Connector With Segmented Separation Walls For Uniform Potting
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Solution Overview
Problem
Existing relay connectors for differential gears in vehicles lack an interpolar rib between terminal fittings, leading to increased costs due to separate potting material injection for each terminal and varying connector sizes, which complicates uniform liquid level distribution of the potting material.
Innovation Solution
A connector design featuring a housing with recesses and separation walls that allow the potting material to spread uniformly, providing deviated passing portions between terminals for creepage distance and eliminating the need for separate injections, with additional features like standing walls and peripheral walls to ensure even distribution and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rib is provided between each pair of adjacent terminal fittings as a measure against external matter or to prevent collision, then the creepage distance is ensured and terminal protection is improved, but the potting material must be made independent for each terminal fitting and the number of times of injection increases, leading to a cost increase
Solution Approach 1:
The separation wall is segmented with passing portions that allow potting material to flow through, creating a structure that both separates terminals for creepage distance and permits continuous material flow for single-injection processing
Solution Approach 2:
The passing portions act as intermediaries that allow the potting material to traverse the separation wall, enabling the material to reach all terminal fittings through a single injection while maintaining the separation structure
2Ease of manufacture
If the injection amount of the potting material is made constant, then the manufacturing process is simplified, but the liquid level height of the potting material cannot be made constant due to variations in connector housing sizes and shapes
Solution Approach 1:
The passing portions are positioned at specific heights on the separation walls to create an equipotential reference level, ensuring that potting material flows to a consistent height across all connector housings regardless of size or shape variations
Solution Approach 2:
The design changes the positional parameter of the passing portions on the separation walls to control the flow and final height of the potting material, achieving uniform liquid levels through structural design rather than precise injection amount control
Data Source
AI summary
A connector (10) disclosed by this specification includes a potting material (50), a housing (20) having a recess (21), the potting material (50) being accommodated in the housing (20), a plurality of terminals (40), and a plurality of separation walls (26, 27). The separation walls (26, 27) each located between a pair of adjacent ones of the terminals (40) include passing portions (21B, 21C, 21D) allowing the passage of the potting material (50) at positions deviated from straight lines each connecting a pair of adjacent ones of the terminals (40) when viewed from a projecting direction of the terminals (40), and the passing portions (21B, 21C, 21D) are located closer to the bottom surface (22) of the recess (21) than projecting ends of the separation walls (26, 27).