Sealed Header Assembly Wire Pass-Through Design
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Solution Overview
Problem
Existing pass-through header assemblies face challenges in sealing electrical connections through panels, leading to unintentional transfer of pressure, gases, and contaminants, which can harm device performance, and are costly due to complex sealing materials and multiple connectors.
Innovation Solution
A sealed header assembly with a housing, cover shroud, mounting, and wire holder portions, featuring a seal and seal cap that securely encase wires and prevent contaminants, eliminating the need for potting or overmolded grommets by using a wire cover to direct wires through a sealed passageway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If known pass-through header assemblies use peripheral seals, potting, or overmolded grommets to seal the header assembly to the panel and prevent contaminant transfer, then sealing effectiveness is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the seal and seal cap into an integrated unit that is received within the housing chamber. The seal cap receives the seal and holds it in position, merging multiple sealing functions into a single assembled component that eliminates the need for separate peripheral seals, potting materials, and overmolded grommets.
Solution Approach 2:
The seal acts as an intermediary element between the wires and the housing chamber. The seal is received in the chamber and sealed to chamber walls, creating an intermediate sealing barrier that prevents contaminant transfer while allowing wires to pass through the header assembly.
2Reliability
If multiple connectors and sealing materials are used to prevent leak paths, then sealing effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The housing integrates multiple functions into a single structure: the mounting portion, wire holder portion, and cover shroud portion are all part of one housing assembly. The seal and seal cap are received within the housing chamber, consolidating multiple sealing components into a single manufactured unit that reduces part count and assembly complexity.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides structural support, mounts the assembly to the panel, holds the wires, contains the seal and seal cap, and prevents contaminant ingress. This multi-functionality eliminates the need for separate connectors and sealing materials.
3Ease of operation
If wires are allowed to pass through the header assembly, then electrical connectivity is enabled, but leak paths form allowing pressure and contaminant transfer
Solution Approach 1:
The seal provides localized sealing at the specific location where wires pass through the housing chamber. The seal is configured to seal against the wires in the wire channels, creating a local barrier that prevents contaminant transfer while allowing electrical connectivity through the wire passageway.
Solution Approach 2:
The seal acts as an intermediary element between the interior and exterior environments. It is received in the chamber and sealed to chamber walls, creating an intermediate barrier that allows wires to pass through while preventing pressure and contaminant transfer between the two environments.
Data Source
AI summary
A sealed header assembly includes a housing having a cover shroud portion, a mounting portion, and a wire holder portion. The sealed header assembly includes a wire cover removably mounted to the housing. A seal is held within the housing by a seal cap. The housing and wire cover include wire guidance features for providing a path for the wire to exit the housing.