Electrical Plug Connector Fluid-Tight Solder Meniscus
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Solution Overview
Problem
Existing electrical connectors in automatic transmissions face leakage issues due to temperature fluctuations, which cause adhesion loss between plug contacts and the connector housing, and potting compounds are not resistant enough to automatic transmission oils, leading to fluid leaks.
Innovation Solution
An electrical plug connector made of non-conductive material with a plug housing and circuit board connection via solder, where the plug contact is securely attached to the circuit board without frictional connection, forming a fluid-tight solder meniscus, eliminating the need for sealing compounds like potting compounds or O-rings, and incorporating a bridge element for support and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plug contacts are sealed against the connector housing using potting compounds or O-rings, then fluid tightness is achieved, but the sealing fails after temperature fluctuations causing leakage
Solution Approach 1:
The invention removes the problematic sealing elements (O-rings, potting compounds) from the connector design. Instead of sealing the plug contacts against the housing, the design accepts that the plug contact area is not fluid-tight, but achieves overall fluid tightness through the sealed connector housing and sealed connection between the circuit board and housing.
Solution Approach 2:
The fluid tightness function is segmented into two separate sealed interfaces: (1) the seal between the connector housing and the transmission housing, and (2) the seal between the circuit board and the connector housing. This eliminates the need for sealing at the plug contact-housing interface, which is prone to failure under temperature cycling.
2Strength
If plug contacts are firmly connected to the connector housing, then mechanical stability is achieved, but adhesion loosens after temperature changes leading to friction loss
Solution Approach 1:
The invention removes the requirement for frictional or adhesive connection between plug contacts and housing. Plug contacts are instead soldered to a circuit board that is sealed to the housing, eliminating the temperature-sensitive adhesive joints between metal contacts and plastic housing.
Solution Approach 2:
The mechanical frictional connection between plug contacts and housing is replaced with a soldered electrical and mechanical connection to the circuit board. The solder joint provides both electrical connectivity and mechanical stability without relying on temperature-sensitive adhesion.
3Reliability
If additional sealing materials like O-rings and potting compounds are used, then fluid tightness is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The invention removes O-rings, potting compounds, and other sealing materials from the plug contact sealing process. Fluid tightness is achieved through the sealed housing structure and sealed circuit board connection, simplifying the overall sealing architecture.
Solution Approach 2:
The mechanical support and electrical connection functions are merged into the circuit board assembly. The circuit board provides structural support for plug contacts while maintaining electrical connectivity through solder joints, eliminating the need for separate sealing components.
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, fluid-tight connection that prevents fluid from leaking between the interior and exterior, maintaining integrity across temperature fluctuations without the use of additional sealing materials, enhancing the stability and durability of the connector.
Implementation Method 1
A soldering point of the plug contact with the printed circuit board and the formation of a solder meniscus is fluid-tight
Data Source
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AI summary
The invention is based on an electrical plug-type connector (2) consisting of an electrically nonconductive material comprising a plug housing (4) with an inner wall (8) and at least one plug-type contact (6). The inner wall (8) delimits a first space (10). The plug-type contact (6) has a first end (12) with which contact can be made by a mating plug-type contact, and a second end (14), which is opposite the first end (12). According to the invention, the second end (14) is connected to a printed circuit board (16, 58) by means of solder (18). The plug housing (4) has been moved from the first end (12) in the direction of the second end (14) via the at least one plug-type contact (6) in the axial direction into a predetermined position. In the predetermined position, the plug-type contact (6) has a lack of force-fitting connection transversely to the axial direction. In the predetermined position, the printed circuit board (16, 58) is fixedly connected to the plug housing (4). In the predetermined position, the first end (12) protrudes into the first space (10).