Integrated Connector Collar for Hermetic Sealing in Vehicle Electronics
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Solution Overview
Problem
Existing plug-in unit can housing concepts for electronic devices in vehicle engineering require extensive sealing measures, leading to increased material and fabrication costs, larger device dimensions, and complex assembly processes due to the external exposure of the joint between the can housing and the multicontact connector.
Innovation Solution
A new can housing concept with an integrated connector collar that surrounds the multicontact connector, eliminating the need for external sealing elements by relocating the joint inside the connector collar, and a method for producing this housing involving injection molding and matching the contact carrier's contour to the connector collar's inner contour for a hermetic seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing elements are added to seal the joint between can housing and connector region, then hermetic protection is improved, but device complexity and material costs increase
Solution Approach 1:
The connector collar is integrally molded as one piece with the can housing, merging two previously separate components (housing and collar) into a single integrated structure. This eliminates the joint between housing and collar, removing the need for sealing elements at this interface and simplifying the overall device structure while maintaining hermetic protection.
Solution Approach 2:
The sealing requirement is extracted from the housing-collar joint and relocated to the connector-mating connector interface. By moving the sealing function to this internal interface, the external joint between housing and collar no longer requires sealing elements, reducing device complexity.
2Reliability
If sealing elements are added to seal the joint between can housing and connector region, then hermetic protection is improved, but material costs increase
Solution Approach 1:
The connector collar is integrally molded as one piece with the can housing, eliminating the need for separate sealing materials at the housing-collar joint. This merging of components directly reduces the quantity of sealing materials required while maintaining hermetic protection through the integral structure.
3Reliability
If sealing elements are added to seal the joint between can housing and connector region, then hermetic protection is improved, but outer dimensions increase
Solution Approach 1:
The connector collar is integrally molded with the can housing, eliminating the need for external sealing elements that would increase outer dimensions. The integral structure allows the sealing function to be achieved without adding external sealing components, thus reducing the overall outer dimensions of the device.
4Reliability
If sealing elements are added to seal the joint between can housing and connector region, then hermetic protection is improved, but fabrication costs increase
Solution Approach 1:
The connector collar is produced as an integral part of the can housing through injection molding, merging two manufacturing steps into one. This eliminates the need to separately manufacture, handle, and assemble sealing elements, thereby reducing fabrication costs and simplifying the manufacturing process while maintaining hermetic protection.
Solution Approach 2:
The integral housing-collar structure is self-sealing through its monolithic construction, eliminating the need for additional sealing components and their associated assembly processes. The structure serves its own sealing function through the integral design, reducing fabrication complexity and costs.
5Ease of manufacture
If the joint between can housing and multicontact connector is located externally, then assembly is simplified, but the joint is exposed to environmental influences requiring additional sealing
Solution Approach 1:
The multicontact connector with contact carrier is nested within the connector collar that is integrally formed with the can housing. This nesting arrangement protects the joint between the connector and housing from external environmental influences, as the collar provides a protective enclosure while maintaining assembly simplicity.
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
This solution reduces the need for additional components and sealing materials, decreases the outer dimensions and weight of the electronic device, lowers material and fabrication costs, and simplifies the assembly process while achieving a hermetic seal without external sealing elements.
Implementation Method 1
the outer contour of the contact carrier is at least partially matched to the inner contour of the connector collar
Data Source
AI summary
An electronic device (1) has a can housing (3) and a method for producing the same. The can housing (3) has an open end face (4). A plug-in unit (5) can be inserted into the can housing (3) through the end face (4). The plug-in unit (5) has a populated circuit board (6) and a multicontact connector (7). The can housing (3) has an integrated connector collar (8), which integrally extends the can housing (3) and surrounds the multicontact connector (7) and contact elements (9). The connector collar (8) forms a fit for a mating connector. The insert has the circuit board (6) and a contact carrier (10) having the multicontact connector (7) without the connector collar (8). The outer contour (11) of the contact carrier (10) is at least partially matched to the inner contour (12) of the connector collar (8).