Connector Assembly Mat Seal Accommodating Varying Conductor Diameters
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Solution Overview
Problem
Existing connector assemblies face challenges in accommodating conductors of varying diameters, requiring different mat seals and increased insertion force, which can lead to damage and ineffective sealing.
Innovation Solution
A connector assembly design featuring a mat seal with uniform seal passages and conductor seals of varying diameters, both made of silicone-based materials, that inhibit contaminants and reduce insertion force by using crimping features and grooves to securely attach terminals without deforming the seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different mat seals are used to accommodate conductors of varying diameters, then the sealing effectiveness is improved, but the device complexity and production costs increase
Solution Approach 1:
The mat seal is designed with a uniform passage that can accommodate conductors of different diameters through a single standardized structure. The flexibility of the elastomeric material allows the same mat seal design to adapt to various conductor sizes without requiring multiple specialized seal variants, thus maintaining sealing effectiveness while reducing device complexity.
Solution Approach 2:
The conductor seal is designed with adjustable parameters including its outer diameter and the dimensions of the crimping features. By varying these parameters within a standardized design framework, the system can accommodate different conductor diameters using the same basic mat seal structure, resolving the contradiction between sealing effectiveness and device complexity.
2Reliability
If insertion force is increased to secure terminals, then the connection reliability is improved, but the risk of damage to seals and conductors increases
Solution Approach 1:
The terminal attachment function is segmented into two distinct components: the conductor seal provides mechanical attachment through crimping features, while the mat seal provides sealing. This segmentation allows the conductor seal to handle insertion forces without compromising the mat seal's sealing integrity, thus maintaining connection reliability while protecting seal integrity.
Solution Approach 2:
The conductor seal acts as an intermediary between the terminal and the mat seal. It absorbs and distributes insertion forces through its crimping features and outer groove structure, preventing direct transmission of high insertion forces to the mat seal and conductor, thereby maintaining both connection reliability and component integrity.
3Ease of operation
If conductor seal extends beyond connector housing, then ease of assembly is improved, but the aesthetic appearance and compactness deteriorate
Solution Approach 1:
The conductor seal is designed with dynamic positioning capability, allowing it to extend beyond the connector housing during assembly for ease of handling and insertion. After assembly, the flexible elastomeric material allows the conductor seal to be compressed and conform to the connector housing dimensions, achieving both ease of assembly and acceptable compactness in the final assembled state.
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 allows for a single mat seal to accommodate conductors of different diameters, reducing production costs and insertion force, while ensuring effective sealing and preventing damage to the mat seal, thus improving ergonomics and reducing conductor bending.
Implementation Method 1
The connector assembly includes a mat seal made of an elastomeric material and a conductor seal made of an elastomeric material
Implementation Method 2
with a second crimping feature, crimping the electrical terminal to an end of the conductor seal
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
A connector assembly (100) includes a mat seal (110) and a conductor seal (120). The mat seal (110) is shaped to fit within an opening (112) in a connector housing (108) of the connector assembly (100). The mat seal (110) defines at least one a seal passage (118) extending therethrough. The conductor seal (120) defines a conductor passage (126) extending therethrough. The conductor seal (120) is configured to receive conductor (102), such as an insulated electrical cable (102), within the conductor passage (126). The conductor seal (120) is received within the seal passage (118). The mat seal (110) and the conductor seal (120) cooperate to inhibit intrusion of contaminants into the connector housing (108). A method (200) of assembling a connector assembly (100) having a mat seal (110) and a conductor seal (120) is also presented herein.