Plastic-Embedded Plug Connector Sealing Against Liquid Ingress
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Solution Overview
Problem
Existing plug connecting elements for motor vehicles are susceptible to foreign body penetration and liquid ingress, leading to corrosion and inadequate electrical contact, which can result in component malfunction, especially in wet environments.
Innovation Solution
A plug connecting element with an electrically conducting element partially embedded in a plastic casing, providing insulation and a secure, non-detachable connection, along with a sealing mechanism and a mechanically conductive fastening element to ensure reliable contact and protection from environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection mechanisms are used, then electrical connection is achieved, but foreign bodies or liquids can penetrate to the electrical contact points causing corrosion and inadequate contact
Solution Approach 1:
The electrical conducting element is nested within the casing element, which provides protective enclosure. The conducting element is partially embedded in the plastic material of the casing, creating a nested structure where the inner component (conducting element) is protected by the outer component (casing element) against foreign bodies and liquids.
Solution Approach 2:
The casing element made of plastic serves as an intermediary between the electrical conducting element and the external environment. This intermediary structure prevents direct contact between harmful external factors (foreign bodies, liquids) and the electrical conducting element, while still allowing electrical function to be performed.
2Ease of operation
If the conducting element is exposed for connection, then electrical connection is accessible, but corrosion can occur at the contact points
Solution Approach 1:
The casing element provides differential protection: it encloses and protects portions of the electrical conducting element that are vulnerable to corrosion, while leaving specific local areas (connection points) accessible for electrical connection. This local quality approach ensures that only the necessary areas are exposed, minimizing corrosion risk while maintaining connectivity.
3Ease of manufacture
If manual assembly processes are used for cable shoes and crimp connectors, then connection is achieved, but quality consistency is compromised and automation is prevented
Solution Approach 1:
The electrical conducting element and the casing element are merged into a single integrated component. The conducting element is partially embedded in the plastic casing during a single manufacturing process (injection molding), eliminating the need for separate manual assembly steps for cable shoes and crimp connectors. This merging enables automated production while ensuring consistent quality.
Solution Approach 2:
The integrated plug connecting element serves multiple functions simultaneously: it provides electrical connection, mechanical support, and environmental protection. This multi-functionality eliminates the need for separate components (cable shoes, crimp connectors, seals) that would require manual assembly, enabling automated manufacturing processes.
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 provides a reliable, flexible, and durable electrical connection that prevents corrosion and maintains contact integrity even in wet conditions, ensuring stable operation of electronic components by shielding the conducting element from foreign bodies and liquids.
Implementation Method 1
a casing element made of plastic, by means of which the conducting element is at least partially electrically insulated. Consequently, if an electrical voltage is applied between two points of the electrical conducting element remote from one another, then an electric current flows through the electrical conducting element between the two points. On the other hand, the plastic of the casing element is an electrically non-conductive plastic.
Data Source
AI summary
A plug connecting element for a motor vehicle includes an electrical conduction element, to which at least one plug of an electronic component of the motor vehicle is able to be connected, and a casing element made of plastic, by way of which the conduction element is at least partially electrically insulated. The electrical conduction element is connected to the casing element in a fixed and non-releasable manner by primary forming of the plastic.