Cylindrical Sealing Element for Electrical Connector Block Seal
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Solution Overview
Problem
Existing sealing systems for electrical connectors face challenges in achieving a reliable seal, especially with small cable cross-sections, as it is difficult to produce openings in block seals with inner diameters less than 0.65 to 0.8 mm, leading to inadequate compressive force and risk of damage during contact insertion.
Innovation Solution
A sealing system that utilizes a sealing element attached to the cable, which provides additional compression by tightly enclosing the cable and being accommodated in the block seal's opening, allowing for larger, easily producible openings in the block seal, and optionally features an elastic material and sealing lips for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the opening in the block seal is made smaller to achieve reliable sealing with small cable cross-sections, then sealing reliability improves, but manufacturing difficulty increases and risk of damage during contact insertion increases
Solution Approach 1:
The sealing function is divided into two independent components: the block seal with larger, easily manufacturable openings, and separate sealing elements that provide the actual sealing compression. This segmentation allows each component to be optimized independently - the block seal for easy manufacturing and the sealing elements for reliable sealing with small cables.
Solution Approach 2:
The sealing element acts as an intermediary component between the cable and the block seal opening. It transfers the sealing function from the block seal to itself, allowing the block seal to have larger openings while the sealing element provides the necessary compression force for reliable sealing.
2Reliability
If the opening in the block seal is made smaller to increase compressive force on the cable, then sealing effectiveness improves, but the risk of damaging the opening during contact insertion increases
Solution Approach 1:
By separating the sealing function from the structural opening, the system allows the opening to be large and robust (resistant to damage) while the sealing element provides the concentrated compressive force needed for effective sealing without requiring the opening itself to be small.
Solution Approach 2:
The sealing element serves as a mediator that concentrates compression force on the cable without requiring the block seal opening to be small. This intermediary component protects the opening from damage while still achieving the necessary sealing pressure.
3Adaptability or versatility
If the block seal is made with universally applicable openings for different cable sizes, then adaptability improves, but sealing precision for specific cable cross-sections decreases
Solution Approach 1:
The block seal is designed with universal, larger openings that can accommodate different cable sizes. The sealing elements are then selected and matched to specific cable cross-sections to provide precise sealing, combining the advantages of universal adaptability with precise sealing for each application.
Solution Approach 2:
While the block seal provides universal openings, the sealing elements are customized locally to match specific cable dimensions. This allows the overall system to be universally applicable while maintaining precise sealing for each specific cable cross-section through locally optimized sealing elements.
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
Ensures reliable sealing for small cable cross-sections without damaging the openings, allowing for universal use across different cable sizes and maintaining the integrity of the electrical connector.
Implementation Method 1
the compression required for sealing is not or at least not exclusively provided by the block seal, but essentially or additionally by the sealing element, which on the one hand tightly encloses the cable and on the other hand is tightly accommodated in the opening of the block seal
Implementation Method 2
The sealing element and/or the block seal are expediently made of elastic material
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The block sealing system (10) has block sealing portions (12) that are inserted into a connector housing, through which the inserted electric contact portion (34) is sealed when assembling the electrical connector. A cylindrical sealing element (30) is attached to a cable (32) connected to the electrical contact portion, and is accommodated in an opening (22A) when the electrical contact portion is pushed-in. The cylindrical sealing element is made of resilient material, having a cross section which is larger than the cross section of the opening. An independent claim is included for assembling method of electrical connector.