Sealed Electrical Plug Connector with Laser Welded Housing
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Solution Overview
Problem
Current electrical connection arrangements for devices like sensors and actuators in bus systems face challenges with increasing complexity and size, leading to high development and manufacturing costs, assembly difficulties due to tolerance issues, and inadequate sealing against environmental influences.
Innovation Solution
The solution involves a housing design where plug connectors are mounted on a printed circuit board first, allowing for an integrally bonded connection with the housing, which includes a gap between the connector housings and the housing wall, sealed by a welding method like laser welding, ensuring mechanical connection and sealing while accommodating production tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of plug connectors in the connection arrangement is increased to support more bus interfaces, then the versatility and adaptability of the device is improved, but the device complexity and manufacturing cost increase, and the sealing difficulty worsens
Solution Approach 1:
The connection arrangement is segmented into modular components: a housing with integrated circuit board, multiple plug connectors with individual sealing, and a cover. This modular structure allows the system to support multiple bus interfaces while keeping each component relatively simple and manageable.
Solution Approach 2:
The housing integrates multiple functions: it provides mechanical support for the circuit board, houses the plug connectors, provides sealing through integrated seals, and protects internal components. This multi-functionality reduces the need for additional components and simplifies the overall structure despite supporting multiple interfaces.
2Adaptability or versatility
If the number of plug connectors is increased to provide comprehensive bus interface support, then the adaptability is improved, but the manufacturing cost and assembly difficulty increase
Solution Approach 1:
The circuit board is pre-mounted inside the housing with the plug connectors already attached and positioned. This preliminary assembly ensures correct positioning and reduces assembly steps, as the entire circuit board assembly can be installed as a single unit into the housing.
Solution Approach 2:
The housing and circuit board are combined into a single integrated assembly, with the circuit board mounted directly inside the housing. This merging eliminates the need for separate mounting operations and ensures proper alignment and positioning of all connectors.
3Object-affected harmful factors
If tight sealing is required for all plug connectors in the connection arrangement, then the protection against environmental influences is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
Each plug connector has its own dedicated seal (first seals and second seals) that provides localized sealing at the interface between the connector housing and the main housing. This local sealing approach ensures protection against environmental influences without requiring a complex overall sealing structure.
4Reliability
If high tolerance requirements are imposed to ensure proper sealing and positioning, then the sealing reliability is improved, but the manufacturing cost and difficulty increase
Solution Approach 1:
The sealing mechanism uses elastomeric materials that can deform and adapt to dimensional variations. The seals are designed with sufficient cross-section and flexibility to accommodate tolerance variations in the plug connector positions and housing dimensions, maintaining reliable sealing without requiring tight manufacturing tolerances.
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
This approach simplifies and cost-reduces the production of sealed, releasable electrical connections by ensuring a secure and watertight assembly, reducing manufacturing costs and improving assembly efficiency.
Implementation Method 1
The housing wall of the housing with the cylindrical plug connector housing(s) is integrally bonded via their outer jacket
Implementation Method 2
sealed by a welding method like laser welding
Data Source
AI summary
The invention relates to an electrical connection arrangement for producing a detachable electrical connection with one or more plug connectors, wherein the connection arrangement comprises the following: a. a housing which forms at least one housing wall in which there are one or more preferably cylindrical openings; b. one or more plug connectors, each of which has a cylindrical plug connector housing protruding through an opening; c. wherein a contact carrier carrying a contact is arranged in each of the cylindrical plug connector housing(s), the contact connections of which are on a common mounting plane for electrically contacting a circuit board, d. wherein the housing wall of the housing is integrally bonded to the cylindrical plug connector housing(s) via their outer casing.