Charging Coupler Tubular Grip Seal Groove Waterproofing
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Solution Overview
Problem
Existing waterproof charging couplers face challenges in automated assembly due to glue filling processes, which result in air gaps, increased manufacturing costs, and weight, making them difficult to assemble and less efficient.
Innovation Solution
A charging coupler design featuring a tubular grip assembled by buckling, with a groove filled with sealant that is squeezed by a rib for sealing, allowing for enhanced waterproof performance and suitability for automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glue filling procedure is used to improve waterproof performance, then waterproof effect is enhanced, but assembly process becomes difficult to automate and production yield rate decreases
Solution Approach 1:
The seal groove is pre-formed on the housing surface before assembly, and the sealant is pre-placed in this groove. This preliminary preparation eliminates the need for complex automated glue filling operations during assembly, as the sealant is already positioned correctly for immediate sealing when components are joined.
Solution Approach 2:
The sealing function is extracted from the complex glue filling process and integrated into the mechanical bonding structure through the seal groove. The seal groove is formed as an integral part of the housing structure, separating the sealing function from the assembly operation and enabling simpler, more automatable assembly processes.
2Reliability
If glue filling procedure is used to improve waterproof performance, then waterproof effect is enhanced, but air gaps may form due to insufficient filling which decreases waterproof effect
Solution Approach 1:
The seal groove acts as an intermediary structure that guides and contains the sealant. This groove ensures the sealant is precisely positioned and distributed along the sealing interface, preventing air gaps and ensuring complete coverage without requiring high-precision automated filling operations.
3Strength
If rivet or screw assembling process is used to improve structural strength, then connection strength is enhanced, but automated assembly becomes difficult
Solution Approach 1:
The housing is segmented into modular components (first housing, second housing, third housing) that can be assembled through simple buckling operations. This segmentation allows each component to be joined through straightforward mechanical interlocking rather than requiring complex rivet or screw fastening operations.
4Reliability
If traditional waterproof structure with rubber ring and rivet/screw is used, then waterproof performance is achieved, but manufacturing cost and weight increase
Solution Approach 1:
The sealing function is merged with the housing structure itself through the integrated seal groove, eliminating the need for separate rubber rings. This integration reduces the number of components and overall weight while maintaining waterproof performance through the sealant-filled groove design.
Solution Approach 2:
The sealing function is extracted from traditional rubber ring components and integrated directly into the housing structure through the seal groove. This extraction eliminates the need for separate sealing components, reducing weight and manufacturing complexity while maintaining waterproof effectiveness.
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 design enhances waterproof performance, reduces assembly costs, and facilitates automated assembly by eliminating the need for screws and minimizing material usage.
Implementation Method 1
The groove is filled with a sealant. The rib is inserted into the groove and the rib is substantially matched with the groove. A gap between the rib and the groove is filled with the sealant.
Data Source
AI summary
A charging coupler has a grip, an electrical connector and a cable holder. The grip has a front opening and a rear opening on two ends thereof The grip has a first half-tube and a second half-tube connected with each other along a longitudinal direction thereof. The first half-tube has a first latch portion and a groove extending along edges thereof to connect the second half-tube. The second half-tube has a second latch portion and a rib extending along edges thereof to connect the first half-tube. The rib is substantially matched with the groove, and a sealant is filled in a gap between the rib and the groove. The first latch portion is latched with the second latch portion to tighten connection of the first half-tube and the second half-tube. The electrical connector is arranged on the front opening, and the cable holder is arranged on the rear opening.