Integrated Seal Member for Electrical Connector Size Reduction
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Solution Overview
Problem
The existing electrical connectors with metal shells face challenges in size reduction while maintaining effective water prevention and electromagnetic shielding, due to the presence of a lock portion that increases the size of the seal cover and seal member, leading to a larger area that needs to be sealed.
Innovation Solution
The electrical connector incorporates a seal member with a peripheral wall that protrudes from the base portion, allowing the shell seal portion to be positioned closer to the electric-wires, eliminating the need for a separate seal cover and reducing the number of components by integrating water prevention functions into a single seal member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lock portion is formed on the seal cover to retain it in the shell, then the seal cover can be securely locked, but the seal cover size increases and the distance from electric-wires to the shell becomes unnecessarily large
Solution Approach 1:
The invention merges the locking function and sealing function into a single integrated structure. The lock portion is formed as an integral part of the seal member itself rather than being a separate component on a seal cover, eliminating the need for a thick seal cover while maintaining both locking and sealing functions.
Solution Approach 2:
The invention extracts the locking function from the seal cover and integrates it directly into the seal member. The lock portion protruding from the seal member engages with the shell to provide locking, while the seal member maintains close contact with the electric-wires, eliminating the unnecessary distance created by a separate seal cover.
2Reliability
If a seal cover is used to press down the seal member, then the seal member can be securely retained, but the number of components increases and the connector size increases
Solution Approach 1:
The invention combines the seal member and seal cover functions into a single integrated seal member. The lock portion of the seal member directly engages with the shell to provide both sealing and retention functions, eliminating the need for a separate seal cover and reducing the number of components.
Solution Approach 2:
The seal member is designed to perform multiple functions: it provides sealing contact with the electric-wires, maintains close contact with the shell for water prevention, and includes a lock portion that engages with the shell for secure retention. This multi-functional design eliminates the need for separate components.
3Reliability
If the seal member extends from electric-wires to the shell to prevent water entry, then water prevention is effective, but the seal cover area to be pressed down becomes large
Solution Approach 1:
Instead of having the seal cover press down a large area to achieve water prevention, the invention inverts the approach by having the seal member's lock portion directly engage with the shell. This creates a localized pressing point that is sufficient for water prevention, dramatically reducing the seal cover area needed.
4Reliability
If a separate seal cover and seal member are used, then water prevention functions are provided, but the manufacturing cost increases
Solution Approach 1:
The invention combines the seal member and seal cover into a single integrated component, reducing the number of parts that need to be manufactured, assembled, and quality-checked. This integration significantly reduces manufacturing cost while maintaining effective water prevention through the lock portion's direct engagement with the shell.
Data Source
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AI summary
A seal member (3) used for an electrical connector (1) is configured to be penetrated by an electric-wire (11) extending rearwardly from a housing (10) enclosed with a shell (20) made of metal. The seal member (3) being pressed between the housing (10) and a shell bottom portion (23). The seal member (3) is integrally provided with an electric-wire seal portion (31) configured to come into contact with an outer peripheral portion of the electric-wire (11), a housing seal portion (32) located on an outer end portion (30C) of a radial outside of a base portion (30) formed with the electric-wire seal portion (31), and configured to be pressed against the housing (10), and a shell seal portion (33) configured to be pressed against at least the shell bottom portion (23) of the shell (20). Size reduction is achieved while the performance of preventing entry of water required for an electrical connector achieving an electromagnetic shielding effect is maintained.