In-line Sealed Electrical Connector Asymmetric D-Shaped Housing
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Solution Overview
Problem
Existing in-line sealed electrical connectors are too large for certain applications, such as automobiles, and smaller versions often make it difficult to ensure proper orientation of mating parts for secure connections.
Innovation Solution
A compact in-line sealed electrical connector design featuring a female and male assembly with D-shaped configurations and retention clips, ensuring proper alignment and secure engagement through close-fitting relationships and resilient mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the connector size is reduced to meet size-driven constraints, then the connector can be used in applications such as automobiles, but it becomes difficult to determine proper orientation of mating parts
Solution Approach 1:
The patent applies asymmetry by providing at least one of the first and second housings with an asymmetric cross-sectional shape (such as D-shaped or oval cross-section) that is different from a circular shape. This asymmetric geometry creates a unique orientation that must be matched between mating connectors, allowing proper orientation to be determined by the physical shape itself rather than requiring visual inspection or markings. The asymmetric shape prevents incorrect mating while enabling compact dimensions.
2Volume of moving object
If the connector size is reduced, then size constraints are satisfied, but the reliability of proper engagement may be compromised
Solution Approach 1:
The asymmetric cross-sectional shape serves as a mechanical keying system that ensures reliable proper engagement. The specific asymmetric geometry (such as the flat side of a D-shape) must align between mating connectors, providing positive mechanical guidance and preventing incorrect orientation. This shape-based locking mechanism reliably ensures that connectors can only be mated in the correct orientation, maintaining engagement reliability despite reduced overall connector size.
Data Source
AI summary
An in-line sealed electrical connector apparatus includes a female connector assembly and a male connector assembly. The female connector assembly includes a female housing, a female wire seal and a female cover. The male connector assembly includes a male housing, a retention clip, a male housing seal defining a male housing seal opening, a male wire seal and a male cover. The retention clip formed in a generally U-shaped configuration to define a generally D-shaped retention clip duct extending longitudinally through the retention clip. The generally D-shaped retention clip duct is sized to slidably receive the female housing such that, upon engaging the female connector assembly and the male connector assembly, the female housing is first received through the generally D-shaped retention clip duct and is thereafter inserted through the male housing seal opening.