Connector Packing Anti-Detachment via Elastic Tensile Stress
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Solution Overview
Problem
Existing connectors for HEV inverters face challenges in reliably securing and waterproofing the packing, leading to potential detachment during removal from electrical devices, due to complex mold structures required for undercut parts and difficulties in forming secure holes in aluminum cases with integrated terminals.
Innovation Solution
A connector design featuring an annular packing with outward ear parts and lock receiving parts, a case with through holes and locking projections, where the packing is elastically deformed to create tensile stress, ensuring secure mounting and preventing detachment, while maintaining waterproof integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hole or locking beak is provided in the aluminum case to secure the packing, then the packing can be reliably held, but an undercut part occurs requiring complex mold structure with additional dies
Solution Approach 1:
The locking function is extracted from the aluminum case body and transferred to the flange part. The through holes are formed in the case body, but the locking projections are provided on the flange part, separating the sealing function (case body) from the locking function (flange part). This avoids creating undercuts in the case body that would require complex mold dies.
Solution Approach 2:
The locking mechanism transitions from a two-dimensional surface feature (locking beak on the case surface) to a three-dimensional through-hole structure with projections extending through the flange. The ear parts with through holes pass through the case body and engage with locking projections on the flange, creating a multi-dimensional locking arrangement that avoids undercuts.
2Reliability
If a hole is formed in the aluminum case to secure the packing, then the packing can be held, but it becomes difficult to maintain waterproof integrity of the case interior
Solution Approach 1:
The case is segmented into two functional parts: the case body part containing through holes for ear part passage, and the flange part containing locking projections. The packing-mounted part is separately formed on the flange, creating distinct zones for sealing (case body) and locking (flange), maintaining waterproof integrity while enabling secure packing attachment.
Solution Approach 2:
The flange part acts as an intermediary element between the case body and the packing. It provides the locking projections that engage with the ear parts, while the case body maintains its waterproof enclosure. The packing-mounted part on the flange serves as the interface for packing attachment without compromising the case body's sealing function.
3Reliability
If the packing is elastically deformed to create tensile stress for secure mounting, then detachment is prevented, but the packing structure becomes more complex with ear parts and lock receiving parts
Solution Approach 1:
The packing transitions from a static rigid structure to a dynamic elastic structure. The ear parts are designed to be elastically deformable, allowing them to be compressed during assembly and then exert tensile stress to maintain constant engagement with the locking projections. This dynamic elasticity provides secure mounting while using a relatively simple added structure of ear parts with through holes.
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 solution effectively secures the packing to the case, preventing detachment during removal and ensuring reliable waterproofing of the connector's interior, even when removed from electrical devices.
Implementation Method 1
the packing is configured to be elastically deformed between the pair of through holes, when the packing is mounted on the case, whereby tensile stress occurs in the packing
Data Source
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AI summary
There is provided a connector of which an interior can be waterproofed, and also, detachment of a packing from a case, while the connector is removed from an electrical device, can be prevented. A connector includes a packing (5) which includes a body part (7) formed in an annular shape, a pair of ear parts (9) extending outward from the body part, and lock receiving parts (11) which are provided in the ear parts, and a case (3) which includes a packing-mounted part (19) in an annular shape which is provided around an opening (17) of a case body part (13) and on which the body part of the packing is mounted, a flange part (15) which is integrally provided on the case body part to surround the packing-mounted part of the body part, a pair of through holes (21) which are formed in the case body part to communicate between a face of the packing-mounted part where the body part (7) is mounted and a back face of the flange part, and through which the ear parts are respectively passed, and a pair of locking parts (27) which are provided on the back face of the flange part and with which the lock receiving parts in the ear parts are respectively engaged.