Compliant Connector Seal Assembly for Low-Force Reliable Sealing
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Solution Overview
Problem
Existing sealed connector assemblies face challenges in maintaining consistent engagement force due to variations in seal gap and material characteristics, often resulting in incomplete sealing and complex assembly processes, with traditional sealing methods like O-rings and integrated seals lacking flexibility and adaptability.
Innovation Solution
A sealed connector assembly featuring a compliant perimeter seal with a seal side wall, end wall, and lip, integrated into a connector housing with a flexible inner portion and L-shaped perimeter wall, which abuts and overlays the seal to prevent bunching and ensure secure sealing, using a silicone-based rubber material for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing methods like O-rings and gaskets are used, then sealing capability is improved, but device complexity and assembly process complexity increase
Solution Approach 1:
The patent combines the sealing function with the connector housing structure itself. The housing includes integrated sealing surfaces and a sealing groove that directly forms the seal chamber, eliminating the need for separate O-rings or gaskets. This integration maintains reliable sealing while significantly simplifying the device structure and assembly process.
Solution Approach 2:
The patent removes traditional separate sealing components (O-rings, gaskets) from the connector assembly. By extracting these separate elements and incorporating the sealing function directly into the housing structure, the design achieves simplified assembly while maintaining sealing effectiveness through the integrated sealing surfaces and groove geometry.
2Manufacturing precision
If connector seal gap variations occur, then manufacturing precision is reduced, but engagement force consistency deteriorates
Solution Approach 1:
The patent employs a resilient sealing element that can dynamically adjust to variations in seal gap. The elastic or resilient nature of the sealing material allows it to deform and maintain consistent sealing pressure despite manufacturing tolerances in the connector housing, thereby ensuring consistent engagement force across varying conditions.
Solution Approach 2:
The patent utilizes materials with specific elastic or resilient properties that allow the sealing element to change its physical parameters (deformation, pressure distribution) in response to seal gap variations. This parameter adaptability compensates for manufacturing imprecisions and maintains consistent engagement force.
3Ease of manufacture
If separate connector housings are mated together, then assembly is simplified, but seal bunching and pinching occur
Solution Approach 1:
The patent incorporates a sealing groove and positioning structures into the housing design before assembly. These pre-configured features guide the sealing element into proper position and prevent it from bunching or pinching during the mating process, thereby maintaining seal integrity while allowing simple assembly of separate housings.
Solution Approach 2:
The patent uses a resilient or flexible sealing material that can accommodate the mating process of separate housings. The flexibility allows the seal to deform during assembly without bunching or pinching, then return to its proper sealing configuration, maintaining reliability while enabling simplified separate housing assembly.
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 provides a reliable and adaptable seal that resists bunching and environmental contaminants, reducing engagement forces and improving ergonomic performance while maintaining sealing effectiveness across varying conditions.
Implementation Method 1
a compliant perimeter seal with a seal side wall, an end wall, and a seal lip
Data Source
Figure 1
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Figure 3A~3C
AI summary
A sealed connector assembly may include a compliant perimeter seal having a seal side wall, a seal end wall extending from a first end of the seal side wall in a first direction, and a seal lip extending from a second end of the seal side wall in a second direction opposite the first direction. The seal side wall defines a sealing rib. The sealed connector assembly may include a connector housing, further including an outer portion having a perimeter wall with a side segment and an end segment. The seal side wall abuts the side segment, and the seal end wall abuts the end segment. The seal lip overlays an end of the side segment of the perimeter wall. An inner portion disposed inside the perimeter wall has a connector lip that overlies the seal lip and an end of the side segment of the perimeter wall.