Relay Connector Housing Structure for Terminal Pitch Correction
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Solution Overview
Problem
The deformation of terminals due to the shrinkage of the potting material in relay connectors reduces connection reliability by varying the pitches of the terminals, leading to potential issues with mating connectors.
Innovation Solution
A relay connector design featuring a first and second housing with a potting material injected into a recess, a first sealing member between the housings, and engaging portions that allow for assembly correction of terminal pitches and provide sealing against liquid intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If potting material is used to enhance oil stop function, then sealing performance is improved, but terminal deformation occurs due to shrinkage during curing
Solution Approach 1:
The housing is divided into two separate parts: a first housing that holds the terminals and a second housing that is assembled afterward. This segmentation allows the potting material to cure and shrink without affecting terminal positions, as the second housing is attached after the potting process is complete.
Solution Approach 2:
The potting material is injected and allowed to cure completely before the second housing is assembled. This preliminary action ensures that terminal deformation from shrinkage is finalized before the sealing structure is completed, preventing further pitch variations.
2Reliability
If terminals are deformed by potting material shrinkage, then connection reliability is reduced, but assembly complexity increases
Solution Approach 1:
The housing is segmented into two parts with engaging portions that connect them. This segmentation enables separate manufacturing and assembly of the terminal-holding section and the sealing section, simplifying the overall structure while maintaining connection reliability.
Solution Approach 2:
The first sealing member acts as an intermediary element between the two housings. It provides the sealing function while the engaging portions provide the mechanical connection, separating these two functions into distinct components that work together.
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 design effectively suppresses the reduction in connection reliability by correcting terminal pitches and preventing liquid ingress, maintaining reliable electrical connections.
Implementation Method 1
The potting material shrinks during curing. According to this shrinkage of the potting material, terminals in a part sealed by the potting material may be deformed.
Implementation Method 2
a first sealing member provided between the first and second housings while being compressed in the first direction
Data Source
AI summary
A relay connector includes a first housing for holding a plurality of terminals and a second housing to be assembled with the first housing along a first direction. The relay connector includes a potting material injected into a recess and a first sealing member provided between the first and second housings while being compressed in the first direction. The first housing includes a first body portion and a first engaging portion. The second housing includes a second body portion including a plurality of insertion holes, through which the plurality of terminals are individually passed, and a second engaging portion engageable with the first engaging portion. The first sealing member is formed to surround the plurality of terminals. The first and second engaging portions are provided outside the first sealing member.