Liquid Extraction Module Plug Connector Leak Tightness
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Solution Overview
Problem
Existing liquid extraction modules for motor vehicle exhaust-gas aftertreatment systems face challenges in maintaining leak tightness and durability due to the need for electrical connections, which are prone to failure and require complex material bonding.
Innovation Solution
A resilient plug connector system is designed with a separately formed housing and insert part, utilizing an encapsulated undercut and intermediate piece for a form-fitting and force-fitting connection, along with a bonding agent to ensure a leak-tight and durable seal, allowing for the use of different materials and enhanced mechanical resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plug connector is integrated into the insert part as a single component, then the manufacturing process is simpler, but the leak tightness and durability are compromised due to material bonding limitations
Solution Approach 1:
The plug connector is separated from the insert part, creating two independent components. This segmentation allows each component to be optimized for its specific function - the insert part for chemical resistance and the plug connector for mechanical resilience and electrical connection - while being joined through a specialized bonding process that ensures leak tightness without compromising the individual advantages of each material.
2Adaptability or versatility
If different materials are used for the plug connector and insert part to optimize their respective functions, then the performance is improved, but the material bonding process becomes complex and expensive
Solution Approach 1:
The bonding process utilizes parameter changes by heating the insert part to a temperature where the plastic material becomes sufficiently soft and pliable. This temperature parameter change allows the insert part to be molded around the plug connector, creating a strong mechanical and chemical bond without requiring complex bonding equipment or additional bonding agents, thus simplifying the manufacturing process while enabling the use of different optimized materials.
3Duration of action of stationary object
If the plug connector is made from a mechanically resilient material independent of the insert part, then the service life is extended, but the connection between the two components becomes more challenging
Solution Approach 1:
The plug connector is prepared in advance as a separate pre-assembled unit with its housing and electrical contacts already in place. This preliminary action allows the resilient material of the plug connector to be fully cured and stabilized before the bonding process, ensuring its mechanical resilience and long service life. The pre-prepared plug connector is then bonded to the insert part through the heated molding process, which creates a strong connection without compromising the plug connector's material properties.
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 provides a reliable, leak-tight, and durable connection that meets the demands of motor vehicle construction, ensuring long service life and resistance to stress and vibrations, while simplifying the manufacturing process and reducing additional effort in material bonding.
Implementation Method 1
The leak tightness between plug connector housing and insert part is increased by the additional use of at least one bonding agent in the material of at least one of the two components. By means of the bonding agent, a solid and particularly leak-tight connection results between the two materials
Implementation Method 2
The plug connector and the insert part are therefore embodied as two separate parts of the liquid extraction module. As a result, each of the parts, the plug connector and the insert part, can be optimally matched in terms of material technology to the tasks respectively associated therewith. Provision is therefore made according to the invention for the housing of the plug connector to have an undercut, which is encapsulated for fastening to the insert part
Data Source
AI summary
The invention relates to a liquid extraction module (1) for extracting liquid from a liquid tank, in particular of an exhaust-gas aftertreatment system of a motor vehicle, having an insert part (2) which is produced at least substantially from plastic and which has at least one extraction opening (5) and at least one plug connector (14) for the electrical contacting of an electrical consumer (10, 7) of the liquid extraction module (1). It is provided that a housing (16) of the plug connector (14) is formed separately and has at least one encapsulated undercut (22, 32) for fastening to the insert part (2).