Integrated Sealing Element for Injection-Moulded Connectors

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Solution Overview

Problem

Existing connectors in automotive engineering require multiple separate parts for assembly, increasing the complexity and risk of errors during the assembly process, and do not adequately ensure longitudinal water tightness without additional overmolding steps.

Innovation Solution

A method where the sealing element is integrated with the contact carrier as a one-piece component or produced separately but attached during assembly, using a two-part design that encloses the cables with a form-fit and pretension mechanism to ensure watertightness, reducing the number of parts and simplifying assembly while preventing overmolding material from entering the contact chambers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate sealing elements are used in the contact carrier, then longitudinal water tightness can be achieved, but the number of parts increases and assembly complexity increases

Engineering Contradiction:

Improvelongitudinal water tightnessVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sealing element is integrated into the contact carrier as a one-piece component, combining the sealing function with the contact carrier structure. This eliminates the need for separate sealing elements and reduces the total number of parts while maintaining the longitudinal water tightness function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The contact carrier is designed to perform multiple functions: it holds the contact partners and simultaneously provides sealing through its integrated sealing element. This multi-functional design reduces the number of separate components needed while achieving both mechanical support and water tightness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate sealing elements are used, then sealing function is provided, but assembly effort increases due to handling multiple parts

Engineering Contradiction:

Improvesealing functionVSAvoidassembly effort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The sealing element and contact carrier are merged into a single integrated component, reducing the number of assembly steps. The sealing function is built into the contact carrier structure, eliminating the need to separately handle and install sealing elements during assembly.

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If the sealing element is designed as a one-piece component with the contact carrier, then the number of parts is reduced, but adaptability to different cable designs is limited

Engineering Contradiction:

Improvenumber of partsVSAvoidadaptability to cable designs

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The sealing element is designed with a localized adaptive geometry at the sealing surface that can accommodate different cable diameters and shapes. While the overall component remains integrated, the sealing area has variable properties that provide adaptability to different cable designs without requiring separate components.

Inventive Principle:

Principle #3Local quality

4Adaptability or versatility

If the sealing element is produced separately and attached later, then different contact carrier designs can be adapted, but assembly complexity increases

Engineering Contradiction:

Improveadaptability of contact carrier designsVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The sealing element is produced together with the contact carrier in a one-piece manufacturing process, eliminating the need for separate attachment steps. This integrated production approach maintains design adaptability while significantly reducing assembly complexity by removing the sealing element attachment operation.

Inventive Principle:

Principle #5Merging (Combining)

5Reliability

If overmolding is performed to ensure longitudinal watertightness, then sealing is achieved, but plastic material may enter the contact chambers and block contact partners

Engineering Contradiction:

Improvelongitudinal watertightnessVSAvoidplastic material intrusion into contact chambers

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sealing element is pre-installed in the contact carrier before the overmolding process. This preliminary sealing barrier prevents plastic material from entering the contact chambers during subsequent overmolding operations, eliminating the harmful effect of material intrusion while maintaining the benefits of encapsulation for longitudinal watertightness.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP2638603B1Sealing contact chambers against injection-moulding material (plastic) during the process of encapsulation by injection moulding

Publication Date: 2021.05.26 HIRSCHMANN AUTOMOTIVE GMBH

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AI summary

Method and apparatus for producing a plug-type connector (6), which has a plastic-injection-moulded contact carrier (1) with contact chambers for accommodating in each case one contact partner, wherein, furthermore, a sealing element is provided which acts on in each case one outer sheath of at least one cable (4) which is passed out of the plug-type connector (6) and is connected at the end of the electrical conductor thereof to the associated contact partner, characterized in that the sealing element is likewise produced in an injection-moulding method from plastic together with the contact carrier (1).