Reinforced Connector Cover Structure for Liquid Ingress Prevention
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Solution Overview
Problem
Existing connectors for electrical devices in vehicles are prone to deformation due to increased pressure from high temperatures, leading to gaps that allow liquids like water to enter the connector, compromising electrical connections.
Innovation Solution
A connector design featuring a cover with reinforcement ribs on multiple surfaces and a sealing portion to enhance rigidity and prevent deformation, combined with guide structures for precise alignment, thereby restricting cover deformation and preventing liquid ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the cover is made thin and lightweight to reduce material usage and cost, then manufacturing cost and material consumption are reduced, but the cover becomes prone to deformation under pressure from high temperatures
Solution Approach 1:
The cover transitions from a uniform thin structure to a non-uniform structure with locally concentrated reinforcement ribs. The ribs are strategically positioned at specific locations where structural support is most needed to resist pressure-induced deformation, while the rest of the cover maintains its thin, material-efficient design.
Solution Approach 2:
The cover design adds vertical dimensionality by incorporating reinforcement ribs that extend in multiple directions (first direction along connection parts, second direction between connection parts). This three-dimensional rib structure provides structural strength without increasing the horizontal footprint or overall cover thickness.
2Stability of the object's composition
If reinforcement ribs are added to the cover to prevent deformation, then structural stability is improved, but manufacturing complexity and device complexity increase
Solution Approach 1:
Multiple reinforcement functions are merged into a single integrated cover component. The first reinforcement ribs (extending in the first direction) and second reinforcement ribs (extending in the second direction) are combined in one piece, eliminating the need for separate reinforcement components and reducing assembly steps.
Solution Approach 2:
The reinforcement ribs serve multiple functions simultaneously: they provide structural strength to prevent deformation, maintain the seal between the cover and connector housing, and potentially guide assembly alignment. This multi-functionality reduces the need for additional specialized components.
3Ease of manufacture
If the cover is designed without reinforcement to simplify manufacturing, then ease of manufacture is improved, but the cover deforms under pressure from high temperatures causing gaps that allow liquid ingress
Solution Approach 1:
Rather than reinforcing the entire cover uniformly (which would complicate manufacturing), reinforcement ribs are placed only at critical locations where deformation would most adversely affect sealing performance. This localized approach maintains manufacturing simplicity while ensuring reliability.
Solution Approach 2:
The reinforcement ribs are built into the cover structure in advance (during molding) to preemptively counteract the deforming pressure that will be applied during operation. This preliminary structural preparation prevents deformation before it can occur, maintaining the seal integrity under thermal pressure.
Data Source
AI summary
In the present invention, a cover closes an opening in a housing holding a plurality of terminals. Each of the terminals has a connection part connecting to a mate terminal. The cover has a first surface, a second surface located at a rear side of the first surface including an exposed surface exposed to the inner side of the housing through the opening, a first reinforcement rib projecting from the first surface, and a second reinforcement rib projecting from the second surface. The direction in which the plurality of connection parts are arranged is defined as a first direction. The direction that intersects the first direction and that is oriented from the basal end toward the distal end of the connection parts is defined as a second direction. The first reinforcement rib extends along the first direction. The second reinforcement rib extends along the second direction between adjacent connection parts.