Integrated Waterproof Seal for Automotive Electrical Connectors
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Solution Overview
Problem
Existing electrical connectors for automobiles require multiple separate waterproof seal members, leading to increased components and assembly time, with a risk of accidental omission during manual attachment, which can result in serious accidents.
Innovation Solution
The electrical connector integrates two seal members on the inner and outer surfaces of a central cylinder through injection molding, allowing them to communicate and be molded together, reducing the number of components and simplifying production while ensuring both seals are securely attached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate waterproof seal members are used at two locations, then waterproof protection is achieved, but the number of components increases and assembly time increases
Solution Approach 1:
The patent integrates two separate seal members into a single integrated seal structure that simultaneously provides waterproof protection at two different locations. The integrated seal includes a first seal portion for the first location and a second seal portion for the second location, connected as one unified component that is injection-molded directly onto the housing, eliminating the need for separate seal members and reducing component count while maintaining dual waterproof functionality.
2Reliability
If separate waterproof seal members are used at two locations, then waterproof protection is achieved, but assembly working time increases
Solution Approach 1:
The integrated seal structure combines two sealing functions into one component that is attached to the housing as a single unit during assembly, reducing the number of attachment operations required and thereby decreasing assembly working time while maintaining waterproof protection at both locations.
Solution Approach 2:
The integrated seal is pre-formed as a single component with both seal portions already connected, so that during assembly, the entire dual-seal structure is installed in one operation rather than requiring sequential installation of separate seals, thus reducing assembly time.
3Ease of operation
If seal members are manually attached, then installation flexibility is achieved, but the risk of accidental omission increases
Solution Approach 1:
By integrating two seal members into one unified structure, the patent ensures that both sealing functions are provided by a single attachment operation, eliminating the possibility that one seal is forgotten while the other is installed, thus reducing the risk of accidental omission while maintaining installation flexibility.
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 integrated design enhances the waterproof structure by reducing the risk of seal detachment and simplifies assembly, eliminating the need for manual attachment of individual seal members and minimizing the risk of accidents due to missed installations.
Implementation Method 1
since the seal portions at the two locations on the both inner and outer surfaces of the central cylinder are integrally molded to communicate with each other through a communication hole provided in the central cylinder by injection molding
Data Source
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AI summary
Seal portions at two locations communicate with each other and are integrated with each other to realize a waterproof structure. A first seal portion is provided onto an outer surface at a tip of a central cylinder inside a housing main body to realize a waterproof structure where a gap between the outer surface and a housing of a mating electrical connector is sealed in a waterproof manner. The seal portion is also connected to an inner surface of the central cylinder through a communication hole provided in the central cylinder, and a second seal portion is provided on the inner surface, integrally with the seal portion, to realize a waterproof structure where a gap between the inner surface and a terminal holder is sealed in a waterproof manner. When the fitting in of the mating electrical connector is performed, the housing of the mating electrical connector is inserted between the central cylinder and an outer cylinder, and a waterproof structure is realized by the seal portion provided on the outer surface of the central cylinder. In addition, a waterproof structure where a gap between the terminal holder and the housing main body is sealed in a waterproof manner is realized by the seal portion provided on the inner surface of the central cylinder.