Sealed Electrical Connector with Integrated Grounding and Waterproofing
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Solution Overview
Problem
Existing electrical connectors are not suitable for high voltage or high current applications and do not accommodate blade-type male terminals, lacking the necessary sealing and grounding features for such uses.
Innovation Solution
The electrical connector design includes a shield cover, cable assembly, conduit, grounding assembly, shield cover seal, fastener structure, and terminal mounting block, which provides a sealed and grounded connection suitable for high voltage or high current applications, accommodating blade-type male terminals and ensuring electrical conductivity and waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical connector designs are used, then device complexity is reduced, but they cannot support high voltage or high current applications and lack proper sealing and grounding
Solution Approach 1:
The connector is divided into distinct functional modules: a sealed connector housing, a separate grounding assembly with grounding terminal, cable seals for waterproofing, and terminal mounting blocks. This segmentation allows each component to be optimized for its specific function while maintaining overall reliability for high voltage/current applications.
Solution Approach 2:
A grounding assembly acts as an intermediary component between the connector housing and the electrical terminals. The grounding terminal provides a dedicated path to ground, while the grounding assembly integrates multiple grounding points and sealing elements, mediating between the external environment and internal electrical components.
2Adaptability or versatility
If conventional connector designs are used, then ease of manufacture is improved, but they do not accept blade-type male terminals or provide proper sealing
Solution Approach 1:
The terminal mounting blocks are designed with universal compatibility to accept both blade-type male terminals and other terminal configurations. The grounding assembly also serves multiple functions including grounding, sealing, and mechanical support, reducing the need for separate specialized components for different terminal types.
3Object-affected harmful factors
If prior art shield connectors are used, then electromagnetic shielding is provided, but they lack proper sealing for waterproofing and grounding capabilities
Solution Approach 1:
The connector housing integrates electromagnetic shielding, waterproof sealing, and grounding capabilities into a single unified structure. The grounding assembly merges grounding terminals, sealing elements, and mechanical fastening features, combining multiple protective functions that were previously separate in prior art designs.
Solution Approach 2:
The connector housing appears to use composite construction combining conductive materials for electromagnetic shielding with sealing materials for waterproofing. The grounding assembly integrates conductive grounding elements with insulating and sealing components, creating a composite structure that simultaneously addresses electromagnetic interference and waterproofing requirements.
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 design effectively supports high voltage or high current applications, accepts blade-type male terminals, and provides a sealed, grounded, and waterproof connection, reducing electromagnetic interference and requiring only a single fastener for surface attachment.
Implementation Method 1
The cable seal surrounds the outer insulating jacket and is in sealing contact with the conduit and the outer insulating jacket. The shield cover seal is in contact with and extends about the connected four side walls adjacent the opening.
Implementation Method 2
The grounding assembly is sized to be received and releasably retained in the shield cover cavity between the terminal mounting block and the conduit passageway.
Implementation Method 3
The cable has a conducting wire with an exposed conducting wire portion, an insulating sheath surrounding the conducting wire and having an exposed insulating sheath portion, a wire shielding surrounding the insulating sheath. The contact portion is in contact with the shielding member.
Data Source
AI summary
An electrical connector includes a shield cover forming a shield cover cavity that receives a grounding assembly and a terminal mounting block. A conduit is integrally connected to the shield cover and receives at least one cable assembly therethrough for connection to the terminal mounting block. The grounding assembly disposed between the conduit and terminal mounting block clamps an exposed wire shielding portion of the at least one cable assembly for electrically grounding the same upon fastening the electrical connector to an electrically-conductive support surface. An O-ring-like cable seal seals the at least one cable assembly in the conduit. An O-ring-like shield cover seal extends externally of and circumferentially about the shield cover to seal the electrical connector when the electrical connector is received in a barrier wall recess formed by a barrier wall structure. The electrical connector and the barrier wall structure form an electrical connector assembly.