Movable Seal Holder for Vibration-Resistant Electrical Connector
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Solution Overview
Problem
Conventional high-voltage connector systems in the automotive sector face challenges in achieving an elastic stop mechanism that is robust against mechanical influences such as vibrations, particularly when a cable outlet is configured at 90°, which makes it difficult to realize an effective seal and stop without increasing the connector's space requirements.
Innovation Solution
The electrical connector features a movable seal holder that compresses the seal upon connection, providing an elastic stop mechanism independently of the collar structure on the mating connector, allowing for reliable sealing and reduced play, thus enhancing robustness against vibrations while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a movable seal holder is used to compress the seal for elastic stop, then the connector's resistance to vibrations is improved, but the device complexity increases
Solution Approach 1:
The seal holder is designed to be movable rather than fixed, allowing it to dynamically adjust position during plugging. The seal holder can move in the plugging direction and compress the seal elastically, providing vibration resistance without requiring complex additional components. This dynamic mechanism transforms a static structure into a responsive one that adapts to mechanical influences.
2Manufacturing precision
If the seal holder is arranged movably on the housing, then manufacturing play is reduced, but the ease of manufacture decreases
Solution Approach 1:
The connector is divided into functionally independent segments: the housing, the seal, and the seal holder. The seal holder is designed as a separate movable component that can be manufactured and assembled independently. This segmentation allows each part to be optimized for its specific function while simplifying the overall manufacturing process through modular assembly.
Solution Approach 2:
The seal holder's mobility parameter is optimized to provide the right balance between reducing manufacturing play and maintaining ease of manufacture. By allowing controlled movement within specific tolerances, the design achieves high precision without requiring overly complex manufacturing processes. The movable arrangement compensates for manufacturing variations through elastic deformation.
3Volume of moving object
If a compact design is maintained with 90° cable outlet, then the volume is reduced, but the elastic stop capability is compromised
Solution Approach 1:
The seal is designed as a flexible element that can be compressed by the movable seal holder. This flexible sealing mechanism provides elastic stop capability without requiring additional space, as the compression occurs within the existing connector volume. The flexible seal deforms elastically to absorb mechanical influences while maintaining the compact 90° cable outlet configuration.
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 effectively reduces manufacturing-related play and enhances the connector's resistance to mechanical influences like vibrations, ensuring a robust and reliable plug-in connection with improved sealing and reduced sensitivity to mechanical stress.
Implementation Method 1
The seal holder is arranged movably on the housing, in order to be moved in the direction of the seal upon producing the plug-in connection with the mating connector and to be pressed against the seal
Data Source
AI summary
The invention relates to an electrical connector (100) for producing a plug-in connection with a mating connector (200). The electrical connector (100) has a housing (110), a seal (160) arranged on the housing (110), and a seal holder (170) arranged on the housing (110) and associated with the seal (160). The seal holder (170) is arranged movably on the housing (110), in order to be moved in the direction of the seal (160) upon the production of the plug-in connection with the mating connector (200) and to be pressed against the seal (160). The invention furthermore relates to a connector system comprising such an electrical connector (100) and a mating connector (200) which can be plugged with the electrical connector (100).