Sealed Connector Assembly Using Channel-Fed Interface Sealing
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Solution Overview
Problem
Existing sealed connector arrangements fail to effectively seal the interface between mating connectors and electronic components, are costly to assemble, and have limited lifetime due to aging of flexible sealings, making repairs difficult.
Innovation Solution
A method involving a channel system within the connector housing that injects sealing material to seal the interface between terminal aggregates and other components, forming a sealed unit that prevents dust and humidity ingress without disrupting electrical or optical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flexible sealings are arranged at the interface between mating connectors, then sealing protection is provided, but assembly complexity increases and cost increases
Solution Approach 1:
The patent combines the sealing function with the connector housing structure itself by integrating a sealing cavity and sealing bead directly into the housing design. This merges what were previously separate components (flexible sealings) into a unified integrated structure, eliminating the need for separate sealing parts and reducing assembly complexity while maintaining sealing protection.
Solution Approach 2:
The connector housing is designed to be self-sealing through its own structural features (sealing cavity and sealing bead) without requiring external flexible sealings or additional sealing components. The housing structure itself provides the sealing function, making the system self-sufficient and reducing overall device complexity.
2Reliability
If flexible sealings are used to seal the interface, then sealing is achieved, but lifetime is limited due to material aging
Solution Approach 1:
The patent replaces long-lasting but complex flexible sealings with a simpler, potentially replaceable sealing bead design. While the sealing bead may have a shorter individual lifetime, the overall system lifetime is extended because the simplified structure is easier and more cost-effective to replace during maintenance, and the integrated design reduces points of failure.
Solution Approach 2:
The patent changes the material or structural parameters of the sealing mechanism by using a sealing bead within a sealing cavity rather than traditional flexible sealings. This parameter change allows for potentially different material properties that may resist aging better or allow for easier replacement, thereby extending the effective service life of the sealing system.
3Reliability
If flexible sealings are arranged manually or automatically, then sealing is provided, but cost increases significantly
Solution Approach 1:
The patent merges the sealing function into the connector housing manufacturing process itself. The sealing cavity and sealing bead are integrated into the housing structure, allowing the sealing components to be manufactured together with the housing in a single production run, thereby eliminating separate sealing assembly steps and significantly reducing manufacturing cost.
Solution Approach 2:
The connector housing is designed to be self-sealing through its own structural features (sealing cavity and sealing bead) without requiring external flexible sealings or additional sealing components. The housing structure itself provides the sealing function, making the system self-sufficient and reducing overall device complexity.
Data Source
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AI summary
The invention refers to a method of producing a sealed connector arrangement, by means of a first terminal aggregate (101) and a connector (200). The first terminal aggregate is adapted to form part of an electronic unit. The connector comprises: a housing (202) supporting a second terminal aggregate (201) adapted to form an electrical and/or optical contact with the first terminal aggregate; and a channel system (206) comprising an inlet opening (207) and a first outlet opening (208). The first outlet opening is arranged adjacent the second terminal aggregate. The method comprises connecting the connector to the first terminal aggregate thereby forming the contact between the first and the second terminal aggregates; and injecting a sealing material (400) into the inlet opening so that the sealing material is forced via the channel system to a vicinity of, or out of the first outlet opening, thereby sealing-off an interface between the first and the second terminal aggregates. The invention also refers to the use of such method to produce a sealed connector arrangement to be used in a road vehicle or in a wearable electronic device and to a sealed connector arrangement as such.