Integrated Connector Seals for Vibration-Stable HV Cable Assembly
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Solution Overview
Problem
Existing electrical connector seals fail to withstand loads, require excessive installation space, and have complex assembly processes, leading to displacement, contamination, and increased assembly effort.
Innovation Solution
A connector housing with integrally formed seals molded to inner walls, reducing installation space and assembly complexity by integrating seals and connection elements through injection molding, ensuring robust sealing against dust, moisture, and dirt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If seals are manually arranged in electrical connectors, then assembly is possible, but seals are displaced under loads such as vibrations
Solution Approach 1:
The patent integrates the seal retention function directly into the seal structure itself by providing a radial seal with an integrated retention portion that engages with the housing body. This merging of functions eliminates the need for separate retention elements and ensures the seal remains positioned under vibration loads while maintaining simple assembly through a single injection-molded component.
2Reliability
If multiple separate seals are used to seal carrier housing and electrical connector, then sealing coverage is improved, but installation space increases
Solution Approach 1:
The patent combines multiple sealing functions into a single radial seal component that simultaneously seals the interface between the electrical connector and carrier housing. The radial seal with its integrated retention portion provides comprehensive sealing coverage at the mating interface, eliminating the need for multiple separate seals and reducing installation space requirements.
3Ease of operation
If seals are exposed during assembly, then assembly access is improved, but seals are damaged or contaminated
Solution Approach 1:
The patent integrates the seal retention function into the seal structure itself, allowing the radial seal to be properly contained and positioned within the housing body during assembly. The integrated retention portion ensures the seal is correctly positioned without being exposed, preventing damage and contamination while maintaining assembly accessibility through the injection molding process.
4Reliability
If carrier housing is sealed before inserting electrical connector, then contamination is prevented, but assembly complexity increases
Solution Approach 1:
The patent provides a radial seal with an integrated retention portion that is injection molded as a single piece and directly engages with the housing body. This integration allows the seal to be properly positioned and secured in a single assembly step when the electrical connector is inserted, eliminating the need for separate pre-sealing operations and reducing overall assembly complexity while maintaining contamination protection.
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
The solution enhances seal durability against vibrations, reduces installation space, simplifies assembly, and minimizes the need for additional seals, providing efficient and reliable protection for electrical connectors.
Implementation Method 1
The first seal, the second seal, and the connection element are integrally formed
Data Source
AI summary
The present disclosure relates to a connector housing for an electrical connector. The connector housing includes a housing body having a first opening and a second opening. The connector housing also includes a first seal and a second seal. The connector housing further includes a connection element connecting the first seal and the second seal. The first seal is molded to inner walls of the first opening and the second seal is molded to inner walls of the second opening. The first seal, the second seal, and the connection element are integrally formed.