Plug Connector Housing Sealing Against Conductive Particles
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Solution Overview
Problem
Existing connector housings face challenges in achieving a cost-effective and efficient seal against conductive solid particles, particularly metallic chips, due to the complexity of assembly and the mismatch between the recess size and the sheathed cable cross-section, leading to inadequate protection against ingress.
Innovation Solution
The recess on the second housing part is made larger than the connecting line's cross-section, and a sword-like projection on the first housing part covers the recess upon connection, creating a small lead-through area that effectively seals the connection line, even when it's routed as individual cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the recess width is matched to the sheathed cable cross-section, then sealing against conductive particles is improved, but assembly difficulty and friction increase significantly
Solution Approach 1:
The recess is divided into two functional zones: a wide lead-in area for easy cable insertion and a narrow sealing area for particle protection. This segmentation allows the recess to fulfill both assembly ease and sealing requirements without compromise.
Solution Approach 2:
The recess transitions from a two-dimensional cross-sectional match to a three-dimensional tapered structure. The width varies along the depth, providing a wide opening for assembly and a narrow bottom for sealing, effectively adding a dimensional solution to a two-dimensional problem.
2Ease of operation
If the recess is made larger than the connecting line cross-section, then assembly is simplified and friction is reduced, but sealing against conductive particles becomes inadequate
Solution Approach 1:
The recess is divided into a wide lead-in section for easy assembly and a narrow sealing section for particle protection. This segmentation allows each zone to optimize for its specific function without compromising the other.
Solution Approach 2:
Different sections of the recess have different width characteristics tailored to their specific functions. The lead-in area is wide to reduce friction, while the sealing area is narrow to prevent particle ingress, applying local quality variations to solve the global contradiction.
3Reliability
If a rubber seal is added to the recess, then sealing against conductive particles is improved, but manufacturing costs and assembly complexity increase
Solution Approach 1:
The sealing function is extracted from a separate rubber seal component and integrated directly into the recess structure itself. The recess geometry provides the sealing action without requiring an additional sealing element, eliminating extra parts and assembly steps.
Solution Approach 2:
The recess structure serves its own sealing function through its tapered geometry. The narrow bottom section of the recess creates natural contact pressure on the cable insulation, providing sealing without external assistance from separate sealing components.
4Adaptability or versatility
If the connecting line is routed as individual cores instead of sheathed, then adaptability is improved, but the unfilled recess area increases and sealing becomes difficult
Solution Approach 1:
The recess is segmented into a wide upper portion that accommodates the dispersed individual cores during insertion and a narrow lower portion that converges the cores for sealing. This segmentation allows individual core routing to maintain both flexibility and sealing effectiveness.
Solution Approach 2:
The recess uses three-dimensional tapering to transition from a wide opening that accepts individual cores to a narrow sealing zone. This dimensional transition allows the connector to accommodate flexible individual core routing while still achieving effective sealing at the closure point.
Data Source
Figure 1
Figure 2~4
AI summary
There is described a plug-connector housing having a first housing part having electrical components, and a second housing part forming a housing cap, said second housing part being connectable to the first housing part, and having a recess in the second housing part, an electrical connecting line for the electrical attachment of electrical components of the first housing part being passable through said recess, wherein the first housing part has a sword-shaped structure which largely covers the recess after the second housing part has been connected to the first housing part. Also described is a plug connector having such a plug-connector housing.