Integrated Sealed Electrical Housing Assembly with Connector
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Solution Overview
Problem
Existing electrical housing assemblies for motor vehicles are limited by the need for auxiliary power distribution boxes that are not watertight, making it difficult to package them in harsh environments, especially when the number of remote electrical loads exceeds the number of relays available in bussed electrical centers.
Innovation Solution
An environmentally sealed electrical housing assembly with an integrated connector is created by mechanically and electrically attaching non-accessible electrical components to a planar circuit board, surrounding them with a dielectric material to form a sealed container, while keeping terminals accessible, and allowing for the connection of removable electrical components like fusible links.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If auxiliary power distribution boxes are used to handle additional electrical loads, then the electrical system capacity is improved, but the environmental sealing capability deteriorates as these boxes are not watertight and limited to low splash zones
Solution Approach 1:
The patent combines the power distribution box housing and the electrical connector into a single integrated sealed assembly. The housing forms a watertight enclosure that completely seals the electrical components, eliminating the need for separate unprotected connector portions. This merging allows the entire assembly to be placed in harsh environments like wheel wells while maintaining both electrical capacity and environmental sealing.
2Ease of manufacture
If traditional separate housing and connector designs are used, then manufacturing simplicity is maintained, but environmental protection capability deteriorates due to gaps and sealing requirements
Solution Approach 1:
The housing and connector are merged into a single integrated component where the connector is formed as an integral part of the housing structure. This eliminates the need for separate sealing gaskets, O-rings, or potting materials that would be required in traditional separate designs. The single-piece construction provides inherent environmental sealing while simplifying the manufacturing process through reduced assembly steps.
3Adaptability or versatility
If remote electrical loads are increased beyond bussed electrical center capacity, then system versatility is improved, but device complexity increases requiring additional auxiliary boxes
Solution Approach 1:
The integrated housing-connector assembly serves multiple functions simultaneously: it provides power distribution, maintains environmental sealing, and enables flexible placement in various vehicle locations. This multi-functional design eliminates the need for separate auxiliary power distribution boxes, reducing system complexity while maintaining the ability to handle additional electrical loads in harsh environments.
Data Source
AI summary
An environmentally sealed electrical housing assembly with an integrated connector and a method for manufacturing same is presented. The assembly includes a non-accessible electrical component, such an electromechanical relay, and a plurality of terminals connected to a circuit board. A dielectric housing encases the non-accessible electrical component. The housing is in intimate contact with the non-accessible electrical component, thereby sealing it from the environment. The housing defines an integral perimeter wall that surrounds the terminals, forming a connector shroud. Removable electrical components, such as fuse assemblies, may be attached to the terminals inside the shroud. When a sealed mating connector is attached to the housing, the removable components are also sealed from the environment. The assembly allows distribution of power switching functions and circuit protection to be distributed to a location near the electrical load instead of a central location, such as a bussed electrical center.