Integrated Sealant Fastener for Fluid-Tight Electrical Terminals
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Solution Overview
Problem
Existing threaded fasteners for electrical terminals often require additional seals and are cumbersome, leading to increased weight, cost, and complexity, especially when dealing with high current or high voltage applications.
Innovation Solution
A fastener assembly with a pair of terminal post ends and an intermediate self-tapping region, where at least one terminal end is threaded, and a synthetic polymer sealant is applied to the intermediate region to provide a fluid-tight seal without additional unitary seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional unitary seals are used with threaded fasteners, then sealing reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the sealing function directly into the fastener body by forming an integral seal groove and seal member as part of the fastener structure. This merging of functions eliminates the need for separate unitary seals while maintaining sealing reliability, thereby reducing device complexity and manufacturing cost.
Solution Approach 2:
The fastener is designed to perform multiple functions simultaneously: mechanical fastening through threading and sealing through the integrated seal member. This multi-functionality allows a single component to replace what would traditionally require multiple separate components (fastener plus separate seal), reducing overall assembly complexity.
2Reliability
If additional unitary seals are used with threaded fasteners, then sealing reliability is improved, but weight and cost increase
Solution Approach 1:
By integrating the seal member directly into the fastener body as an integral component, the patent eliminates the need for separate seal components. This reduction in component count directly reduces the overall weight of the fastener assembly while maintaining the necessary sealing function for high current and high voltage applications.
3Reliability
If additional unitary seals are used with threaded fasteners, then sealing reliability is improved, but manufacturing complexity and labor time increase
Solution Approach 1:
The integral seal groove and seal member are formed as part of the fastener manufacturing process itself, rather than requiring separate assembly steps for adding seals. This integration simplifies the manufacturing process by reducing the number of discrete manufacturing operations and assembly steps required, thereby reducing labor time and manufacturing complexity.
4Reliability
If additional unitary seals are used with threaded fasteners, then sealing reliability is improved, but the fastener becomes cumbersome
Solution Approach 1:
By integrating the sealing function into the fastener body, the patent creates a more compact and streamlined component. This eliminates the bulk and complexity associated with assembling separate seal components, making the fastener less cumbersome and easier to handle and install while maintaining reliable sealing performance.
Data Source
AI summary
A fastener is provided with a pair of terminal ends with an intermediate region therebetween, with at least one of the terminal ends being threaded. The fastener is further provided with a sealant at least partially disposed on the intermediate region.