Composite Mat Seal Structure for Cable Insertion and Sealing
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Solution Overview
Problem
Existing mat seals for electrical connectors face issues with material deformation and displacement when larger cables are inserted, leading to potential damage and compromised sealing against moisture and dirt, especially in automotive applications.
Innovation Solution
A mat seal design featuring a grid of less compressible material with varying cross-sectional areas and a multi-layer structure, where the grid has a higher compression modulus than the outer material layers, reducing deformation and maintaining structural integrity during cable insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mat seal is made with a tight-fitting through-hole to ensure sealing, then sealing performance is improved, but material deformation and cable damage occur during cable insertion
Solution Approach 1:
The mat seal is constructed as a composite material consisting of a first material layer (softer, more compliant), a grid of a second material (stiffer, higher compression modulus), and a second material layer (softer, more compliant). This composite structure allows the outer softer layers to conform to and seal around the cable while the inner stiff grid maintains structural integrity and resists excessive deformation, preventing both sealing failure and cable damage.
2Reliability
If the through-hole cross-section is made smaller to fit the cable tightly, then sealing performance is improved, but frictional forces and material compression increase causing cable damage
Solution Approach 1:
Different regions of the mat seal have different material properties optimized for their specific functions: the first and second material layers have lower compression moduli providing compliance and sealing at the cable interface, while the grid in the middle has a higher compression modulus providing structural support. This local differentiation of material quality allows tight sealing without excessive friction or cable damage.
3Strength
If the mat seal material is made more compliant to reduce cable damage, then cable integrity is improved, but sealing performance deteriorates due to material displacement
Solution Approach 1:
The composite structure combines compliant outer layers for cable protection with a stiff inner grid for sealing stability. The softer first and second material layers reduce friction and protect the cable during insertion, while the stiffer grid maintains the through-hole geometry and prevents material displacement that would compromise sealing performance.
4Device complexity
If a single-layer mat seal is used to simplify structure, then device complexity is reduced, but deformation control and sealing reliability worsen
Solution Approach 1:
The mat seal uses a three-layer composite structure with distinct material properties: outer compliant layers for cable interaction and an inner stiff grid for structural stability. This composite design simultaneously achieves deformation control during cable insertion and reliable sealing performance, overcoming the limitations of single-layer seals without excessive complexity.
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
This design minimizes material deformation and displacement, ensuring reliable electrical and mechanical contacts while maintaining effective sealing against moisture and dirt, reducing the risk of installation faults and cable damage.
Implementation Method 1
The first material of the grid has a greater compression modulus than the second material of the first material layer and the third material of the second material layer
Implementation Method 2
Elastic deformation and compression of the material within the sealing mat occur
Data Source
AI summary
A mat seal for an electrical connector includes a plurality of through-holes extending in a through-hole direction through the mat seal, a grid of a first material having a plurality of grid meshes, the grid is arranged with the through-holes extending through the grid meshes, a first material layer of a second material disposed on a first side of the grid, and a second material layer of a third material disposed on a second side of the grid opposite the first side. The first material of the grid has a greater compression modulus than the second material of the first material layer and the third material of the second material layer.