Sealed Connector Assembly Seal Retention and Engagement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sealed electrical connector assemblies face issues with environmental contamination, pinching, bunching, and rolling of seals, as well as high engagement forces and sensitivity to seal gaps, which affect reliability and ergonomics during hand mating.
Innovation Solution
A sealed electrical connector assembly featuring a female connector body with a resilient seal that includes a forward retaining ledge and hook, and a cavity for expansion, providing asymmetrical contact with the male connector body to prevent rearward movement and reduce engagement force, while maintaining effective sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional seal is used in existing sealed electrical connector assemblies, then the connector provides basic sealing, but the seal is subject to pinching, bunching, and rolling during assembly
Solution Approach 1:
The seal is divided into multiple functional segments: a sealing portion with sealing lips for environmental sealing, a forward retaining hook for preventing rearward movement, and a forward retaining ledge for positioning. This segmentation allows each portion to perform its specific function independently, preventing pinching and bunching during assembly while maintaining sealing reliability
Solution Approach 2:
The forward retaining ledge acts as an intermediary element between the seal and the housing. It provides a controlled engagement surface that guides the seal into proper position and prevents excessive compression, thereby eliminating pinching and bunching issues while maintaining the sealing function
2Reliability
If high engagement force is used to ensure secure connection, then connection reliability is improved, but ergonomics during hand mating deteriorates
Solution Approach 1:
The engagement mechanism uses localized high-force features (the forward retaining hook engaging the forward retaining ledge) combined with localized low-force features (the resilient seal compression). This allows secure connection through precise local engagement while keeping overall assembly force within ergonomic limits for hand mating
Solution Approach 2:
The seal is designed with specific angular parameters: the forward retaining ledge forms an acute angle relative to the longitudinal axis, and the forward retaining hook forms an obtuse angle that is supplementary to the acute angle. These parameter optimizations enable reliable engagement at reduced force levels, improving hand mating ergonomics while maintaining connection reliability
3Manufacturing precision
If the seal is made sensitive to seal gaps to ensure proper positioning, then sealing precision is improved, but sensitivity to manufacturing variations increases
Solution Approach 1:
The forward retaining ledge and forward retaining hook are designed to establish proper seal positioning before final engagement occurs. This preliminary positioning action ensures the seal is correctly located and pre-compressed, reducing sensitivity to subsequent manufacturing variations and eliminating the need for extremely tight gap tolerances
Solution Approach 2:
The seal cross-section is asymmetric with different angles on opposite sides (acute angle on the ledge, supplementary obtuse angle on the hook). This asymmetry creates a self-aligning mechanism that compensates for manufacturing variations, allowing the seal to automatically position itself correctly during assembly while maintaining reliable sealing
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 prevents pinching and rolling of seals, reduces engagement force, and minimizes sensitivity to seal gaps, enhancing reliability and ergonomics for hand mating, allowing safe and robust transmission of electrical currents greater than 200 amperes.
Implementation Method 1
The resilient seal is disposed intermediate the forward portion and the shroud and is in compressive contact with the forward portion and the shroud
Implementation Method 2
a resilient seal axially surrounding the forward portion
Implementation Method 3
The resilient seal defines a forward retaining hook that extends outwardly and engages the forward retaining ledge
Implementation Method 4
The seal lip is disposed intermediate the forward portion and the seal retainer and is in compressive contact with the forward portion and the seal retainer
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A connector assembly (10) includes a female connector body (12) and a male connector body (14) defining a shroud (16) configured to receive the female connector body (12). The electrical connector assembly (10) further includes a resilient seal (22) axially surrounding a portion of the female connector body (12). The seal (22) is disposed intermediate the female connector body (12) and the shroud (16). The connector assembly (10) additionally includes a seal retainer (38) attached to the female connector body (12). The female connector body (12) defines an outwardly extending retaining ledge (26) on the forward portion (18) of the female connector body (12). The seal (22) defines an inwardly extending retaining hook (30) engaging the retaining ledge (26). A portion of the retaining hook (30) is disposed intermediate the female connector body (12) and the seal retainer (38).