Mat Seal Device with Annular Sealing Ribs for Electrical Connectors
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Solution Overview
Problem
Existing mat seal devices for electrical connectors struggle to accommodate terminals of varying configurations and cables of varying diameters without cutting, pinching, or distorting the sealing ribs, and often require specially designed covers or breaks in the peripheral edge seal to function effectively.
Innovation Solution
A mat seal device with radially inwardly-extending annular sealing ribs and non-penetrating relief slots allows for elastic expansion to accommodate different cable sizes and terminal configurations, eliminating the need for a special cover and maintaining a continuous peripheral edge seal, while preventing moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mat seal device uses sealing ribs with apertures smaller than cable diameter to seal against cables, then moisture sealing effectiveness is improved, but the sealing ribs are cut, pinched, or distorted when accommodating terminals of varying configurations and cables of varying diameters
Solution Approach 1:
The cable insertion hole is segmented into multiple functional zones: an upper sealing zone with the annular sealing rib that seals against the cable, and a lower terminal reception zone that accommodates terminals of varying configurations. This segmentation allows the sealing rib to maintain its sealing function while the lower portion flexes to accommodate different terminal sizes and shapes without damaging the sealing rib.
Solution Approach 2:
Different regions of the mat seal device have different properties: the annular sealing rib region has high structural integrity and elastic recovery to maintain sealing pressure, while the surrounding mat material has higher flexibility to accommodate terminal insertion. This local differentiation of material properties allows the device to simultaneously achieve effective sealing and adaptability to varying cable and terminal dimensions.
2Reliability
If a mat seal device uses pressing holes and a special cover with tapered projections to seal slits, then slit sealing is achieved, but device complexity increases due to specially-designed covers and additional apertures
Solution Approach 1:
The sealing function is extracted from the cover assembly and integrated directly into the mat seal device itself through the annular sealing rib structure. The sealing rib is formed as an integral part of the mat, eliminating the need for separate pressing holes, tapered projections, and specially-designed covers. This extraction of the sealing function simplifies the overall device structure while maintaining effective sealing.
Solution Approach 2:
The cable insertion hole, terminal reception area, and moisture sealing function are merged into a single integrated structure. The annular sealing rib is formed as an integral feature of the mat material within the cable insertion hole, combining the functions of cable sealing, terminal accommodation, and moisture prevention in one component without requiring separate covers or additional apertures.
3Reliability
If a mat seal device uses a continuous peripheral edge seal, then moisture prevention at the outer periphery is improved, but the mat cannot be deformed to accommodate cable insertion without risking breaks in the peripheral edge seal
Solution Approach 1:
The mat seal device is segmented into a continuous peripheral edge seal region and separate cable insertion hole regions. The peripheral edge seal forms an unbroken continuous barrier around the outer periphery of the mat, while the cable insertion holes are positioned within the mat body away from the peripheral edge. This spatial segmentation allows the peripheral seal to remain intact and continuous while the cable insertion holes undergo local deformation during terminal insertion.
Solution Approach 2:
The mat exhibits local quality differentiation where the peripheral edge region maintains high structural integrity and continuity for sealing, while the regions surrounding the cable insertion holes have increased flexibility to accommodate terminal insertion. This localized variation in mechanical properties allows the peripheral edge seal to remain undisturbed during cable and terminal insertion operations.
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 device effectively seals electrical connectors without damaging or distorting the mat or sealing ribs, ensuring coaxial alignment of terminals with connector cavities and accommodating a range of cable sizes without the need for additional apertures or covers.
Implementation Method 1
a radially inwardly-extending annular sealing rib having an aperture smaller in diameter than a cable to be received in the hole so that the first annular sealing rib will be elastically enlarged when receiving the cable and will constrict around and seal against an outer surface of the cable
Data Source
AI summary
A mat seal device for preventing water from entering an electrical connector through an opening provided for cables to be inserted into the connector. The device includes an elastic mat that plugs an opening in the connector. A peripheral edge seal of the mat seals between the mat and an inner surface of the connector housing. Cable insertion holes receive cables into the connector and prevent moisture from passing through the holes around the cables received in those holes. Each cable insertion hole includes annular sealing ribs that elastically enlarge when receiving a cable and seal against an outer surface of the cable. Recesses formed in front and back surfaces of the mat adjacent the cable insertion holes relieve expansion of the sealing ribs.