Plug Connector Housing Seal for Fast Ultrasonic Assembly
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Solution Overview
Problem
Existing electrical plug connectors face challenges in achieving optimal sealing while maintaining ease of handling and quick mounting with minimal components, often requiring complex assembly and significant effort for precise positioning.
Innovation Solution
The solution involves a plug connector design with an annular sealing edge on one housing part and a corresponding annular seal on the other, connected radially outside the seal, using raised ribs and indentations for precise orientation and ultrasonic welding for a strong, secure connection, allowing for easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If housing parts are connected by ultrasonic welding without a seal, then assembly is simplified and productivity increases, but sealing reliability deteriorates
Solution Approach 1:
The housing is divided into two separate parts (first housing part and second housing part) that are connected by ultrasonic welding, while the seal is integrated into one of the housing parts as a separate functional element. This segmentation allows the sealing function to be independently optimized without compromising the welding connection.
Solution Approach 2:
The seal is integrated directly into the second housing part as an integral component, merging the sealing function with the housing structure. This eliminates the need for separate sealing components and simplifies the assembly process while maintaining reliable sealing.
2Reliability
If a seal is inserted between housing parts with complex positioning requirements, then sealing reliability improves, but assembly complexity and time increase
Solution Approach 1:
The seal is pre-integrated into the second housing part during manufacturing, so that no separate positioning or installation of the seal is required during final assembly. The seal is already in its correct position and orientation before the housing parts are connected.
Solution Approach 2:
The integrated seal design allows the housing part to self-align and self-seal during the ultrasonic welding process, eliminating the need for manual positioning or additional sealing operations. The seal automatically engages with the corresponding surface of the first housing part.
3Reliability
If multiple components are used for sealing and mounting, then sealing reliability improves, but device complexity increases
Solution Approach 1:
The seal is merged with the second housing part to form a single integrated component, eliminating the need for separate sealing elements. The mounting flange is also integrated into the housing structure, reducing the total number of components while maintaining all necessary functions.
Solution Approach 2:
The second housing part serves multiple functions: it provides the housing structure, integrates the seal for waterproofing, and includes the mounting flange for secure attachment. This multi-functionality reduces component count while maintaining 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
This design achieves an optimal sealing effect while simplifying the assembly process, enabling quick and secure mounting of plug connectors with fewer components, enhancing handling and material contact for reliable connections.
Implementation Method 1
The housing parts are unreleasably connected to one another at multiple locations radially outside the seal and the sealing edge, in particular by means of ultrasonic welding
Data Source
AI summary
The disclosure relates to an electrical plug connector, comprising two housing parts, which are connected in a sealing manner on flat contact surfaces. A first housing part is, on its contact surface, equipped with an annular sealing edge directed at the opposite housing part. A second housing part is, on its contact surface, equipped with an annular seal corresponding to the sealing edge. The housing parts may be unreleasably connected to one another at multiple locations radially outside the seal and the sealing edge.