Elastomeric Seal Lip Geometry for Connector Thermal Stability
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Solution Overview
Problem
Existing interfacial seals for connectors face challenges in maintaining sealing efficiency under demanding operating conditions, such as high temperatures and relative displacements, while also requiring ease of assembly and cost-effectiveness.
Innovation Solution
A thin-profiled seal made of elastomeric material with a stout lip design, featuring a specific geometry and material properties, including a compression ratio of at least 10% and 10% elongation, to effectively seal connectors under varying conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the seal is made with elastomeric material to provide flexibility and sealing, then sealing efficiency is improved, but thermal expansion causes permanent deformation to the housing and impairs sealing after thermal cycles
Solution Approach 1:
The patent changes the physical parameters of the seal by specifying a durometer hardness range of 20-50 Shore A and defining specific thickness ratios (lip thickness 0.4-0.7 of total seal thickness). These parameter optimizations allow the elastomeric material to provide sufficient compliance for sealing while reducing excessive thermal expansion that causes housing deformation.
Solution Approach 2:
The patent applies local quality by creating a profiled seal with different regions having different properties: the base portion provides structural support while the lip portion (with thickness 0.4-0.7 of total) provides the sealing contact surface. This localized differentiation allows the seal to accommodate thermal expansion locally without transmitting excessive forces to the housing.
2Reliability
If the seal is designed with stout lip geometry (internal angle 60°-120°) to improve sealing under displacement, then sealing performance is enhanced, but the complexity of the seal geometry increases
Solution Approach 1:
The patent optimizes the geometric parameters of the seal by specifying an internal angle range of 60°-120° for the lip and defining the lip thickness as 0.4-0.7 of the total seal thickness. These parameter ranges were determined to provide the optimal balance between sealing effectiveness under relative displacement and manufacturing simplicity, avoiding overly complex geometries while ensuring reliable sealing.
3Reliability
If the seal is compressed by at least 10% during assembly to ensure sealing contact, then sealing efficiency is improved, but the force required for assembly increases
Solution Approach 1:
The patent specifies a durometer hardness range of 20-50 Shore A and requires a compression set of at least 10% during assembly. These parameter choices ensure that the seal achieves sufficient compression to maintain reliable sealing contact while remaining soft enough to be installed without excessive assembly forces, balancing sealing efficiency with ease of installation.
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 seal provides enhanced sealing performance and durability by accommodating thermal expansion differences between seal and housing materials, maintaining sealing efficiency even after thermal cycles and relative displacements, without compromising assembly ease or increasing costs.
Implementation Method 1
Because the materials of the seal and that of the housing behave differently under heat, during such a test, the material of the seal will be caused to expand more than that of the surrounding housing
Implementation Method 2
the compression of the seal between its state at rest (not mounted on the connector) and its state once mounted on the connector and compressed by the counterconnector is at least of 10%
Implementation Method 3
the seal undergoes a 10% elongation when mounted on the connector
Data Source
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AI summary
A seal for an electrical connector comprises : a base (34) mounted surrounding a first connector housing, a lip (40a, 40b), projecting outward from the base, in contact with a second connector housing, having an internal angle (a), between 60° and 120°. A ratio between a thickness (t) of the lip and a thickness (T) of the seal is between 0.5 and 0.7.