Sealed Vehicle Ground Connector Assembly Against Galvanic Corrosion
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Solution Overview
Problem
Existing connector assemblies for vehicle electrical systems are prone to galvanic corrosion, especially in high-voltage applications, due to exposure and contact between different metals, which reduces the connection's lifetime and reliability.
Innovation Solution
A connector assembly with a housing featuring a radial seal around a stud aperture and an axial seal around the contact area, providing a sealed and redundant sealing mechanism that reduces moisture ingress and prevents galvanic corrosion, along with an eyelet connector and additional seals for a sheathed wire, ensuring a secure and airtight connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector is exposed without sealing, then the manufacturing process is simple and easy, but the connector is prone to galvanic corrosion and moisture ingress which reduces connection lifetime
Solution Approach 1:
The patent employs a radial seal (a flexible sealing element) disposed around the periphery of the aperture in the housing to seal the junction between the stud and housing. This flexible sealing film prevents moisture and contaminant ingress while maintaining manufacturing simplicity, resolving the contradiction between ease of manufacture and connection reliability
2Reliability
If a seal is added around the stud aperture, then moisture ingress is prevented, but the device complexity increases
Solution Approach 1:
The radial seal is implemented as a simple flexible sealing ring or film that integrates into the housing aperture design. This approach provides effective sealing without adding complex mechanical structures, maintaining reliability while minimizing device complexity
Solution Approach 2:
The radial seal acts as an intermediary element between the stud and housing, providing the sealing function without requiring complex integration. This mediator approach simplifies the overall device structure while achieving the desired protection against moisture ingress
3Reliability
If an axial seal is added for redundant sealing, then sealing efficacy is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The axial seal provides beforehand cushioning by creating a redundant sealing barrier that compresses against the stud base. This preventive measure ensures that even if the radial seal degrades, the connection remains protected, improving sealing reliability while adding a straightforward manufacturing step
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 significantly enhances the reliability and longevity of electrical connections by preventing moisture and contaminant ingress, reducing galvanic corrosion, and ensuring a secure, airtight seal, particularly suitable for high-voltage applications, while simplifying the manufacturing process.
Implementation Method 1
a radial seal disposed around a periphery of the first aperture, the radial seal being arranged to provide a seal between the stud and the housing
Implementation Method 2
the axial seal is arranged to be compressed against a surface of the vehicle ground plane
Implementation Method 3
This occurs at the junction between two different metals, and is more severe when high voltages are transmitted across the junction. Accordingly, such corrosion can be more severe for high-voltage (e.g. 400V) applications
Data Source
AI summary
A connector assembly for electrically connecting a vehicle electrical system to a vehicle ground plane includes: a housing having a first aperture arranged to receive a stud, an electrical connector disposed within the housing and arranged to be electrically connected to the stud, and a radial seal disposed around a periphery of the first aperture, the radial seal being arranged to provide a seal between the stud and the housing.