Overmolded Electrical Connector Assembly for Automotive Coaxial Cables

Solution Overview

Problem

Existing electrical connector assemblies for coaxial cables in automotive applications require numerous parts for mechanical protection and sealing, leading to increased cost and bulk, which is inefficient and not fully compatible with USCAR and ISO standards.

Innovation Solution

The solution involves an overmolded electrical connection assembly where a conductive envelope, formed by cutting and rolling a metal strip, is used to integrate mechanical protection and sealing directly on the connector housing and cable sheath, eliminating the need for additional parts and using a low-pressure overmolding process to ensure compatibility with USCAR and ISO standards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple separate parts (sealing rings, protective covers, ferrules) are used for mechanical protection and sealing, then the sealing and mechanical protection functions are achieved, but the number of parts increases, cost increases, and bulk increases

Engineering Contradiction:

Improvesealing and mechanical protectionVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (sealing ring, protective cover, ferrule) into a single integrated injection-molded housing that performs all functions simultaneously. The housing includes integrated sealing elements, protective structure, and cable management features, eliminating the need for multiple separate parts while maintaining reliable sealing and mechanical protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The injection-molded housing serves multiple functions: it provides mechanical protection for the connector contacts, ensures sealing against environmental contaminants, protects the cable connection point, and provides structural support. This multi-functional design replaces several specialized components with a single universal housing structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple separate parts (sealing rings, protective covers, ferrules) are used for mechanical protection and sealing, then the sealing and mechanical protection functions are achieved, but the production cost increases

Engineering Contradiction:

Improvesealing and mechanical protectionVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple separate components (sealing ring, protective cover, ferrule) into a single integrated injection-molded housing that performs all functions simultaneously. The housing includes integrated sealing elements, protective structure, and cable management features, eliminating the need for multiple separate parts while maintaining reliable sealing and mechanical protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical assembly of multiple parts (requiring sealing rings, snap-fits, screws) with a single injection-molding process. This manufacturing substitution eliminates complex assembly operations, reduces labor costs, and simplifies production while maintaining the same protective and sealing functions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If multiple separate parts (sealing rings, protective covers, ferrules) are used for mechanical protection and sealing, then the sealing and mechanical protection functions are achieved, but the overall size and bulk of the assembly increases

Engineering Contradiction:

Improvesealing and mechanical protectionVSAvoidassembly bulk

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent combines multiple separate components (sealing ring, protective cover, ferrule) into a single integrated injection-molded housing that performs all functions simultaneously. The housing includes integrated sealing elements, protective structure, and cable management features, eliminating the need for multiple separate parts while maintaining reliable sealing and mechanical protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a nested structure where the sealing elements and protective features are integrated within the housing walls and cavities. The sealing rings are positioned within grooves in the housing, the protective structure forms part of the housing body, and cable management features are built into the housing, creating a compact nested arrangement that minimizes overall assembly bulk.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentEP3540859B1Electrical connection assembly with electrical connector mounted and overmoulded on an electrical cable, associated manufacturing method

Publication Date: 2023.05.03 RAYDIALL SAS

Figure 1~2
Figure 3~3A
Figure 4~4A

AI summary

The present invention essentially consists of replacing all the mechanical protection parts (corrugated tube, hood) and sealing parts (ring seals) which are mechanically attached in electrical connection solutions, in particular coaxial connection, according to the state of the art, by a junction overmolded directly onto the conductive envelope (ferrule, shell, or two half-shells), partly inside the connector housing and around the part of the outer sheath of the cable which is close to the housing.