Molded Sealed Cable Connector for Compact Fluid Ingress Protection
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Solution Overview
Problem
Existing cable connectors fail to provide a reliable seal against humidity and fluids, especially when sealing rings are detached or cables are cut, leading to environmental impacts on electrical connections.
Innovation Solution
A sealed cable connector design featuring an electrically insulating housing with molded electric cables and terminals, where an electrically isolating material is injected into a cavity to seal the connections, minimizing size and using an anti-interference filter connected by crimping, with an upper and lower cover to manage material injection and prevent air bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing rings are used to seal openings in known cable connectors, then sealing against humidity and fluids is improved, but the connector size becomes larger than necessary
Solution Approach 1:
The invention removes the separate sealing rings from the connector structure and integrates the sealing function directly into the housing cavity. The cavity itself is designed to seal around the cables and terminals without requiring additional sealing components, thereby achieving reliable sealing while minimizing connector size.
Solution Approach 2:
The sealing function is merged with the housing cavity structure. Instead of having separate sealing rings attached to cables or inserted into openings, the cavity walls directly provide the sealing surface against which the cables and terminals are sealed, combining the housing and sealing functions into a single integrated structure.
2Ease of operation
If sealing rings are detached or cables are cut in known connectors, then accessibility or cable replacement is improved, but sealing reliability deteriorates allowing environmental ingress
Solution Approach 1:
The housing cavity is pre-designed with sealing surfaces and geometry that maintain sealing integrity regardless of cable position or connection state. The sealing structure is prepared in advance to accommodate cable insertion, withdrawal, or replacement without requiring separate sealing components that could detach or fail.
Solution Approach 2:
The cavity structure automatically maintains sealing through its geometric design and material properties. The sealing surfaces self-adjust to accommodate cable movement or replacement, and the integrated structure ensures that sealing integrity is maintained without requiring separate sealing rings that could detach when cables are manipulated.
3Volume of stationary object
If a compact connector design is used, then connector size is reduced, but sealing capability against environmental impacts deteriorates
Solution Approach 1:
The cavity structure utilizes the flexible and conformal nature of the molded housing material to create effective sealing surfaces. The cavity walls are designed to flex or conform to the cable and terminal geometry, creating a tight seal without requiring large clearance or additional sealing components, thus achieving compact size while maintaining environmental protection.
Solution Approach 2:
The housing is molded as a composite structure integrating the cavity, sealing surfaces, and terminal mounting features into a single multi-functional component. This composite design allows the housing material itself to provide both structural support and sealing functionality, eliminating the need for separate sealing components and reducing overall connector size while maintaining protection against environmental factors.
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 compact, reliable sealing of electrical connections, preventing environmental ingress while maintaining a size comparable to standard connectors, ensuring durability and efficiency in vehicle applications.
Implementation Method 1
an electrically isolating material is injected into the cavity such that it seals the connected end portions of the electric cables and the electrical terminals
Implementation Method 2
the housing is molded onto the connected electric cables and the electrical terminals
Implementation Method 3
the electric cables are electrically connected to the electrical terminals by welding
Implementation Method 4
at least one anti-interference filter is housed in the cavity and is electrically connected to a pair of the electrical terminals by crimping
Data Source
AI summary
The invention relates to a sealed cable connector, including electric cables; an electrically insulating housing; electrical terminals, each of the electrical terminals having an end portion that is electrically connected to an end portion of a corresponding electric cable; the housing having a frame forming a cavity that extends in a z-direction, wherein connected end portions of the electric cables and the electrical terminals are provided within in the cavity of the frame; wherein the electrical terminals have a planar shape in the cavity and are oriented in the x-direction and the z-direction, in that the housing is molded onto the connected electric cables and the electrical terminals, and in that an electrically isolating material is injected into the cavity such that it seals the connected end portions of the electric cables and the electrical terminals. A manufacturing method and use of the sealed cable connector is also provided.