Planar Seal Structure for Angled Connector Wire Entry
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Solution Overview
Problem
Existing angled connectors face challenges in providing a reliable and cost-efficient seal, particularly at the interface between the top and bottom covers and the wire insertion point, which can lead to contamination and electrical shorts due to inadequate sealing designs.
Innovation Solution
A seal with a planar plate-shaped configuration featuring a rim wall with continuous sealing passages that allow the wire to enter and bend at an angle, providing uniform compression and enhanced sealing performance, including undulating inner walls for wire size tolerance and radially protruding sealing lips for increased durability and sealing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional seal design with transition areas or steps is used, then the seal structure can accommodate wire insertion, but the sealing performance deteriorates due to non-uniform compression
Solution Approach 1:
The seal is designed with a homogeneous planar plate-shaped configuration where the entire rim wall has uniform thickness, eliminating transition areas or steps. This homogeneity ensures uniform compression distribution across the seal interface, maintaining reliable sealing performance without requiring complex multi-level structures.
Solution Approach 2:
The sealing function is achieved by transitioning from a multi-level vertical structure to a planar two-dimensional configuration. The seal operates effectively in a single plane with uniform thickness, distributing compression forces evenly across the entire rim wall area rather than concentrating them at specific transition points.
2Volume of moving object
If the seal rim wall is made thin to reduce connector size, then the connector becomes more compact, but the sealing performance deteriorates due to insufficient compression
Solution Approach 1:
The seal structure is segmented into distinct functional zones: the rim wall for interface sealing, the central opening for wire access, and the undulating inner wall for wire sealing. This segmentation allows each zone to be optimized independently, enabling the rim wall to maintain sufficient thickness for reliable sealing while the overall connector remains compact.
Solution Approach 2:
Different regions of the seal have different local properties optimized for their specific functions. The rim wall maintains uniform sufficient thickness for interface sealing, while the central opening area provides wire access and the undulating inner wall provides enhanced wire sealing. This local quality differentiation allows compact overall dimensions while maintaining reliable sealing performance at critical interfaces.
3Ease of manufacture
If a fixed-size sealing passage is used, then the manufacturing is simplified, but the adaptability to different wire sizes is reduced
Solution Approach 1:
The inner wall of the sealing passage features an undulating geometry with peaks and valleys that can dynamically adapt to different wire diameters. When compressed, the material deforms to conform to the wire size, providing effective sealing across a range of wire dimensions while maintaining a simple overall seal structure for easy manufacturing.
Solution Approach 2:
The sealing passage geometry incorporates variable parameters through its undulating inner wall profile. The peaks and valleys create a compliant structure that changes its effective sealing dimension based on compression force and wire diameter, allowing a single seal design to accommodate multiple wire sizes without requiring complex adjustable mechanisms.
4Reliability
If compression ribs are added to enhance sealing, then the sealing performance improves, but the device complexity increases
Solution Approach 1:
The compression ribs are merged into the seal as an integrated feature rather than separate components. The ribs are formed as part of the monolithic seal structure, eliminating the need for additional assembly steps or separate compression mechanisms. This integration enhances sealing performance while avoiding the complexity of multi-component systems.
Solution Approach 2:
The compression ribs are designed to automatically engage and provide sealing enhancement when the seal is installed and compressed between the connector housing and cover. The ribs self-adjust to the interface geometry and provide enhanced sealing without requiring external actuation or complex control mechanisms, maintaining simplicity while improving reliability.
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 ensures a reliable and cost-effective seal for angled connectors, improving sealing performance by eliminating transition areas and accommodating various wire sizes, while reducing permanent strain on the connector covers and enhancing durability.
Implementation Method 1
The seal may be uniformly compressed within the cavity of the connector housing without having any transition areas caused by steps or the like in the seal
Implementation Method 2
The peaks of the undulating shape may be compressed, ensuring a reliable sealing between the wire and the connector. When the peaks are compressed, material may be deflected into the indentations between two adjacent peaks
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to a seal (1) for an angled connector (40), the seal (1) having a planar plate-shaped configuration and the seal (1) having a rim wall (2) that encloses a central opening (4), wherein at least one sealing passage (6) extends from outside the seal (1) through the rim wall (2) into the central opening (4). Due to the planar plate-shaped configuration of the inventive seal (1) an essentially uniform contact interface may be provided between a connector housing (41) and the seal (1). Thus, the reliability and sealing performance of the seal (1) may be improved.