Slanted Sealed Connector Assembly for Low-Force Mating
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Solution Overview
Problem
Existing electrical connector systems in vehicles require high forces to mate and seal, often resulting in irregular forces due to flexible seals, which can lead to user fatigue and potential misalignment or damage during the sealing process.
Innovation Solution
A sealed electrical connector assembly featuring slanted sealing walls and a flexible sealing element with compressible lips, providing a watertight seal with reduced friction and force peaks, allowing for easier assembly and ensuring proper alignment through force feedback mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flexible seals are employed to provide sealing, then sealing effectiveness is improved, but irregular forces and friction increase during mating
Solution Approach 1:
The sealing wall is designed with a specific angle (e.g., 15-45 degrees) relative to the mating direction, changing the geometric parameter to transform the force interaction. This angular configuration allows the flexible seal to compress gradually along the inclined surface, converting irregular force peaks into a more uniform force distribution during the mating process, while maintaining effective sealing.
2Reliability
If high forces are applied to mate and seal connectors, then sealing reliability is improved, but user fatigue and potential damage increase
Solution Approach 1:
The sealing mechanism utilizes the flexibility of the sealing element to dynamically adapt to the mating process. The flexible seal deforms progressively as the connectors come together, allowing the sealing force to build up gradually rather than requiring a sudden high force application. This dynamic behavior reduces the peak force needed and distributes the effort over the mating sequence.
Solution Approach 2:
By changing the angle of the sealing wall, the force required for mating is optimized. The inclined surface allows a component of the applied force to naturally compress the seal, reducing the total force the user must apply compared to a perpendicular sealing interface.
3Object-affected harmful factors
If flexible seals are used to ensure sealing, then watertight protection is improved, but frictional forces during mating increase
Solution Approach 1:
The angle of the sealing wall is specifically designed to optimize the balance between sealing effectiveness and friction. The inclined configuration allows the sealing force to be applied more efficiently, reducing the normal force between the seal and the mating surface, thereby lowering friction while maintaining the watertight seal.
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 enables quick, reliable, and low-force sealing with reduced user effort, preventing damage and misalignment, while providing unambiguous haptic feedback for complete sealing, thus enhancing the reliability and ease of use of electrical connections in vehicles.
Implementation Method 1
the flexible sealing element is compressed in the sealing region between the connector member sealing wall and the connector housing sealing wall
Implementation Method 2
a user closing the electrical connector by a pushing movement often experiences irregular forces when flexible seals are employed due to the additional frictional and compressive forces
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The present invention relates to a sealed electrical connector assembly, comprising a first connector member and a second connector member, wherein the first connector member is adapted to be arrangeable in an open position and a sealed position, wherein, in the sealed position, the first connector member is fully mated and sealed with the second connector member, wherein the first connector member comprises a first connector member sealing wall extending essentially in a first direction, and wherein the second connector member comprises a second connector member sealing wall extending essentially in the first direction, wherein in a sealed position, the first connector member sealing wall and the second connector member sealing wall face each other in a sealing region, a flexible sealing element, wherein, in the sealed position, the flexible sealing element is adapted to be arranged between and contacting the sealing walls of the first connector member and the second connector member in the sealing region, wherein the flexible sealing element is fixed with respect to one of the sealing walls and adapted to be releasably engageable with the respective other one of the sealing walls for providing a watertight seal, wherein the sealing wall for releasably engaging the flexible sealing element is slanted with respect to the first direction along the entire sealing region.