Sealed Electrical Wire Harness With Integrated Flexible Sealing Member
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Solution Overview
Problem
Existing electrical connectors for vehicles' safety devices, particularly in wet areas outside the passenger compartment, require sealing against humidity and dirt but existing solutions either increase size, weight, and cost or compromise on sealing effectiveness.
Innovation Solution
A sealed electrical wire harness with a connector housing that integrates a flexible silicone sealing member, injected during molding, ensuring a compact, lightweight, and cost-effective design with enhanced sealing properties, utilizing channels within the housing to distribute the sealing material efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a watertight cover is provided around an existing SQUIB connector, then sealing ability is improved, but the overall size of the connector increases
Solution Approach 1:
The sealing function is merged with the connector housing structure itself. The flexible sealing member is integrated into the housing as an internal cavity that receives and seals around the terminal, eliminating the need for a separate external cover while maintaining waterproof protection.
Solution Approach 2:
The flexible sealing member is nested within the connector housing structure. The sealing member forms an internal cavity that contains the terminal, creating a nested configuration where the seal is housed within the existing connector body rather than adding external bulk.
2Strength
If the cover has sufficient thickness to withstand damages during assembly, then mechanical strength is improved, but the size and weight of the connector increase
Solution Approach 1:
The mechanical protection function is combined with the primary connector housing structure. The housing itself provides the necessary mechanical strength for assembly operations, while the integrated sealing member provides protection without requiring additional thickness from a separate cover.
Solution Approach 2:
A flexible sealing member is used instead of a thick rigid cover. The flexible material provides sufficient mechanical protection during assembly while maintaining a thin profile that does not increase the overall connector size or weight.
3Reliability
If a separate watertight cover is added, then sealing ability is improved, but the weight of the connector increases
Solution Approach 1:
The sealing function is merged into the connector housing, eliminating the need for a separate cover component. This integration reduces the total weight by removing redundant structural elements while maintaining the waterproof sealing capability through the flexible sealing member.
4Reliability
If a separate watertight cover is added, then sealing ability is improved, but manufacturing cost increases
Solution Approach 1:
The sealing member is manufactured as an integral part of the connector housing using injection molding. This combines multiple functions (housing structure and sealing) into a single manufacturing process, eliminating the need for separate cover production and assembly operations, thereby reducing manufacturing cost.
Solution Approach 2:
The connector housing is designed to serve multiple functions: providing mechanical structure, housing terminals, and creating the sealed environment. This multi-functionality reduces the number of separate components needed, simplifying manufacturing and reducing costs.
5Reliability
If a separate watertight cover is added, then sealing ability is improved, but device complexity increases
Solution Approach 1:
The sealing function is merged into the housing structure, reducing the number of separate components. The flexible sealing member is received within an internal cavity of the housing, creating a simplified integrated structure that maintains sealing capability without adding complexity.
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 provides a compact, lightweight, and cost-effective sealed electrical wire harness that effectively seals against humidity and dirt, improving handling and longevity while maintaining mechanical integrity and reducing production complexity.
Implementation Method 1
The injecting molding tool comprises a heating protrusion adapted to extend, through an opening in the connector housing, to inside the connector housing
Implementation Method 2
the fluid sealing material can flow through the channel, pushed by the injection machine
Data Source
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AI summary
Sealed electrical wire harness (10) for connecting safety devices in vehicles, comprising an electrical connector (20), comprising a connector housing (100), having a wire inlet portion (110), a connector position assurance (CPA) holder portion (120) and a interface portion (150), wherein at least one electrical terminal (30) is located and electrically connected to an electrical wire (40) inside an internal cavity (140) that is located central inside the connector housing (100), wherein the internal cavity (140) extends into the interface portion (150), the electrical wire (40) extends to outside the connector housing (100) passing the wire inlet portion (110), that is located between the internal cavity (140) and the outside of the connector housing (100), a flexible sealing member (200), adapted to seal the internal cavity (140), when the electrical connector (20) is electrically connected to a counter connector and when a connector position assurance device is activated in the connector position assurance holder portion (120) to mechanically lock the electrical connector (20) to the counter connector, whereby the flexible sealing member (200) is made in one piece.