Plug Connector Housing Structure for Durable Vehicle ECU Sealing
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Solution Overview
Problem
Existing control devices for vehicles suffer from structural failures in adhesively bonded connections between the housing and plug connector parts, leading to sealing failures and potential moisture ingress, which can cause malfunctions.
Innovation Solution
A plug connector part with a connector structure on its inner face, which absorbs operational forces via holding means on the housing, reducing the load on the adhesively bonded connection and ensuring a permanent sealing function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an adhesively bonded connection is used to couple the plug connector part to the housing part, then a sealed connection is achieved, but the sealing function fails when forces act on the plug connector part
Solution Approach 1:
The connection system is segmented into two distinct functions: the adhesively bonded connection provides sealing, while a separate structural coupling mechanism (threaded connection or clamp connection) provides mechanical strength. This separation allows each connection type to optimize for its specific function without compromise.
Solution Approach 2:
A structural coupling mechanism acts as an intermediary between the plug connector part and the housing part, bearing the mechanical forces that would otherwise transfer to and compromise the adhesively bonded sealed connection. This intermediary protects the sealing function from mechanical stress.
2Force
If forces are transmitted through the adhesively bonded connection, then structural support is provided, but moisture can penetrate into the interior of the control device
Solution Approach 1:
The load-bearing function and sealing function are segmented into separate coupling mechanisms. The structural coupling (threaded or clamp connection) handles all mechanical forces, while the adhesively bonded connection maintains pure sealing without force transmission, preventing moisture ingress.
Solution Approach 2:
The structural coupling mechanism serves as an intermediary that intercepts and bears mechanical forces before they can reach the sealed adhesively bonded connection, thereby protecting the seal integrity and preventing moisture penetration.
3Reliability
If a separate connector structure is added to the plug connector part, then forces are absorbed without compromising the sealed connection, but the device complexity increases
Solution Approach 1:
The connector structure is merged with the plug connector part as an integrated component, reducing the number of separate parts. The holding means are merged with the housing part, eliminating the need for additional separate fastening components. This integration maintains reliability while minimizing complexity.
Data Source
AI summary
A plug connector part is configured for cooperating with at least one housing part. The plug connector part and the at least one housing part are configured to form a housing for a control device for vehicles. The control device has control elements connected together in a signal-conducting manner for controlling functions of the vehicle. The plug connector part has one or more plug connectors for signal lines and a contact region extending along at least one portion of the plug connector part and is configured for the sealed connection to the housing part. The plug connector part also has at least one connector structure arranged on the inner face thereof defining an interior of the housing and configured to hold the plug connector part in position relative to the housing part via retainers arranged on the housing part or which can be connected to the housing part.