Sealed Electrical Connection Through Engine Block Wall
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Solution Overview
Problem
Existing solutions for sealed electrical connections through engine block crankcase walls face challenges with sealing between the crankcase passage connector, wiring harness, and electrical contacts, including issues with capillary oil rise, gasket deterioration, and increased manufacturing costs due to precision requirements and potential short-circuits.
Innovation Solution
An electrical connection device featuring a crankcase passage connector with bores for electrical contacts, sealed by conventional gaskets, and an over-moulded part for mechanical maintenance and insulation, which is formed outside the wall, reducing the complexity and cost of manufacturing while ensuring leak-tight sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pins are provided to maintain the contact during injection, then the axial position of the electrical contact is controlled, but the contact becomes visible through the connector at pin passages and risks of short-circuits arise in the presence of conductive liquid
Solution Approach 1:
The invention extracts the contact positioning function from the injection mould pins and transfers it to a separate locating feature on the electrical contact itself. The contact is positioned by its own geometric features (such as a locating ring or protrusion) that interface with corresponding features in the connector bore, rather than being held by pins that would create passages through the connector. This eliminates the short-circuit risk while maintaining manufacturing precision.
Solution Approach 2:
The invention introduces an intermediary locating feature - such as a locating ring or protrusion on the electrical contact - that mediates between the contact and the connector bore. This intermediary feature provides precise axial positioning during assembly without requiring pins that would create passages through the connector body, thereby preventing potential short-circuit paths while maintaining manufacturing precision.
2Manufacturing precision
If precision positioning of the contact in the mould is required, then the contact position is controlled, but the over-moulding time is extended and the manufacturing cost increases
Solution Approach 1:
The invention performs preliminary positioning of the electrical contact by mounting it in the connector bore before the over-moulding operation, using pre-formed locating features such as a locating ring or protrusion that fits into a corresponding recess in the bore. This preliminary positioning eliminates the need for precision positioning during the injection moulding process itself, reducing over-moulding time and manufacturing cost while maintaining accurate contact position control.
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 robust, cost-effective, and simple-to-manufacture sealed electrical connection with improved sealing efficiency, reduced risk of short-circuits, and controlled positioning of electrical contacts, suitable for the automobile field.
Implementation Method 1
sealing means being interposed between the contacts and the inner surface of the bores
Implementation Method 2
means of mechanically maintaining the electrical harnesses with respect to the crankcase passage connector produced in the form of an over-moulded part surrounding a portion of the contacts protruding from the bore and a portion of electrical harnesses
Data Source
AI summary
The invention relates to a device for producing a sealed electrical connection through an engine block crankcase wall in order to connect a sensor or actuating unit contained in the engine block to a central unit comprising a connector provided with at least one bore, which is intended to be arranged in an opening of said wall, at least one electrical contact connected to a wiring harness, said electric contact being surrounded by at least one O-ring seal and arranged in the bore of the connector, said device also comprising an over-moulded part on the wiring harness, an end of the electrical contact connected to the wiring harness and an end of the connector, such that, after the device has been mounted in the opening, the junction between said over-moulded part and the connector is situated on one side of the wall.