Seal Retainer Assembly for Mat Seal Expansion and Alignment

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Solution Overview

Problem

The gap between the mat seal and the seal retainer in electrical connectors allows movement and bowing of the mat seal during terminal insertion, leading to misalignment and assembly defects, while reducing this gap can cause damage due to thermal expansion.

Innovation Solution

A flexible member, such as resilient cantilever arms, connects the seal retainer to the connector housing, allowing longitudinal movement to accommodate thermal expansion and maintain contact between the mat seal and housing, preventing bowing and ensuring proper alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a gap is formed between the mat seal and the seal retainer to accommodate thermal expansion, then thermal expansion is accommodated, but the mat seal moves and bows during terminal insertion causing misalignment

Engineering Contradiction:

Improvethermal expansion accommodationVSAvoidseal aperture alignment

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The seal retainer is made movable relative to the housing through a flexible member (cantilever arm) that allows longitudinal movement. This dynamic configuration enables the seal retainer to move with the mat seal during thermal expansion while maintaining contact, eliminating the gap that causes misalignment during normal operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible member changes its physical state between flexed and unflexed positions, allowing the seal retainer to adjust its position dynamically. This parameter change enables the system to accommodate thermal expansion while preventing seal bowing and misalignment during terminal insertion.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the gap between the mat seal and seal retainer is reduced to minimize movement and bowing, then seal alignment is improved, but thermal expansion causes damage to the connector assembly

Engineering Contradiction:

Improveseal aperture alignmentVSAvoidconnector assembly integrity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The flexible member provides a dynamic connection that allows the seal retainer to move longitudinally with the mat seal during thermal expansion. This eliminates the need for a large gap while preventing damage, as the flexible member absorbs the expansion movement through flexing.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible member acts as an intermediary between the housing and the seal retainer, mediating the thermal expansion forces. It allows the seal retainer to move with the expanding mat seal while maintaining a secure connection, preventing damage to the connector assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the flexible member allows longitudinal movement of the seal retainer, then thermal expansion is accommodated and seal contact is maintained, but the device complexity increases

Engineering Contradiction:

Improveseal contact maintenanceVSAvoidflexible member mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flexible member is implemented as a thin, flexible component (cantilever arm) that provides the necessary movement capability. This flexible element maintains seal contact during thermal expansion while adding minimal complexity to the overall device structure.

Inventive Principle:

Principle #30Flexible shells and thin films

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 flexible member provides sufficient travel to accommodate thermal expansion while maintaining contact and preventing bowing of the mat seal, ensuring proper assembly and meeting retention force thresholds for electrical connector specifications.

Implementation Method 1

the material used to form most mat seals typically has a higher coefficient of thermal expansion than the materials used to form the housing and retainer

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

a flexible member configured to urge the mat seal into contact with the connector housing and allow longitudinal movement of the seal retainer relative to the connector housing

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP4387000A1Seal retainer with seal expansion compensation features and method of assembly thereof

Publication Date: 2024.06.19 APTIV TECHNOLOGIES AG

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AI summary

An electrical connector assembly includes a connector housing (102) defining a plurality of terminal cavities (104) in which electrical terminals attached to wire cables are received, a mat seal (202) formed of a compliant material and having a plurality of seal apertures (204) through which the electrical terminals are inserted into the plurality of terminal cavities (104), and a seal retainer. The mat seal (202) is disposed between the seal retainer and the connector housing (102). The seal retainer is connected to the connector housing (102) by a flexible member configured to urge the mat seal (202) into contact with the connector housing (102) and allow longitudinal movement of the seal retainer relative to the connector housing (102).