Electrical Connector Sealing Structure for Adhesion Loss
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Solution Overview
Problem
Existing electrical connectors face issues with the deterioration of sealing member adhesion between the insulative housing and outer cover under environmental tests, leading to a decrease in gas-tight sealing effectiveness.
Innovation Solution
The electrical connector design includes a rear platform with a roughened peripheral surface and a gap from the outer cover, which enhances the bonding of the sealing member, ensuring it remains securely in place even if adhesion deteriorates, using a combination of design features like a chamfered face and increased surface roughness (Ra > 3.15 micrometers) to maintain the sealing integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a smooth surface is used for the insulative housing, then manufacturing is easier, but the sealing member adhesion deteriorates under environmental tests
Solution Approach 1:
The patent applies local quality by creating a roughened surface only at specific locations where the sealing member contacts the insulative housing, rather than roughening the entire surface. This localized roughening (through machining, sandblasting, or chemical treatment) provides enhanced adhesion exactly where needed while keeping the rest of the housing easy to manufacture.
Solution Approach 2:
The patent changes the surface parameter (roughness) of the insulative housing to improve sealing member adhesion. By controlling the surface roughness degree, the patent enhances the mechanical interlocking between the sealing member and housing, preventing adhesion deterioration under environmental tests while maintaining manufacturability.
2Reliability
If the sealing member is tightly bonded to the insulative housing, then sealing integrity is improved, but thermal expansion differences cause adhesion deterioration
Solution Approach 1:
The patent applies beforehand cushioning by designing a gap between the insulative housing and outer cover, and incorporating a chamfered face on the rear platform. These features create缓冲 zones that accommodate thermal expansion differences between materials, preventing stress concentration that would otherwise cause adhesion deterioration while maintaining sealing integrity.
Solution Approach 2:
The patent explicitly addresses thermal expansion by designing the sealing structure to accommodate differential thermal expansion between the insulative housing and outer cover. The gap and chamfered face allow for expansion and contraction without compromising the sealing member's adhesion or the overall sealing integrity.
3Ease of manufacture
If a flat surface is used for the rear platform, then manufacturing is simpler, but the sealing member cannot be securely retained
Solution Approach 1:
The patent applies local quality by creating a roughened surface specifically on the rear platform where the sealing member is retained, rather than roughening the entire platform. This localized treatment provides enhanced mechanical bonding strength exactly where the sealing member contacts the platform, while keeping the rest of the platform simple to manufacture.
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 effectively maintains the sealing integrity by ensuring the sealing member remains securely attached, preventing gas leakage and maintaining the connector's functionality despite adhesion deterioration, through enhanced mechanical bonding and thermal expansion accommodation.
Implementation Method 1
the peripheral face has a roughened surface
Implementation Method 2
increased surface roughness (Ra > 3.15 micrometers)
Data Source
AI summary
An electrical connector includes: an insulative housing having a base and a rear platform; an outer cover enclosing the insulative housing to define a front chamber and a rear chamber; plural contacts secured to the insulative housing, exposed to the front chamber, and extending through the rear chamber; and a sealing member formed in the rear chamber to seal an interface between the insulative housing and the outer cover, wherein the rear platform has a peripheral face spaced a gap from the outer cover and the peripheral face has a roughened surface.