FAKRA Connector Sealing System for Moisture Protection
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Solution Overview
Problem
Conventional FAKRA connectors in the automotive sector fail to prevent moisture ingress, leading to malfunctions and corrosion, which can result in the failure of printed circuit boards and connected devices.
Innovation Solution
An electrical connector design featuring a sealing system with annular sections and projections that surround the coaxial conductor and mounting plate, providing a watertight seal to prevent moisture penetration, with a sealing system that maintains tightness according to protection class IP67 or IP68, even in high humidity environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional FAKRA connectors are used for automotive applications, then temperature resistance and vibration resistance are improved, but moisture protection is insufficient leading to corrosion and malfunctions
Solution Approach 1:
The sealing system is divided into multiple independent sealing elements (first sealing element, second sealing element, third sealing element) that work together to provide comprehensive moisture protection. Each sealing element is positioned at different locations to seal specific gaps, creating a multi-layer defense against moisture ingress while maintaining the connector's existing structural integrity
Solution Approach 2:
The sealing elements act as intermediary components between the connector housing and the external environment. These elastomeric seals create a barrier that prevents direct contact between moisture and the electrical contacts, shielding the sensitive internal components from harmful environmental factors
2Device complexity
If the connector structure is simplified without sealing elements, then manufacturing cost and complexity are reduced, but moisture protection capability is lost
Solution Approach 1:
The sealing elements are made from elastomeric materials that form flexible sealing barriers. These thin, compliant components conform to the mating surfaces and create effective seals against moisture ingress. The flexible nature of these seals allows them to accommodate manufacturing tolerances and assembly variations without requiring complex precision machining
Solution Approach 2:
The connector combines different materials with complementary properties: the housing material provides structural strength, while the elastomeric sealing elements provide moisture barrier properties. This composite approach integrates multiple functions (mechanical support and environmental protection) into a single connector assembly without significantly increasing complexity
3Duration of action of stationary object
If sealing elements are added to prevent moisture ingress, then moisture protection and service life are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The sealing elements are pre-installed into grooves or channels in the connector housing during manufacturing. This preliminary placement ensures proper positioning and alignment before the final assembly process, eliminating the need for complex adjustment mechanisms and reducing assembly complexity. The seals are ready to function immediately upon connector assembly
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The present invention relates to an electrical connector, a connector element, and a related use. The electrical connector (100; 200; 300; 500; 600) comprises: - at least one coaxial conductor (10); - at least one shielding element (40) which at least partially surrounds the at least one coaxial conductor (10) at a circuit board-side end (18) of the connector (100; 200; 300; 500; 600);- a connector element (20) which at least partially surrounds the at least one coaxial conductor (10) at a plug-side end (16), wherein a plug-side section (22) of the connector element (20) is designed for plugging together with a complementary connector, wherein a board-side section (28) of the connector element (20) is designed for arranging the connector element (20) on the at least one shielding element (40), and wherein the connector element (20) has a stop section (26) between the plug-side section (22) and the board-side section (28), which is arranged on a mounting plate (30) in the assembled state;- a sealing system (60) arranged between the stop section (26) and the mounting plate (30), wherein the sealing system (60) comprises at least one annular first section (70) extending along the circumference of the at least one coaxial conductor (10) and having a circumferential projection (72) extending to a lateral surface of the coaxial conductor (10), and wherein the sealing system (60) comprises a second section (80) circumferentially surrounding the at least one coaxial conductor (10) and having a circumferential projection (82) extending to the mounting plate (30).