Transmission Module Assembly Thermal Deformation Control
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Solution Overview
Problem
Existing transmission module assemblies fail to maintain sealing functionality due to deformation of the elongated connector housing caused by variations in environmental temperature, leading to changes in the interstitial space and compromised waterproofing.
Innovation Solution
The transmission module assembly incorporates a cover with a U-shaped gap between the body and housing, featuring a tuber and resilient stoppers to prevent deformation, along with a sealant injection system that ensures a consistent gap for reliable waterproofing, using a needle-like injecting tool to fill the U-shaped gap from bottom to top.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the connector housing is made elongated to accommodate multiple terminals, then the electrical connection capability is improved, but the housing deforms under temperature stress causing sealing failure
Solution Approach 1:
The patent applies local quality by making only the critical sections of the housing (where thermal stress concentrates) thickened and reinforced, rather than uniformly thickening the entire elongated housing. This localized reinforcement prevents deformation at stress points while maintaining the overall elongated structure needed for multiple terminals.
Solution Approach 2:
The patent uses composite material structure by combining the insulating housing material with reinforcing ribs or thickened sections that have different mechanical properties. This composite approach allows the housing to maintain electrical insulation while gaining the structural strength needed to resist thermal deformation.
2Reliability
If the housing is reinforced to prevent deformation, then the sealing function is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the housing reinforcement into separate functional elements such as reinforcing ribs, thickened sections, and support structures that can be integrated into the molding process. This segmentation allows each reinforcement element to address specific stress points without requiring complete redesign of the entire housing structure.
Solution Approach 2:
The patent incorporates reinforcement features directly into the housing molding process, so that the structural strengthening is built in during manufacturing rather than requiring subsequent assembly steps. This preliminary action reduces manufacturing complexity by combining multiple functions into a single production operation.
3Reliability
If sealant is applied to fill the interstitial space, then the waterproofing is improved, but the assembly process becomes more complex
Solution Approach 1:
The patent designs the housing with pre-formed sealing features such as grooves, channels, or integrated sealant application paths that guide the sealant to the correct locations during assembly. This preliminary preparation of sealing paths simplifies the assembly process by eliminating the need for complex sealing procedures.
Solution Approach 2:
The patent uses the sealant as an intermediary substance that fills the interstitial space between the housing and cover, creating a waterproof barrier. The sealant acts as a mediator that accommodates minor dimensional variations and ensures sealing without requiring precision machining or complex mechanical sealing structures.
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 design effectively prevents the connector from deforming under temperature stress, maintaining a consistent interstitial space and ensuring a reliable waterproof seal, enhancing the assembly's durability and performance.
Implementation Method 1
a pair of resilient stoppers disposed at the body and abutting forwardly against two lateral sides of the housing
Implementation Method 2
a gap locating between the body and the housing for sealant being poured thereinto
Data Source
AI summary
A transmission module assembly comprises a cover and an electrical connector received in the cover. The cover includes a body defining a receiving cavity and a mating section extending forwardly from the body. The connector includes an insulating elongated housing and a number of terminals retained in the housing. Each terminal includes an engaging portion extending forwardly beyond the body into the mating section, a tail portion extending upwardly beyond the housing and a connecting portion retained in the housing. There is a gap between the body and the housing for pouring sealant thereinto. A tuber is defined between the housing and the body, and a pair of stoppers positioned at the body abut forwardly against two lateral sides of the housing in an elongated direction, which can prevent the housing from deforming when temperature changes.