Automobile Charging Plug Hose Seal for Vibration Resistance
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Solution Overview
Problem
Existing car charger plugs face challenges in sealing high-current connections reliably and economically, especially under conditions of strong vibrations, as traditional sealing methods are complex, expensive, and not sufficiently reliable.
Innovation Solution
A plug connector design featuring a hose-shaped seal that encompasses the contact carrier and cable, providing axial and radial pressure for effective sealing, with an optional thermally conductive gel filling to enhance heat dissipation and mechanical protection, and recesses for electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing methods are used for car charger plugs, then sealing can be achieved, but the sealing becomes complex and expensive
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated seal element. The seal integrates the sealing collar, sealing lips, and cable sealing into one component that simultaneously seals the contact carrier, housing, and cable connection, eliminating the need for separate sealing components and reducing overall complexity
Solution Approach 2:
The seal is designed as a multi-functional component that performs multiple sealing tasks: sealing the contact carrier at one end, sealing the housing opening at the other end, and providing cable sealing through the sealing collar. This universal seal replaces what would traditionally require multiple separate sealing components
2Reliability
If traditional sealing methods are used for car charger plugs, then sealing can be achieved, but it becomes expensive
Solution Approach 1:
By merging multiple sealing functions into one integrated seal component, the patent reduces the total number of parts that need to be manufactured, stored, and assembled. This consolidation lowers manufacturing costs while maintaining comprehensive sealing coverage for all critical areas
3Device complexity
If a tubular seal pressed against the end wall is used, then sealing is simple, but it is not reliable under strong vibrations
Solution Approach 1:
The patent employs a flexible seal design with sealing lips that can deform and adapt to vibrations. The seal material and structure allow for elastic deformation under vibrational stress while maintaining continuous sealing contact, ensuring reliability in high-vibration environments like automotive applications
Solution Approach 2:
The seal extends in multiple spatial dimensions: it seals the contact carrier end face axially, seals the housing opening radially, and provides cable sealing through the collar. This multi-dimensional sealing approach ensures comprehensive protection against dust and water penetration from all directions, enhancing reliability under vibration
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 achieves reliable sealing against dust and water, improves heat dissipation during high-current operations, and provides mechanical protection, making it suitable for high-current applications like car charging while being cost-effective and durable.
Implementation Method 1
The seal is designed in the shape of a hose and thus comprises a first and a second end. The first end of the seal encompasses the end face of the contact carrier... The second end of the seal surrounds the cable protruding into the housing
Implementation Method 2
with an optional thermally conductive gel filling to enhance heat dissipation
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a plug‑type connector, in particular an automobile charging plug, wherein the plug‑type connector (1) comprises a contact carrier (2), in which at least one contact element (3) is arranged, wherein the at least one contact element (3) is connected to a conductor of a connected cable (6), wherein the contact carrier (2) is arranged in a housing (8) of the plug‑type connector (1), and wherein the connected cable (6) protrudes into the housing (8) of the plug‑type connector (1), wherein the plug‑type connector (1) comprises a seal (10), which seals off simultaneously the contact carrier (2) and a subsection of the cable (6) protruding into the housing (8) of the plug‑type connector (1).