RF Connector Interface Seal In-Situ Molding
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Solution Overview
Problem
Radio frequency (RF) connector assemblies face challenges in sealing against external debris, contaminants, and environmental elements due to limited space for seals, leading to potential damage and signal disruption, especially in applications like automotive and military settings where standardization restricts size increases.
Innovation Solution
The connector assembly incorporates an interface seal with a molded body that follows the contours of both the inner and outer surfaces within an annular gap, and a wire seal at the cable end, both formed in-situ to ensure effective sealing without the risks of pre-molded seal installation issues, such as tearing or misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-molded seals are used to seal the connector assembly, then sealing effectiveness is improved, but the risk of seal tearing or rolling out during assembly increases due to limited space
Solution Approach 1:
The seal is integrated directly into the housing structure as an integral sealing element, merging the seal function with the housing component. This eliminates separate seal installation steps and prevents seal tearing or rolling out during assembly, as the seal becomes part of the housing itself rather than a separate pre-molded component
Solution Approach 2:
The sealing approach transitions from using pre-molded seals with specific dimensional parameters to an integral seal design where the sealing parameters are defined by the housing geometry itself. This changes the sealing mechanism from relying on separate seal component parameters to relying on the integrated structural parameters of the housing
2Reliability
If the connector assembly size is increased to accommodate pre-molded seals, then sealing capability is improved, but compliance with industry standards is compromised
Solution Approach 1:
The seal is positioned within the existing annular gap space in a different dimensional arrangement, utilizing the radial space between the inner and outer housing surfaces. This allows effective sealing within the standardized connector dimensions by creatively using the available three-dimensional space rather than increasing overall connector size
Solution Approach 2:
The integral seal is nested within the annular gap between the inner and outer housing components, fitting the sealing element into the existing spatial configuration. This nesting approach allows the seal to be accommodated within the standardized connector size without requiring additional external space
3Adaptability or versatility
If multiple openings are provided in the housing for electrical components, then functionality is improved, but the number of ingress locations for debris and contaminants increases
Solution Approach 1:
The integral seal structure serves multiple sealing functions simultaneously, sealing around multiple electrical components and openings within a single continuous sealing element. This multi-functional seal design protects all ingress locations without requiring separate seals for each opening, maintaining functionality while comprehensively preventing debris entry
Data Source
AI summary
A connector assembly includes an electrical contact subassembly and an outer housing. The contact subassembly is terminated to an electrical cable. The outer housing defines a cavity and holds the contact subassembly in the cavity. A mating segment of the outer housing defines a socket of the cavity that is configured to receive a plug end of a mating connector assembly. The outer housing further includes an interface seal within the cavity. The interface seal is configured to engage the plug end of the mating connector assembly during a mating operation to seal an interface between the connector assembly and the mating connector assembly. The seal may be formed by in-situ molding in the outer housing.