Integrated Terminal Seal With Circumferential Ribs for Connector Sealing
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Solution Overview
Problem
Existing electrical connectors, particularly those for electric vehicle charging, face challenges in efficiently sealing high voltage terminals against environmental contaminants like dust, dirt, and water, especially in outdoor environments, where individual O-ring seals can be labor-intensive and less effective.
Innovation Solution
An electrical terminal seal featuring a base with integrally formed cylindrical protrusions and circumferential ribs, made of self-bleeding silicone rubber, provides compressive contact and sealing efficiency by interfering fit with both the terminals and the housing, mimicking the sealing efficiency of individual O-ring seals but applied en masse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual O-ring seals are used for each terminal, then sealing effectiveness is maintained, but manufacturing complexity and labor costs increase
Solution Approach 1:
The patent combines multiple individual O-ring seals into a single integrated seal member that simultaneously seals multiple terminals. The seal member includes a body with multiple sealing elements arranged to engage with multiple terminals, eliminating the need for separate O-ring seals for each terminal while maintaining the sealing effectiveness of individual seals.
Solution Approach 2:
The seal member is designed to perform multiple sealing functions simultaneously by incorporating multiple sealing elements in different locations. This single component can seal multiple terminals of different sizes and configurations, making it a universal sealing solution that replaces multiple specialized seals.
2Reliability
If individual O-ring seals are used for each terminal, then sealing effectiveness is maintained, but installation time and labor costs increase
Solution Approach 1:
The patent combines multiple individual O-ring seals into a single integrated seal member that simultaneously seals multiple terminals. The seal member includes a body with multiple sealing elements arranged to engage with multiple terminals, eliminating the need for separate O-ring seals for each terminal while maintaining the sealing effectiveness of individual seals.
Solution Approach 2:
The seal member is pre-assembled with all sealing elements in their correct positions and orientations before installation. This preliminary assembly ensures that during installation, the entire sealing system can be installed in a single operation without requiring separate installation steps for each individual seal, significantly reducing installation time.
3Productivity
If a single seal structure is used for multiple terminals, then installation efficiency improves, but sealing precision for each terminal may deteriorate
Solution Approach 1:
The seal member incorporates different types of sealing elements at different locations to match the specific requirements of each terminal. Each sealing element can be optimized for its particular terminal's dimensions, shape, and sealing needs, ensuring precise sealing for each terminal while maintaining the integrated structure that provides installation efficiency.
Solution Approach 2:
The seal member is designed with flexible or elastomeric materials that can dynamically adapt to the specific geometry of each terminal during installation. This dynamic capability allows the single seal structure to conform precisely to each terminal's unique shape and size, maintaining high sealing precision while achieving efficient installation.
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 effectively inhibits the ingress of contaminants into the connector housing, enhancing sealing efficiency and reducing labor costs by sealing multiple terminals simultaneously, while maintaining the reliability of O-ring seals in harsh outdoor conditions.
Implementation Method 1
a base (12) formed of a compliant material and several cylindrical protrusions (14) that are integrally formed with the base (12)
Implementation Method 2
The first pair of ribs (20) extend into the terminal aperture (18) from an inner surface (22) of the protrusion (14) and are in an interference fit with the terminal (106) to provide compressive contact
Data Source
Figure 1
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AI summary
An electrical connector assembly includes a connector housing (102) defining a cylindrical terminal cavity (104), an electrical terminal (106) having a cylindrical portion (108), and an electrical terminal seal (10). The electrical terminal seal (10) includes a base (12) formed of a compliant material and a cylindrical protrusion (14) integrally formed with the base (12) and extending from a major surface (16) of the base (12). The electrical terminal seal (10) defines a cylindrical aperture (18) extending through the protrusion (14). The protrusion (14) includes a first circumferential rib (20) that is integrally formed with the protrusion (14). The first circumferential rib (20) extends into the aperture (18) from an inner surface (22) of the protrusion (14).