Thermoplastic Socket Sealing Contour for Water Tightness
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Solution Overview
Problem
Existing electrical connector systems for mobile and stationary use face challenges in meeting water tightness standards like IP44 or IP54 due to complex construction, material sensitivity to mechanical influences, and increased manufacturing costs, particularly because they require a separate sealing contour made of soft materials like rubber or TPE.
Innovation Solution
A socket design where the mounting flange, plug receptacle, and sealing contour are manufactured in a single injection molding process using a harder thermoplastic material, with a sleeve-like sealing contour that surrounds the plug, allowing for swiveling and expansion to ensure tightness without additional components, thus simplifying production and enhancing resistance to external influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate sealing contour made of soft material (rubber or TPE) is attached to the socket, then water tightness protection class IP44 or IP54 is achieved, but the construction and manufacture become more complex requiring additional work steps
Solution Approach 1:
The sealing contour is integrated directly into the plug receptacle structure as a built-in feature rather than being a separate attached component. The plug receptacle includes a sealing contour that extends into the plug insertion direction, forming an integral part of the receptacle wall that seals against the plug during insertion.
Solution Approach 2:
The sealing contour is formed from the harder thermoplastic material of the basic housing rather than soft materials like rubber or TPE. The wall thickness of the sealing contour is specifically controlled to be less than 1.2 mm to provide adequate sealing while maintaining plug insertability.
2Reliability
If a separate sealing contour made of soft material is attached to the socket, then water tightness protection is achieved, but manufacturing cost increases due to additional components and work steps
Solution Approach 1:
The sealing contour is manufactured as an integral part of the plug receptacle in a single injection molding process, eliminating the need for separate manufacturing and assembly operations. This reduces manufacturing steps, labor costs, and assembly complexity while maintaining effective sealing.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The socket has a base housing (1) with a plug connector retainer (3) formed as a single piece with a mounting flange (2), and a plugging contour (5) lying at a plug connector in a plugged condition for connecting the connector with the retainer. The contour and the housing are made of thermoplastic, where the contour is sleeve-shaped. The retainer has two sections (7, 9), where one of the sections is pot-shaped and arranged behind a surface (8) of the flange turned towards the connector in a plugging direction (10) of the connector. The other section is arranged before the flange surface.