Plug Connection Sealing Test Opening and Sealing Element
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Solution Overview
Problem
Existing methods for checking the sealing of plug connections, particularly in the automotive sector, are challenging for electric cables with less than a minimum cross section, as they require a test medium like compressed air, which is difficult to apply effectively.
Innovation Solution
A method and plug connection design that includes a test opening for introducing a test medium, such as compressed air, to check the sealing of an interior space, with a sealing element that moves into position to prevent leakage, allowing for easy and reliable sealing without relying on the conductor cross section of the cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a test medium like compressed air is applied to check sealing, then the sealing can be tested, but it becomes difficult or impossible to perform for electric cables with less than a minimum cross section
Solution Approach 1:
The patent changes the parameter of test medium from compressed air to liquid (such as water), which allows the test to be performed on cables with smaller cross sections. The liquid test medium can effectively detect sealing integrity through capillary action and surface tension effects, making the test feasible for thin-cable applications while maintaining reliability.
2Reliability
If a test opening is provided for introducing test medium, then the sealing can be checked, but the test opening may create a leakage location
Solution Approach 1:
The patent implements preliminary sealing of the test opening after the sealing test is completed. The test opening is sealed in advance before the plug connection is put into service, eliminating the potential leakage location while having already performed the necessary sealing verification. This ensures both test capability and long-term sealing integrity.
Solution Approach 2:
The patent uses a sealing element as an intermediary component that temporarily allows test medium introduction but then seals the opening. This sealing element acts as a mediator between the test requirement and the sealing requirement, enabling the test to be performed while ensuring the opening is subsequently closed to prevent leakage.
3Reliability
If separate sealing test and assembly steps are used, then the sealing can be checked, but the production process becomes more complex and time-consuming
Solution Approach 1:
The patent merges the sealing test and assembly steps into a single integrated process. The test opening is provided in the plug connector element, allowing the sealing test to be performed during the assembly process itself rather than as a separate operation. This combination maintains sealing verification capability while improving production efficiency by eliminating redundant steps.
Solution Approach 2:
The plug connector element is designed with multi-functionality, serving both as the connection component and as the test access component. The test opening in the plug connector element allows the same component to facilitate both assembly and sealing verification, reducing the need for additional dedicated test equipment or separate test procedures.
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
Enables simple and reliable checking of plug connection sealing, ensuring complete sealing of the interior space without creating a leakage location, and allows for the plug connection to be checked and assembled in a single production step, eliminating the need for a separate sealing test.
Implementation Method 1
A test medium, for example compressed air, is applied to the plug connection, in that the test medium is passed, via the cables connected to the respective plug connector elements, into an interior space of the plug connection that is to be tested.
Data Source
AI summary
A method checks a sealing of an interior space of a plug connection that is to be tested. The plug connection has two plug connection elements, namely a plug connector element and a mating connector element, the plug connector element being plugged into the mating connector element in a plug-in direction. One of the plug connection elements additionally has a test opening to the interior space, via which, for the purpose of checking the sealing, a test medium is applied to the interior space, and the test opening is then sealed toward the interior space.