Sealed Connector Housing With Protected Fasteners Against Corrosion
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Solution Overview
Problem
Existing connector assemblies for vehicles face challenges related to corrosion and sealing due to exposed bolts and hardware, which affect the robust coupling and reliability of electrical connections.
Innovation Solution
A connector assembly design that integrates a device case with a header, base, and fasteners, featuring a sealing surface and internal seals to minimize exposure to environmental factors, enhancing corrosion resistance and reducing the number of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate external sealing and shielding components are used in connector assemblies, then the coupling robustness is improved, but the device complexity and number of components increases
Solution Approach 1:
The patent combines separate sealing components, shielding components, and coupling features into an integrated connector housing structure. The housing incorporates sealing surfaces, shielding surfaces, and coupling surfaces as integral parts of a single component, eliminating the need for separate external sealing and shielding components while maintaining coupling robustness
Solution Approach 2:
The connector housing is designed to perform multiple functions simultaneously: it provides structural support for coupling, incorporates sealing surfaces for environmental protection, includes shielding surfaces for EMI/RFI protection, and integrates fastening features. This multi-functional design reduces the total number of components while maintaining all necessary protective and coupling functions
2Ease of manufacture
If bolts and hardware are exposed to the environment in connector assemblies, then the assembly process is simplified, but corrosion resistance deteriorates
Solution Approach 1:
The patent uses sealing surfaces and shielding surfaces that extend over and protect the fasteners and hardware. These surfaces create a protective barrier that shields the bolts and hardware from environmental exposure, preventing corrosion while maintaining assembly simplicity through the integrated design
3Adaptability or versatility
If multiple separate components are used in connector assemblies, then the adaptability is improved, but the manufacturing cost increases
Solution Approach 1:
The patent integrates multiple functional components into a single molded housing structure, combining coupling features, sealing surfaces, and shielding surfaces in one piece. This reduces the number of parts to manufacture, assemble, and inventory, lowering overall manufacturing costs while maintaining the adaptability needed for various connector applications
Data Source
AI summary
A device case for a connector assembly includes a header, a base, and a set of fasteners. The base includes a body portion and a wall extending from the body portion. The wall defines a sealing surface configured to engage a seal. The set of fasteners couples the header to the base. The set of fasteners is surrounded by the sealing surface.