Connector Sealing Member Damage Prevention via Terminal Edge Curvature
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Solution Overview
Problem
Conventional connectors with waterproof properties often damage the sealing member during the terminal insertion process, leading to compromised waterproof integrity.
Innovation Solution
The connector design incorporates a sealing member with a wire insertion hole featuring a protruding lip, and a terminal with a cylindrical body where the curvature radius and compression ratio are optimized to prevent damage during penetration, using the formula difficulty of sealing member breakage=f(R1/CR1) to ensure secure assembly without breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal is inserted through the wire insertion hole to achieve waterproof connection, then the waterproof property is improved, but the sealing member is damaged due to expansion force and edge contact
Solution Approach 1:
The patent applies preliminary action by forming a curved surface at the edge part of the terminal's cylindrical body before insertion. This pre-formed curvature prevents the edge from directly contacting and damaging the sealing member during the insertion process, while still allowing the terminal to pass through the wire insertion hole and achieve waterproof connection.
Solution Approach 2:
The patent implements spheroidality by providing a curved surface at the edge part of the terminal's cylindrical body that contacts the sealing member. This curved surface distributes the contact area and reduces stress concentration, preventing the sealing member from being damaged during terminal insertion while maintaining the waterproof sealing function.
2Ease of manufacture
If the wire insertion hole is expanded to accommodate the terminal, then the terminal can be mounted, but the sealing member structure is compromised
Solution Approach 1:
The patent applies preliminary action by pre-forming a curved surface at the terminal's edge before insertion. This prevents excessive expansion force from being applied to the sealing member during mounting, allowing easy terminal installation while preserving the sealing member's structural integrity and composition stability.
3Manufacturing precision
If the terminal has a sharp edge for precise insertion, then the positioning accuracy is improved, but the sealing member breakage risk increases
Solution Approach 1:
The patent implements spheroidality by providing a curved surface at the edge part of the terminal's cylindrical body. This curved leading edge maintains precise positioning capability during insertion while distributing contact stress, thereby preventing sealing member breakage that would occur with a sharp edge.
Data Source
AI summary
A connector includes a mat seal in which lips are protruded from an inner circumferential surface of a wire insertion hole, and a terminal to which an electric wire is connected and which has a cylindrical body to be inserted a mating terminal. The terminal is accommodated in a position that passes through the wire insertion hole, and the electric wire is arranged in a press-fitted state in the wire insertion hole. When a curvature radius of an edge part of the cylindrical body that contacts to the inner circumferential surface of the wire insertion hole in a process of passing through the wire insertion hole is denoted by R1 and a compression ratio of the lip in the process of passing through the wire insertion hole is denoted by CR1, the curvature radius R1 is set based on a formula of difficulty of mat seal breakage =f(R1/CR1).