Sealed Electrical Connector Shield Seal Deflects High-Pressure Spray
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Solution Overview
Problem
Conventional waterproof electrical connector systems fail to prevent moisture and debris ingress under high-pressure spray conditions due to the inability to deflect pressure, leading to increased manufacturing costs with the use of additional components like wire dress covers or back shells.
Innovation Solution
A sealed electrical connector system featuring a primary seal and a secondary shield seal, where the secondary seal deflects high-pressure spray away from the primary seal, enhancing sealing performance and preventing moisture and debris ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a standard silicone seal is used in the electrical connector system, then the sealing structure is simple and manufacturing cost is low, but the seal fails under high-pressure spray conditions allowing moisture and debris ingress
Solution Approach 1:
The sealing system is divided into two distinct segments: a primary seal (standard silicone seal) and a secondary shield seal. The shield seal is positioned upstream to deflect high-pressure spray, while the primary seal provides the main sealing function. This segmentation allows each seal to perform its specific function optimally without requiring a complete redesign of the sealing structure.
Solution Approach 2:
The shield seal performs a preliminary action by deflecting high-pressure spray away from the primary seal before the spray can reach it. This preliminary deflection protects the primary seal from direct high-pressure contact, allowing it to maintain its simple structure while achieving reliable sealing under high-pressure conditions.
2Reliability
If additional components like wire dress covers or back shells are added to deflect high-pressure spray, then sealing performance under high-pressure spray improves, but manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The shield seal and primary seal are merged into a single integrated sealing assembly that works together as one unit. The shield seal is positioned and configured to work in conjunction with the primary seal, combining their functions into a unified structure that achieves S3 performance without requiring separate wire dress covers or back shells.
Solution Approach 2:
The shield seal serves multiple functions: it deflects high-pressure spray, protects the primary seal, and contributes to the overall sealing performance. This multi-functionality eliminates the need for separate protective components like wire dress covers or back shells, simplifying the overall structure and reducing manufacturing costs.
3Reliability
If additional components like wire dress covers or back shells are added to deflect high-pressure spray, then sealing performance under high-pressure spray improves, but assembly steps increase and installation complexity increases
Solution Approach 1:
The sealing assembly is segmented into two functional parts (shield seal and primary seal) that are designed to work together in a predetermined configuration. This segmentation allows for modular assembly where the shield seal and primary seal can be installed as an integrated unit, reducing the number of separate assembly steps compared to adding multiple separate protective components.
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
The system achieves high-pressure spray sealing (S3) performance by effectively deflecting high-pressure liquid away from the primary seal, ensuring the integrity of the electrical connector system without the need for additional components like wire dress covers or back shells, thus reducing manufacturing costs.
Implementation Method 1
The shield seal deflects the high-pressure spray away from the primary seal
Data Source
AI summary
A sealed electrical connector system has a first connector assembly and a second connector assembly which are mated together at front ends thereof. In an embodiment, each assembly includes an insulative outer housing, shield seal cap, and terminal housing and an elastomeric shield seal and mat seal, each having terminal receiving passageways through which a terminal is seated. The shield seal caps are attached to rear ends and hold the shield seals in the outer housings. In an embodiment, the second connector assembly includes an insulative outer housing and an elastomeric seal, each having terminal receiving passageways through which a terminal is seated. The shield seal prevents high-pressure spray from directly contacting the mat seal.