Connector Seal Membrane Design for Bore Detection
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Solution Overview
Problem
Conventional connector seals fail to accurately inspect the presence of bores in unused terminal insertion bores due to compression forces from adjacent electrical wires, leading to potential water ingress during use.
Innovation Solution
The connector seal design features terminal insertion bores with membranes having upper and lower portions interconnected by a lamella or curved grooves, which form a cavity when subjected to radial compression, allowing for reliable detection of bore presence through test pins or air-leak tests.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the membrane is subjected to compression force from adjacent terminal insertion bore, then the bore closes and prevents water entry, but the inspection fails to detect the bore presence
Solution Approach 1:
The membrane is designed to be dynamically deformable, allowing it to close under compression during normal operation to prevent water entry, while maintaining the ability to form visible cavities during inspection when not under full compression. This dynamic behavior resolves the contradiction between sealing reliability and inspection accuracy.
Solution Approach 2:
The inspection process is performed before the membrane is subjected to full compression force from adjacent terminals. By conducting the air-leak test or visual inspection at this preliminary stage, the bore presence can be detected before the membrane closes and masks the defect, thus resolving the detection accuracy issue while maintaining sealing reliability during actual use.
2Ease of operation
If the membrane is made easily breakable for terminal insertion, then insertion is facilitated, but the membrane may break unintentionally during inspection or handling
Solution Approach 1:
The membrane incorporates localized weak points or notches at specific positions where terminal insertion is intended. These localized features reduce the breaking strength only at the designated insertion points, allowing easy terminal insertion while maintaining sufficient strength elsewhere to prevent unintentional breaking during inspection or handling.
Solution Approach 2:
The membrane is designed with curved or rounded edges and smooth transitions rather than sharp corners. This curvature distributes stress more evenly and prevents stress concentration that could lead to unintentional breaking, while still allowing the membrane to break cleanly at the intended insertion points when subjected to terminal forces.
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
Ensures accurate detection of bore formation in unused terminal insertion bores, preventing water entry and ensuring the integrity of the connector seal during use.
Implementation Method 1
the membrane portions are subjected to a compression force in a radial direction thereof and forms a cavity in the bore
Implementation Method 2
the groove of the incorrectly-inserted terminal insertion bore absorbs the compression force exerted on the membrane and prevents closure of the bore formed in the membrane
Data Source
AI summary
The present invention is to provide a connector seal allowing an accurate inspection of presence of an incorrectly formed bore in a terminal insertion bore of the connector seal. A connector seal includes a seal main body and a plurality of terminal insertion bores. Each terminal insertion bore has an upper membrane potion and a lower membrane portion, which are spaced one another and interconnected together with a lamella. Preferably, the terminal insertion bore has a membrane, which includes a substantially curved groove and a substantially curved lamella. Preferably, the terminal insertion bore has a membrane which includes a lamella, the lamella being oriented in a direction coincident with a diagonal line of a rectangular cross-section of a terminal so that corners of the terminal hit opposite ends of the lamella.