Electrical Coupling Part Sealing Element Design
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Solution Overview
Problem
Existing electrical coupling parts face challenges in effectively sealing through-holes to prevent moisture and contamination, particularly when using insulating materials and injection molding, and require additional measures to secure contact elements and wires against axial displacement and wear.
Innovation Solution
An electrical coupling part with a contact carrier made of plastic, featuring through-holes with sealing elements and a support body with radially protruding arms and a central ring, which provides a secure seal and counteracts vibrations and wear, allowing for universal and automated assembly with minimal additional space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing elements are added to seal through-holes, then moisture protection is improved, but device complexity increases
Solution Approach 1:
The sealing element integrates multiple functions into a single component: it seals the through-hole against moisture, supports the contact element axially, and provides structural reinforcement. This merging of functions reduces the number of separate components needed while achieving comprehensive protection.
Solution Approach 2:
The sealing element is made from elastomeric material that combines sealing properties with mechanical strength. The material's inherent elasticity and durability allow it to perform both sealing and support functions without requiring additional reinforcement components.
2Reliability
If contact elements are secured with latching elements, then axial displacement protection is improved, but ease of manufacture deteriorates
Solution Approach 1:
The latching element is integrated directly into the contact element as a single piece, eliminating the need for separate attachment steps. The contact element is formed with built-in latching features that engage with the sealing element, simplifying the manufacturing process while maintaining secure axial positioning.
3Object-affected harmful factors
If through-holes are sealed tightly, then contamination protection is improved, but wire insertion difficulty increases
Solution Approach 1:
The sealing element is made of elastomeric material that dynamically adapts to the wire during insertion. The material deforms elastically to allow wire passage, then returns to its original shape to create a tight seal, providing both easy insertion and effective contamination protection.
Solution Approach 2:
The sealing element's physical state changes during the insertion process: it transitions from a deformable state during wire insertion to a rigid sealing state after insertion completes, optimizing both insertion ease and seal effectiveness.
4Reliability
If support bodies with protruding arms are added, then wire support against vibrations is improved, but device complexity increases
Solution Approach 1:
The support body with radially protruding arms is integrated into the sealing element as a single component. The arms extend from the sealing element's body to provide wire support and vibration resistance, eliminating the need for separate support structures while maintaining effective wire stabilization.
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 effectively seals the coupling part, preventing moisture ingress and reducing wear on contacts, while supporting wires to prevent breakage and ensuring a secure connection, enabling fully automated assembly with reduced space requirements.
Implementation Method 1
A sealing element with radially outwardly protruding sealing lips is attached to the wire and rests against the wall of the corresponding through-hole of the contact carrier in the assembled position
Implementation Method 2
a support body is inserted into the sealing element, which has a central ring with a through opening for the wire and at least three spaced apart from one another in the circumferential direction, radially outwards has extending arms which protrude in the radial direction beyond the sealing element
Data Source
Figure 1~2
Figure 3A~3D
AI summary
An electrical coupling component is proposed, comprising a plastic contact carrier with a through-hole. An electrical contact element is connected to a conductor of an electrical cable within this through-hole. The conductor exits the through-hole of the contact carrier at one end. The electrical coupling component is characterized by a sealing element mounted on the conductor, equipped with radially outwardly projecting sealing lips. In the installed position, this sealing element rests against the wall of the corresponding through-hole in the contact carrier. At the end of the sealing element that, in the installed position, faces away from the contact element connected to the conductor, a support body is inserted. This support body has a through-opening for the conductor and at least three circumferentially offset arms extending radially outward.Furthermore, a suitable sealing element is proposed.