Elastomeric Gasket Assembly With Integral Electrical Connector
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Solution Overview
Problem
Current electric vehicle component assemblies, such as battery coolant heaters, face issues with large packaging requirements and additional leak paths due to the need for separate harness connectors and wiring, which complicate assembly and increase complexity.
Innovation Solution
Integration of an elastomeric gasket with an integral electrical connector that passes power or signals directly through the gasket, eliminating the need for a separate harness connector and reducing the cover depth, thereby simplifying assembly and reducing potential leak points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate harness connector and wiring are used to provide electrical power to the electric component, then electrical connection is achieved, but the cover depth increases and packaging requirements become larger
Solution Approach 1:
The patent combines the gasket and electrical connector into a single integrated component. The gasket serves dual functions: sealing the joint between the cover and base, and providing a pathway for electrical conductors to pass through to the electric component. This eliminates the need for a separate harness connector and reduces cover depth requirements.
2Reliability
If a separate harness connector is installed in a hole in the cover, then electrical power can be provided to the electric component, but an additional leak path is created
Solution Approach 1:
The gasket and electrical connector are merged into a single component. The electrical conductors pass through the gasket material itself rather than through a separate hole in the cover, eliminating the additional leak path while maintaining electrical connection functionality.
3Reliability
If wiring is threaded through the cover and connector is installed separately, then electrical connection is established, but assembly becomes difficult and requires additional awkward steps
Solution Approach 1:
The gasket and electrical connector are combined into a single pre-assembled unit. The electrical conductors are already positioned within the gasket structure, eliminating the need for separate wiring threading and connector installation steps. This significantly simplifies the assembly process.
Solution Approach 2:
The electrical conductors are pre-positioned within the gasket structure during gasket manufacturing. This preliminary arrangement of conductors eliminates the need for complex wiring operations during final assembly, as the conductors are already in their correct positions and orientations.
4Reliability
If enough cover depth is provided to accommodate harness connector and wiring, then electrical connection is possible, but packaging requirements become unnecessarily large
Solution Approach 1:
The gasket and electrical connector are merged into a single compact component that passes through the sealed joint between the cover and base. This integration eliminates the need for deep cover structures to accommodate separate connectors and excess wiring, thereby reducing overall packaging volume requirements.
Data Source
AI summary
A gasket with at least one integral electrical connector adapted for an assembly includes an elastomeric gasket main body adapted to seal a joint between one or more assembly components and a cover, and at least one electrical connector extending through and formed integrally with the elastomeric gasket main body so as to provide power or electric signals to at least one electrical component of the assembly.