Angled Connector Assembly With One-Piece Terminal Laser Sealing
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Solution Overview
Problem
Right angle sealed electrical connectors conforming to the FAKRA standard typically require a two-piece terminal, which results in inferior electrical performance compared to a one-piece terminal.
Innovation Solution
A right-angled electrical connector assembly with a one-piece terminal is designed, featuring a first and second attachment surface with complementary angles, where the first attachment surface defines a circumferential ridge and the second attachment surface defines a circumferential groove, and these are welded using an infrared laser welding process, allowing for a direct insertion of a one-piece terminal shield and providing a hermetic seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-piece terminal is used in right angle sealed electrical connectors conforming to the FAKRA standard, then the connector can be manufactured with standardized assembly processes, but the electrical performance becomes inferior compared to a one-piece terminal
Solution Approach 1:
The housing is divided into two separate pieces (first housing and second housing) that are joined together, allowing the terminal to be a single integrated piece while maintaining ease of manufacture through modular assembly processes
2Reliability
If a one-piece terminal is used, then the electrical performance is superior, but the manufacturing complexity increases compared to two-piece terminal configurations
Solution Approach 1:
The housing is segmented into two separate pieces that can be manufactured independently and then joined together, reducing the complexity of manufacturing the housing while accommodating a one-piece terminal for superior electrical performance
3Adaptability or versatility
If two housing pieces are joined together, then the connector can accommodate a one-piece terminal, but additional sealing measures are required to prevent water ingress
Solution Approach 1:
The sealing between housing pieces is achieved through laser welding instead of traditional mechanical sealing methods, eliminating the need for separate gaskets or sealing elements and simplifying the overall sealing structure
Solution Approach 2:
The housing pieces are made from laser-weldable materials that can be joined hermetically, creating a composite structure that provides both structural integrity and water-tight sealing
4Reliability
If traditional welding methods are used to join housing pieces, then the sealing effectiveness is adequate, but the manufacturing cost and time increase compared to laser welding
Solution Approach 1:
Traditional mechanical or thermal welding processes are replaced with laser welding technology, which provides equivalent or superior sealing effectiveness while significantly reducing manufacturing time and increasing production efficiency
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 provides more reliable connection properties and a water-tight seal, eliminating the costly and unstable connection issues associated with two-piece terminal configurations.
Implementation Method 1
the first attachment surface is welded to the second attachment surface by welding the upper surface of the ridge to the lower surface of the groove using an infrared laser welding process
Data Source
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AI summary
An electrical connector assembly includes an electrical terminal (108) having an attachment end (110) and a connection end (112), a first terminal (108) housing having a first cavity (116) in which the attachment end (110) is disposed. The first cavity (116) defining a terminal extension opening (120) through which the connection end (112) extends. The assembly also includes a second terminal (108) housing having a second cavity (124) in which the connection end (112) is disposed. The second cavity (124) defining a terminal reception opening (126) through which the connection end (112) is received. The first terminal (108) housing defines a first attachment surface (130) surrounding the terminal extension opening (120) and the second terminal (108) housing defines a second attachment surface (132) surrounding the terminal reception opening (126). The first attachment surface (130) is sealed to the second attachment surface (132). The first attachment surface (130) forms a first angle relative to the longitudinal axis (X) and the second attachment surface (132) forms a second angle relative to the lateral axis (Y).