Connector Wire Bulge Seals Housing Step Without Rubber Plug
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Solution Overview
Problem
Existing waterproof connectors require enlargement and deteriorate in operability as wire diameters increase, necessitating the use of larger rubber plugs to maintain effectiveness, which is inefficient and prone to failure at high temperatures.
Innovation Solution
A connector system where a bulge is formed on the insulation coating of the wire, allowing it to contact a step within the connector housing, sealed by a retainer, eliminating the need for a rubber plug and ensuring reliable water cutoff even at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rubber plug is used to waterproof the connector, then water cutoff is achieved, but the connector must be enlarged as wire diameter increases, deteriorating operability
Solution Approach 1:
The invention extracts and eliminates the rubber plug component from the connector assembly. Instead of using a separate rubber plug for waterproofing, the solution forms a bulge directly on the insulation coating of the wire itself, which then contacts the step in the connector housing to achieve water cutoff. This removes the need for the rubber plug and its associated mounting operations.
Solution Approach 2:
The insulation coating of the wire serves a dual function: electrical insulation and waterproofing sealing. By forming a bulge on the insulation coating, the wire itself provides the sealing function that previously required a separate rubber plug component. The wire's own structure is modified to perform the waterproofing function.
2Reliability
If a rubber plug is used for waterproofing, then water cutoff is achieved, but the assembly process becomes complex requiring precise positioning
Solution Approach 1:
The invention removes the rubber plug component and the associated positioning mechanisms (front stop, position adjusting means, rubber plug pressing member) from the connector assembly. The waterproofing function is achieved through the bulge on the wire's insulation coating contacting the step in the housing, eliminating the complex assembly process.
Solution Approach 2:
The wire with the bulge on its insulation coating self-positions and self-seals within the connector housing. The bulge naturally contacts the step in the housing to create the waterproof seal, eliminating the need for separate positioning and compression mechanisms that were required for the rubber plug.
3Reliability
If the insulation coating is formed of highly heat resistant resin, then water cutoff reliability is improved at high temperatures, but manufacturing complexity increases
Solution Approach 1:
The invention changes the material parameter of the insulation coating by specifying highly heat resistant resin. This material selection ensures that the bulge maintains its shape and sealing capability at high temperatures, preventing deterioration that would compromise water cutoff performance in automotive environments.
Data Source
AI summary
A connector-equipped wire includes a terminal, and a wire including a core and an insulation coating provided around the core. The terminal is connected to an end part and is formed with a bulge so that a part of an end part of the insulation coating protrudes radially out. Further, the connector-equipped wire includes a connector housing including a body formed with a cavity into which the wire is to be inserted, and formed with a step on an inner peripheral surface of the cavity of the body. The bulge comes into contact with the step, and a retainer to be locked to the connector housing with the bulge pressed toward the step.