Water-Protected HSD Connector With Multi-Layer Sealing
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Solution Overview
Problem
Existing HSD connectors fail to meet water- and dust-proof requirements of Ingress Protection standards, particularly in environments with high humidity and coarse dust, leading to functional breakdowns.
Innovation Solution
An HSD connector design featuring a male and female connector with multiple sealing and hardening measures, including exterior and die cast component sealing rings, terminal protectors, and double clamping mechanisms, to ensure water- and dust-proof integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing HSD connector structure is used, then device complexity is low, but water- and dust-proof capability is insufficient
Solution Approach 1:
The connector is divided into multiple assemblies (male connector assembly, female connector assembly, terminal assemblies, shield assemblies) with distinct sealing components at each interface. This segmentation allows targeted sealing at critical interfaces while maintaining overall structural clarity and assembly efficiency.
Solution Approach 2:
Multiple sealing rings are nested at different levels and interfaces within the connector structure. The sealing rings are positioned at the male connector assembly, female connector assembly, terminal assemblies, and shield assemblies, creating layered protection similar to nested dolls.
2Reliability
If sealing components are added to improve water- and dust-proof capability, then reliability improves, but manufacturing complexity increases
Solution Approach 1:
Rubber sealing rings are used throughout the connector structure to provide flexible sealing at various interfaces. These thin film-like sealing components effectively block water and dust penetration while being relatively simple to manufacture and install.
Solution Approach 2:
The connector combines different materials (metal for structural components, rubber for sealing rings, plastic for protective caps) to achieve both water-proofing and ease of manufacture. Each material is selected for its specific properties, creating a composite structure that balances reliability and manufacturability.
3Reliability
If multiple sealing layers are implemented, then water- and dust-proof capability improves, but device complexity increases
Solution Approach 1:
Sealing components are strategically positioned only at critical interfaces where water and dust penetration is most likely (male connector assembly, female connector assembly, terminal assemblies, shield assemblies). This local quality approach provides effective sealing without unnecessarily increasing overall device complexity.
Solution Approach 2:
The sealing protection is extended from a single plane to multiple spatial dimensions and levels within the connector structure. Sealing rings are positioned at different depths and interfaces, creating a three-dimensional sealing network that effectively blocks ingress paths without requiring excessive sealing components in any single plane.
Data Source
AI summary
The present invention relates to an HSD connector comprising a male connector and a female connector; a male end main body assembly includes a male end main body and an exterior sealing ring; a male end terminal assembly includes a male end terminal, a male end terminal protector and a male end terminal sealing ring; an exterior sealing ring is mounted on a mating end of the male end main body; a male end terminal protector is mounted on a periphery of the male end terminal; a male end terminal sealing ring is mounted at a juncture at the ends of the male end protector and the male end main body; a die cast component assembly includes a die cast component main body and a die cast component sealing ring; a die cast component sealing ring is mounted on a mating area of the die cast component main body and the male end main body; a front sealing ring is mounted outside of the female end main body. The present invention provides a water- and dust-proof connector with an optimized structure by disposing eight layers of protection and adopting five hardening measures.