribution.
Innovation Solution
A plug design featuring a cup-shaped plug housing with cut-outs that guide plug contacts into a recess, where adhesive bonding secures the plug contacts, socket, and plug housing, providing superior sealing without the need for a separate sealing material and allowing for immediate further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If molding compound is used to seal plug contacts, then sealing protection is achieved, but curing time increases and processing speed decreases
Solution Approach 1:
The patent changes the chemical parameters of the sealing material by using adhesive with different curing characteristics than traditional molding compound. The adhesive can be rapidly cured with UV radiation or heat, transforming the sealing process from a slow thermal curing process to a fast-curing process that enables immediate further processing
Solution Approach 2:
The patent extracts the sealing function from the structural molding compound and separates it into a dedicated adhesive application step. This allows the sealing material to be specifically optimized for rapid curing while the structural integrity is maintained by the mechanical joining of plug housing and socket
2Productivity
If curing is accelerated by heat or UV radiation, then processing time is reduced, but process management problems arise such as shadows cast by plug contacts or excessive heat-up
Solution Approach 1:
The adhesive is applied locally only in the recess of the socket where sealing is needed, rather than applying molding compound throughout the entire plug housing. This localized application ensures uniform UV or heat exposure without shadows cast by plug contacts, and prevents excessive heat-up of the plug housing while achieving complete curing of the sealing material
3Reliability
If sealing material is applied around plug contacts, then sealing is achieved, but additional processing steps are required and time is lost
Solution Approach 1:
The patent merges the sealing function with the joining operation by applying adhesive that simultaneously bonds the plug housing to the socket and seals the plug contacts. This integration eliminates separate sealing steps and allows immediate further processing after the joining operation completes
4Reliability
If plug contacts are enclosed in molding compound, then sealing is achieved, but the plug housing may overheat during curing
Solution Approach 1:
The patent changes the thermal parameters of the sealing process by using adhesive with lower curing temperature requirements compared to traditional molding compound. The adhesive can be cured with UV radiation or moderate heat, preventing excessive temperature rise in the plug housing while achieving complete sealing of the plug contacts
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 effective sealing against dirt, moisture, and water spray, even when no mating connector is fitted, while enabling rapid assembly and integration with other processes, eliminating the need for additional sealing steps and allowing for a more compact design.
Implementation Method 1
the plug housing and the socket are connected to one another in an adhesive bonding process
Data Source
AI summary
A plug for an electrical connector arrangement may include a plug contact arranged in a socket on one side and in a plug housing on the other side. The plug housing may be cup-shaped and include a base with a region that projects downward as a connecting part. In the region of the connecting part, a cut-out may pass through the base via which the plug contact is guidable. The plug contact may be positioned in the socket with a recess. The plug contact may be connected to the socket in the recess, and the connecting part of the plug housing may be adhesively bonded in the recess of the socket such that the plug contact is sealed against dirt and moisture in the region of the cut-out relative to the plug housing.