Electrical Connector Assembly Waterproof Sealing and Touchproof Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector assemblies for electricity-fuel hybrid and fully electric vehicles face challenges in providing reliable and safe waterproof connections with high current and voltage, while preventing user contact with power terminals and ensuring watertightness against harsh environments.
Innovation Solution
The design incorporates a sealing system with a frontward and rearward portion on the second casing, surrounding the cylindrical sleeve and rear housing, respectively, to create a watertight connection between the cylindrical socket and sleeve, and includes touchproof features to prevent user contact with power terminals, utilizing a silicon-based sealing system for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single sealing means is used in the connector assembly, then the structure is simple, but the waterproof reliability is insufficient
Solution Approach 1:
The sealing system is divided into multiple independent sealing means: a first sealing means (first seal) and a second sealing means (second seal). Each sealing means is positioned at different locations and provides independent sealing functionality, ensuring that if one seal fails, the other continues to provide waterproof protection.
Solution Approach 2:
The dual sealing system acts as a preventive measure against potential seal failures. By providing redundant sealing means before any failure can occur, the system ensures continuous waterproof protection even if one seal degrades or fails during operation.
2Ease of operation
If the connector assembly exposes power terminals for easy connection, then the ease of operation is improved, but user safety is compromised due to risk of contact with high voltage
Solution Approach 1:
The cylindrical sleeve is inserted into the cylindrical socket, creating a nested structure where the sleeve acts as an internal protective barrier. This nested design allows the terminals to remain accessible for connection while being physically enclosed by the sleeve, preventing direct user contact with high voltage components.
Solution Approach 2:
The cylindrical sleeve serves as an intermediary protective element between the user and the power terminals. It provides physical isolation that prevents direct contact with high voltage, while still allowing the connection function to be performed through the structured interface of the socket and sleeve.
3Object-affected harmful factors
If the connector housing is designed with touchproof walls to prevent terminal contact, then user safety is improved, but the ease of operation deteriorates due to reduced accessibility
Solution Approach 1:
The cylindrical sleeve nested within the cylindrical socket creates a protected access path. The sleeve extends beyond the housing walls to provide touchproof protection, while the nested structure allows operators to still perform connections by guiding connectors through the defined interface, maintaining accessibility without compromising safety.
Data Source
Figure 1~3B
Figure 4~5A
Figure 5B
AI summary
An electrical connector assembly comprising a first connector and a second connector. The first connector comprises a socket and the second connector comprises a sleeve, the socket being adapted to surround the sleeve. A sealing system (28, 32) comprises a frontward portion (3A, 30B) surrounding the sleeve and a rearward portion (32) surrounding a rear housing of the second connector.