Supply Cable Connector Sealing for PCB Vibration Protection
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Solution Overview
Problem
Existing connectors for supply cables used in electric vehicle charging are prone to mechanical damage from shocks, vibrations, and pressure, which can impair the functionality of the printed circuit board and make the connector heavy, costly, and difficult to repair.
Innovation Solution
A connector design featuring a housing with two shells that enclose a printed circuit board in a clamped manner, using a seal element to seal the housing interior and reduce mechanical influences, allowing for the use of SMD components and eliminating the need for potting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If THT components are used on the printed circuit board, then mechanical durability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent changes the mounting technology parameter from THT (Through-Hole Technology) to SMD (Surface-Mount Device) while compensating for mechanical durability through the sealing housing design. This allows using lighter, cheaper SMD components without sacrificing reliability, as the sealed housing protects them from mechanical influences during drops and vibrations.
2Reliability
If the printed circuit board is encapsulated with gel or resin, then protection against mechanical influences is improved, but weight and cost increase
Solution Approach 1:
The patent extracts the protection function from the printed circuit board itself and relocates it to the housing level. Instead of encapsulating the PCB with heavy gel or resin, the housing is designed with a sealed structure that protects the PCB from mechanical influences, thereby reducing weight while maintaining protection.
3Object-affected harmful factors
If potting compound is used to seal the housing, then protection against dirt and moisture is improved, but manufacturing cost and environmental impact increase
Solution Approach 1:
The patent replaces the chemical potting process with a mechanical sealing system using a seal element and clamping mechanism. This substitution eliminates the need for expensive and environmentally harmful potting compounds while achieving the same protection against dirt and moisture through purely mechanical means.
4Object-affected harmful factors
If the connector is designed as a single piece, then sealing is improved, but ease of repair deteriorates
Solution Approach 1:
The patent segments the connector into a housing and a seal element that can be separately assembled and disassembled. This segmentation maintains sealing effectiveness through the seal element while enabling easy repair by allowing access to internal components without damaging the entire connector structure.
5Device complexity
If SMD components are used instead of THT, then device complexity is reduced, but reliability under mechanical stress worsens
Solution Approach 1:
The patent provides beforehand cushioning for SMD components through the sealed housing structure. The housing is designed to absorb and distribute mechanical stresses from drops and vibrations, protecting the fragile SMD components before they can be damaged, thereby enabling their use without compromising reliability.
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 effective sealing against dirt, grime, and moisture, while damping mechanical loads to protect the printed circuit board, resulting in a lightweight, cost-effective, and easily repairable connector with improved durability and reliability.
Implementation Method 1
a seal element (24) is provided, which is configured to seal off a housing interior (40) of the housing (20) against an outer surrounding area (41) of the housing (20)
Implementation Method 2
the printed circuit board (50) is held in a clamped manner at least in sections by the interposition of the seal element (24) between the printed circuit board (50) and the first housing shell (21), in that an intensity of mechanical loads acting on the printed circuit board (50) is damped with respect to the printed circuit board (50)
Data Source
AI summary
The invention relates to a connector (14, 15) for a supply cable (10) for electrically connecting a vehicle (12) to an energy supply device (16) which provides electrical energy and/or to a consumer (19) which requires electrical energy. The connector (14, 15) comprises:—a housing (20) having at least one first housing shell (21) and a second housing shell (22), in particular a second housing shell which is separate from the first housing shell (21),—a printed circuit board (50) which comprises an electric and/or electronic circuit (31) in particular, and—a seal element (24), wherein the housing (20) encloses a housing interior (40), wherein the seal element (24) is configured to seal off the housing interior (40) from the outer surrounding area (41) of the housing (20), wherein the seal element (24) is arranged between the first housing shell (21) and the second housing shell (22), wherein the printed circuit board (50) is held in a clamped manner along the clamping direction (K) between the first housing shell (21) and the second housing shell (22), wherein the printed circuit board (50) is, at least in sections, held in a clamped manner by the interposition of the seal element (24) between the printed circuit board (50) and the first housing shell (21).