Vibration damping and clearance compensation element
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors face challenges in achieving a precise fit between male and female connectors to prevent fretting corrosion and nonuniform contact pressure, particularly in automotive applications, while also requiring complex tooling and compromising on mating force and vibration damping.
Innovation Solution
A vibration damping and clearance compensation element with a flexible wall mounted in a cantilevered fashion, featuring a hollow space and contact elements, which compensates for manufacturing tolerances and provides uniform contact pressure and reduces vibrations, using materials like EPDM rubber or glass-fiber reinforced PBT/PA.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If crush ribs are used to improve tight seat between connectors, then clearance between female and male connectors is reduced, but device complexity increases due to complex debugging of molding tools and coordination of rib height with gap size
Solution Approach 1:
The connector interface is segmented into multiple functional elements: the seal element for contact pressure, the vibration damping element for vibration reduction, and the position assurance element for alignment. This segmentation allows each element to be optimized independently, eliminating the need for complex coordination of crush rib heights and molding tool debugging.
Solution Approach 2:
A vibration damping element with a flexible wall is introduced as an intermediary component between the seal element and the housing. This flexible wall acts as a mediator that compensates for manufacturing tolerances and clearance variations, providing uniform contact pressure without requiring precise coordination of multiple components during molding.
2Stress or pressure
If crush ribs are designed to be compressed to provide uniform contact pressure, then contact pressure uniformity is improved, but manufacturing precision deteriorates due to difficulty in ensuring dimensional accuracy
Solution Approach 1:
The vibration damping element is designed with a flexible wall that can elastically deform to compensate for manufacturing tolerances. Instead of relying on precisely controlled rigid crush ribs, the system uses the flexibility parameter of the wall to adapt to dimensional variations, ensuring uniform contact pressure while being tolerant of manufacturing imprecision.
Solution Approach 2:
The vibration damping element is made from materials such as EPDM rubber or glass-fiber reinforced PBT/PA, which combine elasticity with structural integrity. This composite material approach allows the element to provide both the compliance needed for tolerance compensation and the strength required for vibration damping, eliminating the need for high dimensional accuracy in rigid components.
3Reliability
If a precise fit between female and male connectors is provided to avoid fretting corrosion, then reliability is improved, but mating force increases
Solution Approach 1:
The function of providing a precise fit to prevent fretting corrosion is extracted from the mechanical interference of crush ribs and assigned to a dedicated seal element. The seal element is specifically designed to provide the necessary contact pressure for corrosion prevention, while the vibration damping element handles clearance compensation, allowing the overall assembly to achieve precise fit with reduced mating force.
Solution Approach 2:
The flexible wall of the vibration damping element acts as a compliant interface that adapts to the mating connector's geometry. This flexibility allows the system to achieve a precise fit and uniform contact pressure distribution without requiring high mating forces, as the flexible wall conforms to the mating surface rather than forcing a rigid fit.
4Object-affected harmful factors
If crush ribs are used to reduce clearance between connectors, then vibration damping is improved, but ease of manufacture deteriorates due to inability to completely demold from mold without draft angle
Solution Approach 1:
The vibration damping element incorporates a flexible wall that is mounted in a cantilevered fashion, allowing it to dynamically adapt to vibrations during operation. The flexible wall can elastically deform to dampen vibrations while maintaining a simple molded structure that can be easily demolded, eliminating the draft angle requirements of rigid crush ribs.
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 solution ensures uniform contact pressure and reduces mating forces, dampens vibrations, and maintains a watertight seal by compensating for clearances and tolerances, enhancing connector reliability and reducing friction.
Implementation Method 1
The cantilevered flexible wall on the one hand has an elasticity to compensate for any manufacturing tolerances and compensates any desired clearances
Implementation Method 2
provides sufficient compression force onto the contact element to dampen any vibrations within the electrical connector
Data Source
AI summary
This disclosure relates to a vibration damping and clearance compensation element for an electrical connector, featuring a flexible wall with a first and second main surface, mounted in a cantilevered manner. A hollow space is positioned adjacent to the first main surface of the flexible wall, allowing for enhanced flexibility and vibration absorption. At least one contact element extends from the second main surface of the flexible wall, providing electrical connectivity while accommodating movement and misalignment. This configuration effectively dampens vibrations and compensates for clearance variations, ensuring reliable electrical connections under dynamic conditions. The design is particularly suited for applications requiring robust performance in environments subject to mechanical stress and movement, enhancing the durability and reliability of electrical connectors.