Vehicle Door Cable Bushing for Electrical Connection
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Solution Overview
Problem
Existing vehicle door designs require large openings and complex sealing methods to route electrical connections between wet and dry areas, limiting flexibility and increasing costs, as they only allow electrical lines from components within a shared housing to be routed through the wall, and do not permit additional connections beyond the housing.
Innovation Solution
A vehicle door design with a cable bushing system that uses a small opening in the wall, featuring a first electrical plug connection penetrating the wall from the dry side and a second plug connection on the wet side, allowing electrical components on both sides to be connected without additional wall openings, with internal electrical connection between the two, and optional sealing and latching mechanisms to prevent moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large opening is provided in the wall to route electrical connections between wet and dry areas, then electrical components can be connected across the wall, but the opening size increases and sealing complexity increases
Solution Approach 1:
The electrical connection system is segmented into two separate plug connections: a first plug connection on the dry room side and a second plug connection on the wet room side. This segmentation allows each plug connection to be independently sized and sealed, enabling a small opening in the wall while maintaining full electrical connectivity flexibility across both sides of the wall.
Solution Approach 2:
The first plug connection serves as an intermediary element that penetrates the wall opening and provides electrical connection between the dry room side and the wet room side. By using this intermediary plug structure, the opening size is minimized while still enabling electrical components on both sides to be connected through the wall.
2Adaptability or versatility
If a large opening is provided in the wall to route electrical connections, then electrical components can be connected across the wall, but sealing complexity and cost increase
Solution Approach 1:
The sealing system is segmented and integrated with the plug connections themselves. The first plug connection includes sealing elements that seal the opening around it, and the second plug connection is similarly sealed on the wet room side. This segmentation allows each plug connection to be independently sealed, reducing overall sealing complexity and cost compared to sealing a large opening.
Solution Approach 2:
The plug connections serve multiple functions: they provide electrical connection, structural support, and sealing. By integrating these functions into a single component, the design eliminates the need for separate sealing mechanisms for large openings, thereby reducing sealing complexity and cost while maintaining electrical connection flexibility.
3Ease of manufacture
If electrical lines are routed only through components in a shared housing, then routing is simplified, but additional components cannot be connected beyond the housing
Solution Approach 1:
The electrical connection system is segmented into two independent plug connections located on opposite sides of the wall. This segmentation allows electrical lines to be routed from any component on the dry room side to any component on the wet room side, providing full connection flexibility while maintaining routing simplicity through standardized plug interfaces.
Solution Approach 2:
The first plug connection acts as an intermediary that enables electrical lines to pass through the wall opening and connect components across the wall. This intermediary structure allows additional components to be connected on both sides of the wall without requiring complex routing through a shared housing, thereby maintaining ease of manufacture while significantly improving adaptability.
Data Source
Figure 1
AI summary
The car vehicle door (1) has a line through at a wall (2), a wet chamber side (N), two electrical connectors (5,6) and a dry side of the room (T). The wall at the wet side of the room is located in a housing (3). An electrical component (4) of electrical connectors connects the wet side of the room. Both connectors are electrically connected together.